Professional Documents
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[75-83], 2014
ENGINEER - Vol. XLVII, No. 02, pp. [page range], 2014
© The Institution of Engineers, Sri Lanka
© The Institution of Engineers, Sri Lanka
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The total amount of impact depends on the Therefore when anode and cathode are
nature of environment , level of corrosive present a electrochemical reaction is formed
agents in environment and the amount of use and corrosion of a metal is occurred.
of metals especially, iron base alloys. The
corrosion loss is comparatively higher in 2. Atmospheric corrosion
industrialized countries due to higher usage of
metals and their atmosphere is more polluted. Corrosion occurs in atmospheric environment
The term corrosive environment includes the referred as atmospheric corrosion is the most
atmosphere, water, soil, acids, bases, inorganic destructive type of corrosion that causes
solvents, molten salts and liquid metals. serious damage to metallic structures, vehicles
Moisture which contains dissolved oxygen is and equipment. The corrosion damage mainly
the primary corrosive agent in atmospheric depends on exposure time (t) and some
environment. Other substances, sulfur, climatic factors like relative humidity (RH),
nitrogen and chloride compounds and sodium temperature (T), sulfur content, salinity
chloride, may also contribute to this. (chloride), time of wetness (TOW) and the
Water environments can also have a variety of presence of some other pollutants such as air
compounds with corrosion characteristics. bone particles, nitrogen dioxide etc. [1]
Fresh water normally contains dissolved Corrosion Scientists and Engineers of many
oxygen, as well as other minerals several of countries have carried out numerous amount
which account for hardness. Seawater contains of investigations on atmospheric corrosion.
approximately3.5% salt (predominantly These studies reveal that the effect of corrosion
sodium chloride) as well as some minerals and is so serious that the annual cost of
organic matter and it is generally more atmospheric corrosion is approximately half
corrosive than fresh water. the total annual cost of all types of corrosion of
Soils have a wide range of compositions and metals. As previously mentioned the cost
susceptibilities to corrosion. Compositional depends on many factors, for example
variables include moisture, oxygen, salt industrialized countries have higher corrosion
content, alkalinity and acidity as well as the cost due to the usage of more metals and
presence of various forms of bacteria. [4] higher level of atmospheric pollution. Areas
near to the coastal line also have higher
1.1. Theoretical aspect of corrosion corrosive environments.
Although there are many classification Corrosion cost cannot be totally eliminated but
could be minimized by using appropriate
methods to identify the corrosion phenomena,
corrosion control techniques or corrosion
for metallic materials the corrosion process is management. Better corrosion management
normally electrochemical, that is a chemical can be achieved through preventive strategies
reaction in which there is a transfer of in non-technical and technical areas. For the
electrons from one chemical species to another, implementation of preventive strategies
metal atoms characteristically lose or give up against corrosion it is important to study the
corrosive behavior of atmosphere.
electron in what is called an Oxidation
Internationally researches have conducted
reaction.
great amount of research to understand this
For example Metal M Which has a valance of “ phenomena and it is a very difficult task due
n “ oxidize according to the equation to the complex nature of atmospheric
M----------->Mn++ ne corrosion. However, many approaches have
The place which oxidation occurs is called as been taken to understand the corrosivity of
anode. The process the oxidation is sometime atmosphere, evaluation of corrosivity as a
function of environmental variables, which is
called as anodic reaction.
known as corrosion modeling, and
The electron generated due to the oxidation classification of corrosivity of atmosphere.
must be transferred to another place then the Those approaches can be considered as some
reaction occurs due to the transferred electron popular method use to assess the corrosive
is called as reduction reaction, and the location environment.
at which the reduction occurs is called as
cathode.
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3. Review of atmospheric corrosion (T4 in Table 3) the metal steel comes under
Classification corrosion category C4 (Table 1) which corrode
with the rate of 401-650 g/m2.year The table 5
shows relevant standards for this classification
3.1 European standard classification
and measurements for rate of corrosion.
