10 Different forms of corrosion in

various piping systems

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Table of contents:
1. Uniform Corrosion
2. Galvanic Corrosion
3. Crevice Corrosion
4. Pitting Corrosion
5. Selective Leaching (Dezincification)
6. Intergranular Corrosion
7. Erosion Corrosion
8. Cavitation Damage
9. Fretting Damage
10. Stress Corrosion Cracking

Forms of Corrosion:
There are different forms of corrosion of which below are commonly referred corrosion forms with ways to identify
corrosion and preventive measures.

1. UNIFORM CORROSION:
Though uniform corrosion is an idealized form of corrosion and causes less damage than the other forms of corrosion, it is
more appropriate to understand this form of corrosion.
This leads to uniform thinning of the structures. The attack is measured in terms of penetration. They have the units mpy(mills
per year)or mm per year. This can be determined by any gravimetry method. Depending on the applications the tolerance of
the alloy towards corrosion is chosen as given in the Table 1.

Corrosion Rate

Application

<5

valves, pumps, shafts and impellers

5-50

tanks, piping, valve bodies, bolt heads

>50

not satisfactory

<.5

pharmaceuticals. implants for bodies.

Prevention
One or more of the following methods can be adopted to prevent uniform corrosion.

Cathodic Protection

Inhibitors

Protective Coatings

Selecting Proper Materials

2. GALVANIC CORROSION:

When dissimilar metals or alloys differing in their galvanic or corrosion potential are employed and if they are electrically
shorted they induce this type of corrosion. The corrosion rate of the alloy with lower corrosion potential will be accelerated by
that of higher corrosion potential.

Identification

The active metal is corroded

Grooving of the interface

Noble metal deposits from the stream

Graphite lining or bricks

Prevention

Provide electrical insulation between the metal

Choose alloys closer in the galvanic series

Provide design in structure so as to make anodic to cathodic ratio extremely large.

Coat both anode and cathodic areas. Otherwise coat only the cathode.

Protect the corroding metal with a sacrificial anode, which is anodic to the corroding metal.

3. CREVICE CORROSION:
Accelerated corrosion occurs if differential aeration exists due crevice, metal joining (lap joints, flanges etc.) or any deposits.
Interestingly the location starving for oxygen is forced to become anodic and the region having free access to oxygen
becomes cathode.

Identification

Rivets, flanges, lap joints are attacked internally.

Deposits such as corrosion products, organic deposits, growth of organisms etc. cause corrosion.

Improper drainage of vessels, pipelines cause accelerated attack.

Prevention

Avoid riveting, go in for welding

Design for proper drainage

For stainless steels high Mo content (316,317 and Haste alloys) reduces crevice corrosion

Remove the deposits

Use solid non-absorbent gaskets

4. PITTING CORROSION:
Alloys in presence of certain ions (such as halides) are prone to pitting. The rate of penetration within the pit can be as high
as one million times as compared to the surroundings.

Identification

Pinholes

Normally grow in the direction of gravity

The alloy environment combination is likely to promote pitting

Pitting has taken place along inclusion

Prevention

Eliminate the specific ions responsible for pitting (say halides in the case of SS)

Choose alloy resistant to pitting. In stainless steels high Mo promotes resistance (haste alloys, duplex stainless
steels)

Mild steels serve better in chloride environment than SS if certain amount of uniform corrosion is tolerated. Monel
has more resistance in this environment.

5. SELECTIVE LEACHING (DEZINCIFICATION):

When noble and active elements form an alloy it results in selective removal of the latter. As a consequence the alloy loses its
strength and fails prematurely. Cu-Zn alloys are well known where in dezincification occurs if Zn content exceeds beyond 15
wl. Similarly we have
denickelification, desiliconation, decobaltification.

Identification

They give rise to plug and layered types of attack.

Change in color (from yellow to brown in the cases of brasses)

X-ray diffraction can sometimes reveal selective removal of one element

There can be a change in density in some cases.

Prevention

Addition of any one of the elements namely Sn, As, Sb and P

Al addition reduces overall corrosion and to some extent dezincification.

6. INTERGRANULAR CORROSION:
This type of corrosion occurs as a result of selective attack of the grain boundaries when either grain boundary becomes
highly active or phases prone to selective attack are formed.
Stainless steels, which are normally resistant to intergranular attack, when subjected to an heat treatment between 400-900
C become sensitive to intergranular corrosion (IGC). This range can vary depending on the composition of the alloy. This
treatment is called sensitization treatment and alloy is said to be sensitized. This is mainly due to the formation of Cr23C6
and the consequent grain boundary depletion. Welding, a common practice in fabrication causes such an IGC attack.

Identification

Attack of the alloy away from the weldment called heat affected zone.

Clear ditch type of attack along the grain boundary and consequent weakening seen at higher magnification.

Prevention
Choose low carbon and extra low carbon stainless steels (such ss are 3041, 3161, 3171)
Choose Ti or Ta and Nb containing alloys (321,347)
Provide a solutions treatment to redissolve the carbides (1050 C, 30 m)

7. EROSION CORROSION:
When there is a relative movement of the corrosive environment with respect to the alloy it can lead to erosion corrosion.
Pipelines and heat exchangers are subjected to such a kind of failure.

Identification

Attack at the bends in pipelines

Grooves in the direction of liquid flow.

Prevention

Reduce the velocity of the medium

Choose hard materials

Avoid sharp turns

Provide hard coatings.

8. CAVITATION DAMAGE:

Some variation in erosion corrosion is cavitation damage. Here there is damage due to bubble formation and collapse when
there is hydrodynamic variation in pressure difference along the line. At low pressure water/liquid vaporizes. When the same
is subjected to higher pressure bubble forms and subsequently implodes. This leads to plastic deformation and formation of
cavities as brought out in.

9. FRETTING DAMAGE:
Moving/vibrating interfaces under load causes damage akin to wear called fretting damage.
Here the relative movement is relatively small in angstroms. Typical failed surface under this process is brought out in.

10. STRESS CORROSION CRACKING:

When there is a conjoint action of stress and environment. Stress corrosion cracking occurs (SCC). However SCC is specific
to environment. The alloys are susceptible to SCC only when specific ions are present akin to pitting corrosion. In addition the
alloys fail only if the stress exceeds a threshold level below which they are safe.

Identification

SCC in austenitic stainless steels are predominantly transgranular in nature

Failure occurs by brittle mode.

Ions promoting SCC of that particular alloy must be present. Say Cl and O2 for austenitic

SS and ammoniacal solution for Cu base alloys.

If the alloy is sensitized it can promote intergranular mode of cracking.

Prevention

Select the alloy that is not susceptible to the environment.

In the case of SS control either Cr or O2. As seen from the we can keep either one of them low.

Apply load lower than the threshold stress.

Provide compressive stresses by sand blasting. or shot blasting.

Avoid stress concentration.