Ashes to Ashes, Dust to Dust, Rust to Rust: 10,000 Years of Corrosion Control

Introduction

Corrosion is the deterioration of materials due to chemical reactions with their environment. It is a major problem in many industries, including construction, manufacturing, and transportation. The cost of corrosion in the United States alone is estimated to be $2.5 trillion per year.

The process of corrosion can be divided into three stages:

1. Initiation: The first stage of corrosion is the initiation of a reaction between the metal surface and the environment. This can be caused by a variety of factors, including:
   • Mechanical damage: Scratches or other damage to the metal surface can create a path for corrosive agents to reach the underlying metal.
   • Environmental exposure: Exposure to corrosive agents, such as oxygen, water, and salt, can cause the metal to corrode.
   • Electrochemical reactions: Electrochemical reactions can occur between different metals in contact with each other, or between the metal and the environment.
2. Propagation: Once the corrosion process has been initiated, it can propagate through the metal. This can occur through a variety of mechanisms, including:
   • Pitting corrosion: Pitting corrosion is the formation of small, localized pits in the metal surface. These pits can grow and merge, eventually leading to the failure of the metal.
   • Crevice corrosion: Crevice corrosion is the formation of corrosion in crevices or other areas where there is little or no oxygen. This type of corrosion is often difficult to detect and can cause significant damage before it is discovered.
   • Stress corrosion cracking: Stress corrosion cracking is the formation of cracks in the metal under stress. This type of corrosion is often caused by exposure to corrosive agents, such as hydrogen sulfide, and can lead to the sudden failure of the metal.
3. Failure: The final stage of corrosion is the failure of the metal. This can occur when the metal has been weakened by corrosion to the point where it can no longer withstand the stresses it is subjected to.

History of Corrosion Control

The history of corrosion control can be traced back to the early days of metallurgy. The ancient Egyptians used a variety of methods to protect their metals from corrosion, including:

• Sacrificial anodes: Sacrificial anodes are metals that are more reactive than the metal they are protecting. When the two metals are connected, the sacrificial anode corrodes instead of the protected metal.
• Coating: Coatings can be applied to metals to protect them from exposure to corrosive agents. Coatings can be made of a variety of materials, including paint, rubber, and plastic.
• Inhibitors: Inhibitors are chemicals that can be added to a corrosive environment to slow down the rate of corrosion. Inhibitors can be used in a variety of applications, including water treatment, oil and gas production, and manufacturing.

Modern Corrosion Control Methods

Modern corrosion control methods include a wide range of techniques, including:

• Cathodic protection: Cathodic protection is a method of protecting metals from corrosion by making them the cathode in an electrochemical cell. Cathodic protection can be applied using a variety of methods, including:
  • Sacrificial anodes: Sacrificial anodes are used to protect metals by sacrificing themselves to corrosion. The sacrificial anode is connected to the metal to be protected, and the two metals are immersed in an electrolyte. The sacrificial anode corrodes instead of the metal to be protected.
  • Impressed current: Impressed current cathodic protection is used to protect metals by applying a current to the metal to be protected. The current is applied using an external power source, and the metal to be protected is connected to the positive terminal of the power source.
• Anodic protection: Anodic protection is a method of protecting metals from corrosion by making them the anode in an electrochemical cell. Anodic protection can be applied using a variety of methods, including:
  • Active anodic protection: Active anodic protection is used to protect metals by applying a current to the metal to be protected. The current is applied using an external power source, and the metal to be protected is connected to the negative terminal of the power source.
  • Passive anodic protection: Passive anodic protection is used to protect metals by forming a protective oxide layer on the metal surface. The oxide layer is formed by applying a current to the metal to be protected, and the metal to be protected is connected to the positive terminal of the power source.
• Coatings: Coatings can be applied to metals to protect them from exposure to corrosive agents. Coatings can be made of a variety of materials, including paint, rubber, and plastic. Coatings can be applied using a variety of methods, including:
  • Liquid coatings: Liquid coatings are applied to metals by dipping, spraying, or brushing. Liquid coatings can be made of a variety of materials, including paint, rubber, and plastic.
  • Powder coatings: Powder coatings are applied to metals by spraying a powder onto the metal surface. The powder is then heated to fuse it together. Powder coatings can be made of a variety of materials, including paint, rubber, and plastic.
• Inhibitors: Inhibitors are chemicals that can be added to a corrosive environment to slow down the rate of corrosion. Inhibitors can be used in a variety of applications, including water treatment, oil and gas production, and manufacturing. Inhibitors can be applied using a variety of methods, including:
  • Injection: Inhibitors can be injected into a corrosive environment using a pump.
  • Addition: Inhibitors can be added to a corrosive environment manually.

Pain Points in Corrosion Control

Corrosion control can be a challenging and time-consuming process. There are a number of pain points that can make it difficult to effectively control corrosion, including:

• The wide range of corrosive environments: Metals can be exposed to a wide range of corrosive environments, each with its own unique challenges. This makes it difficult to develop a one-size-fits-all corrosion control solution.
• The complex nature of corrosion: Corrosion is a complex process that is influenced by a number of factors, including the type of metal, the environment, and the presence of other materials. This makes it difficult to predict and prevent corrosion.
• The cost of corrosion control: Corrosion control can be a costly process, especially for large-scale applications. This can make it difficult to justify the investment in corrosion control measures.

Motivations for Corrosion Control

Despite the challenges, there are a number of motivations for corrosion control, including:

• Protecting human health and safety: Corrosion can lead to the failure of metal structures, which can pose a risk to human health and safety. Corrosion control measures can help to prevent these failures and protect people from harm.
• Saving money: Corrosion can cost billions of dollars each year in damage to metal structures and equipment. Corrosion control measures can help to save money by preventing this damage.
• Improving efficiency: Corrosion can reduce the efficiency of metal structures and equipment. Corrosion control measures can help to improve efficiency and save energy.
• Protecting the environment: Corrosion can release harmful pollutants into the environment. Corrosion control measures can help to protect the environment from these pollutants.

Tips and Tricks for Corrosion Control

There are a number of tips and tricks that can help to improve corrosion control, including:

• Use the right materials: The type of metal used in a particular application can have a significant impact on the rate of corrosion. Choose materials that are resistant to the corrosive environment in which they will be used.
• Coat the metal: Coatings can provide a physical barrier between the metal and the corrosive environment. Apply coatings to all exposed metal surfaces.
• Use inhibitors: Inhibitors can slow down the rate of corrosion. Use inhibitors in corrosive environments.
• Monitor the metal: Regularly inspect metal structures and