The European standard EN 12500-2000 [5]
Although the ISO methodology represents a
defines five categories of outdoor environment
simple approach to corrosivity classification it
on the basis of the presence of corrosive agents
has considered only three atmospheric
in the air namely
variables, sulphur dioxide deposition rate
Rural atmosphere: countryside and small
chloride deposition rate and time of wetness
towns, minor corrosive agent contamination
(TOW).Therefore it is limited in its accuracy
(carbon dioxide, chlorides, artificial fertilizers).
and precision. Since the atmospheric
Urban atmosphere: densely populated areas,
parameters determining the corrosivity
few industrial activities, medium corrosive
classification do not include the effects of
agent contamination (sulfur dioxides)
potentially important corrosive pollutants and
Industrial atmosphere: intensive industrial
impurities such as NOx, hydrogen sulfide,
activities, high corrosive agent contamination
carbon dioxide, temperature, rainfall, wind
(sulfur dioxides);
speed etc..
Marine atmosphere: areas close to the sea, or
internal zones strongly affected by airborne
Table 1 - ISO Classification of Corrosion rate
salinity. Corrosion effects are influenced by
after one year exposure predicted for
topographic conditions, prevailing wind
different corrosivity classes
direction.
Marine Industrial atmosphere: complex
environment, areas close to both the sea and
industrial districts, or internal zones located in
the prevalent wind direction, Medium and/ or
high corrosive agent contamination (sulfur
dioxides, chlorides).
Due to its simplicity this has been the most
commonly used method to classify the Table 2 - ISO Classification of sulfur dioxide
corrosive environment but the main drawback and chloride
of this method is there is no clear boundary to
distinguish each environment
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Table 4 – ISO Classification of Corrosivity (CDA) has been proposed as a guide for
and Pollutions levels anticipating extent of corrosion damage for
planning maintenance operations. This
classification scheme was developed primarily
for uncoated aluminum, steel, titanium, and
magnesium alloys exposed to the external
atmosphere at ground level and applicable for
other metals with appropriate modifications.
The CDA algorithm is presented in Fig.1 and
considers the distance to salt water, leading
either to the very severe AA rating for close
distance to seashore or a consideration of
moisture factors. Following the moisture
factors, pollutant concentrations are compared
with values of working environmental
Corrosion Standards (WECS). For example, a
severe A rating would be given if any of the
three pollutants considered in this scheme,
that is, sulfur dioxide, total suspended
particles (TSP), and ozone levels, would
exceed the WECS values in combination with a
high moisture factor. Considering the
simplicity of the algorithms and simplifying
assumptions in obtaining relevant
environmental and maintenance data, the
environmental corrosivity predicted from the
CDA algorithm, was considered to be
Numerical 1,2,3,4 & 5 shown in table 4
reasonable. However in this case also it is
represent the corrosivity categories
limited in its accuracy and precision since it
C1,C2,C3,C4 & C5 respectively
has not considered other atmospheric
parameters that determine the rate of
corrosion.
Table 5 - Relevant ISO Standard for
Subsequent attempts to enhance the CDA
atmospheric corrosion
algorithm by using the results obtained from
Standard Title broad based corrosion testing programs have
ISO 9223: Corrosivity of atmospheres – failed to provide enough differentiation
1992 Classification between moderately corrosive environments.
[9, 10]
ISO 9224: Corrosivity of atmospheres -
1992 Guiding values for the corrosivity
categories
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Figure 3 - Corrosion map Mexico
Where, temperature (T), sulfur content (SO2), Principally by the deposition rates of chloride
salinity (Cl-), time of wetness (TOW). and SO2, and adding the effect of cleansing of
Then the relation between these parameters the metallic surface, the following model is
and atmospheric variables are determined by proposed.
field exposure program and suitable statistical
or software based method. {C=a+b Cl¯ τ5-25 +c Cl¯ τ25-35 +d SO2 τ5-25 +
eSO2 τ25-35 + fCl¯ τrain +g SO2 τrain+
In some cases researchers have considered the h mm τrain, (8)}
rate of corrosion as a direct function of
atmospheric variables.
where C is the weight loss in g/m2 during 6,
{C=f(TOW,Cl- ,SO2,T , etc..) (5)} 12 and 18 months of exposure, Cl¯ is the
deposition rate of chloride ions in mg/m2day,
SO2 is the deposition rate of sulphur
compounds in mg/m2day, τrain and mm are the
time and millimeters of rainfall, respectively,
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τ5-25 and τ25-35 the time of wetness at {𝑛𝑛 = 1 + 0.477(log( )2 − log
( )1 )
𝑑𝑑𝐶𝐶 𝑑𝑑𝐶𝐶
(14)}
𝑑𝑑𝑡𝑡 𝑑𝑑𝑡𝑡
temperatures of 5-25°C and 25-35°C,
respectively, when the RH is over 80%. [12]. 1 𝑑𝑑𝐶𝐶
{k= ( )1 (15)}
This model can be applicable for ferrous metal n 𝑑𝑑𝑡𝑡
𝑑𝑑𝐶𝐶 𝑑𝑑𝐶𝐶
also. Where( )1 ,( )2 represent the first year and
𝑑𝑑𝑡𝑡 𝑑𝑑𝑡𝑡
second year corrosion losses respectively. [14]
A model has been developed by International
Cooperative Program ICP group with the aim Table 6 - Values of n and k
to generalize the corrosion loss over time for Low carbon Copper Aluminium
different environments, reporting the climate location steel
and pollutants variables as independent n k n k n k
factors. These functions have been formulated 1 1.55 71.25 0.72 8.43 0.58 1.12
for different metallic materials and are based 2 0.86 22.13 1.12 2.88 1.02 0.17
on both long-term exposures and trend
analysis based on repeated one-year Research project conducted by group of
measurements of exposure. The degradation of Iberoamerican presented an Artificial Neural
metal over time is expressed by means of mass Network (ANN)-based solution methodology
loss (ML) as a function of climatic parameters for modeling atmospheric corrosion processes
(Rh; T), gaseous pollutants (SO2, O3) and from observed experimental values, and an
precipitation parameters (Rain, H+ Cl–) as ANN model developed using the cited
reported as fallows . [13] methodology for the prediction of the
corrosion rate of carbon steel in the context of
Weathering Steel the Iberoamerican Corrosion Map (MICAT)
{ML= 34[SO2]0.33exp{0.020Rh+ Project, [15] which includes seventy-two test
f(T)}t0.33 (9)} sites in fourteen countries throughout
Iberoamerica. Classical regression model also
Zinc developed in the context of this study,
{ML=1.4[SO2]0.22exp{0.018Rh+ f(T)}t0.85 + Fe=b0+Cl-(b1+b2xp+b3xRH)+b4xTOWxSO2
0.029Rain[H+]t (10)}
Withb0=6.8124, b1=1.6907, b2=0.0004,
Aluminum b3=0.0242, and b4=2.2817.
{ML = 0.0021[SO2]0.23.Rh exp{f(T)}t1.2 +
0.000023Rain[Cl–]t (11)} A research conducted by Klinesmith Scientist
University of Maryland, USA developed a
Copper model for the atmospheric corrosion of carbon
{ML=0.0027[SO2]0.32[O3]0.79Rh exp{f(T)}t0.78 + steel, zinc, copper and aluminum, taking into
0.050Rain[H+]t0.89 (12)} account the effects of four environmental
variables (TOW; sulfur dioxide, salinity and
temperature).(Ref) The general form of the
where: degradation model is as follows:
ML: Mass loss [g/m2], t: exposure time
D F H J(T+T )
(years), Rh: Relative humidity (%), T: average {𝑌𝑌 = 𝐴𝐴𝑡𝑡 𝐵𝐵 TOW
C
1+
SO2
E
1+
Cl
G
e 0 (16)}
annual temperature (°C), f(T): a(T – 10) when
T< 10 °C, otherwise b (T – 10), with a, b being C=3800, E=25, G=50, T0=20
constant values depending on the specific
metal, SO2: Sulfur dioxide concentration Where y = corrosion loss (μm); t = exposure
(μg/m3), O3: ozone concentration (μg/m3); time (years); TOW = time-of-wetness (h/year);
Rain: Average annual rainfall precipitation
SO2 = sulfur dioxide concentration (μg/m3); Cl
(mm), H+: hydrogen ion concentration in
is chloride deposition rate (mg/m2 /day); T =
precipitation (mg/L), Cl–: Chloride ion
concentration in precipitation (mg/L). air temperature (°C); and coefficient of
Field exposure test conducted by a research equation are given below.[16]
group of Brazil obtained values for parameter
n and k of Power law C=ktn (Table 4) with the
following equations.
𝑑𝑑𝑐𝑐
{ = 𝑛𝑛𝑘𝑘𝑡𝑡 𝑛𝑛−1 (13)}
𝑑𝑑𝑡𝑡
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Table 7 - Coefficient of Equation 16 Furthermore the author is conducting research
to find out effect of different Sri Lankan
environmental conditions on corrosion of steel.
And finally find out a suitable atmospheric
corrosion model.
References
1. Roberg., Pierre, R., Hand book of corrosion
engineering, New York, 2000, 58P,pp66-
69,pp84-85.
2. http://corrosion-doctors.org/Why-
Study/Strategic-Impact.htm , Visited , 7th
5. Discussion June 2012.
3. Trethewey, K. R., Chamberlain, J.,
Corrosion for Students of Science and
Basically, a model is considered to be a
Engineering, New York , 1988, 5P
representation of some object, behavior, or
4. William, D., Callister, J. R., Fundamentals
system that one wants to understand. Thus the
of Materials Science and Engineering,
purpose of a corrosion model is to predict an
outcome. As such, a model can test or express University of Utah , 2000, P S-229
a theoretical hypothesis in order to increase 5. EN 12500, Corrosion Likelihood in
understanding of phenomenon. Models are Atmospheric Environment, European
useful only if they are validated and provide Committee for Standardization (CEN),
reasonable outcomes so that predictions can be Brussels, Belgium, 2000.
tested. This will strongly depend on the 6. International standard organization,
relevance and accuracy of the data collected ISO 9223 - Corrosion of metals and alloys –
the level of understanding of the key corrosiovity of atmospheres –
parameters, and the observed knowledge. Classification.
The validity of a model rests not only on its fit 7. International standard organization, ISO
to empirical observations but also on its ability 9224 – Corrosivity of atmospheres- guiding
to extrapolate to situations or data beyond values for the corrosivity categories.
those originally described in the model. Once 8. International standard organization, ISO
validated, corrosion models can support a 9225 – Corrosivity of atmospheres-
variety of analyses, such as estimating the measurement of pollutions.
required interval between maintenance and 9. Summitt, R., Fink. F, T., "PACER LIME: An
repair actions, gauging the effectiveness of Environmental Corrosion Severity
various corrosion mitigation approaches, Classification System," AFWAL-TR-80-
aiding in the selection of materials and 4102 Part I, AD AIOO 496 Air Force Wright
coatings, and performing sensitivity analysis Aeronautical Laboratories, Wright-
regarding the basic assumptions Patterson AFB OH, 1980. p 48
In this framework, models are particularly
10. Pierre, R., Roberge., Corrosion
valuable tools to gain knowledge and insight
Engineering principal and practice, New
relatively quickly for assessing difficult,
York, 2008, 358P.
complex corrosion problems. It is challenging
11. Winston, R. R., Uhling’s Corrosion
to predict the result when the environment
Handbook, New York, 2005, 580P.
varies dynamically in its corrosion potential.
12. Antonio, R., Mendoza, Francisco, Corvo,
In Sri Lanka corrosion receives very little
“Outdoor and indoor atmospheric
attention in engineering design; more often we
use some other countries designs for our corrosion of non ferrous metal”, J.
purposes. It has been occurred many corrosion Corrosion Science, Vol 42, 2000, PP 1123-
failures of structures due to non compatibility 1147.,
of these designs to our environment but many 13. Kucera, V., Mapping Effects on materials
corrosion problems can be solved at the design in Manual Mapping Critical Load, ICP
stage. For this purpose the understanding, Materials Coordination Centre, Stockholm,
knowledge and research on corrosion in Sri Sweden, 2004, Available online:
Lanka is becoming an essential requirement. http://icpmapping.org (accessed on 1
December 2004).
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14. Elaine, D. K., Ramón, S. C. P., Luiz, A.,
Yuri, C. D. L., Gabriel, P. P., Souza D.,
Lázaris, J., “Artificial neural network
corrosion modeling for metals in an
equatorial climate” , J. Corrosion Science,
Vol 51, 2009, pp 2266-2278.,
15. Salvador, Pintosa., Nestor, V., Queipoa,
OladisTroconis., deRincoÂnb., Alvaro
RincoÂnb., Manuel Morcilloc, Artificial
neural network modeling of atmospheric
corrosion in the MICAT project
16. Klinesmith, D. E., McCuen, R., Albrecht,
P., “ Effect of environmental condition on
corrosion rate”, J. Materials in Civil
Engineering., ASCE, Vol. 19, February,
2007, pp. 121–129.
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