THE MOST COMMON TYPES OF CORROSION AND HOW TO HANDLE IT

Corrosion is a problem that many manufacturers face over time, and it ultimately leads to premature equipment failure if left untreated. Although corrosion is naturally occurring and there is no way to completely prevent it, there are proper measures you can take to save your equipment from the negative effects.

Before preventative efforts are put in place, it’s important to know which type of corrosion your equipment may experience. There are many different forms of corrosion that occur under specific circumstances, such as chemical exposure or high temperatures. To get a better understanding of what your equipment is up against, here are the most common types of corrosion and how to effectively manage it.

Uniform Attack
A uniform attack is the most common form of corrosion. Typically, it’s categorized as a general, evenly distributed attack across the surface of a material. Uniform corrosion is often caused by a chemical or electrochemical reaction that evenly deteriorates the entire exposed surface. Eventually, the affected metal will become so thin and weathered, it will ultimately fail.

While uniform corrosion can cause major damages to metal parts, it is often considered a safe form of corrosion because it can be easily predicted, manageable and preventable through monitoring chemical exposure.

Galvanic Corrosion
Galvanic corrosion is another extremely common type of corrosion, but it is also the most impactful. This form of corrosion occurs when two different metals are in contact in the presence of a corrosive electrolyte. This will cause the anode, or less resistant metal, to corrode at a rapid pace, while the more resistant metal, or cathode, deteriorates a slower pace than it normally would. Since corrosion occurs more rapidly here, it can often be difficult to catch it in time to avoid significant damage.

There are multiple factors that play into the effects of galvanic corrosion, including the types of metal, size of the anode, temperature and humidity. These factors should all be considered when looking for ways to minimize galvanic corrosion.

Stress Cracking
This form of corrosion is often caused by the combination of tensile stress and the presence of a corrosive environment. Stress cracking is the result of external stress such as tensile load and rapid temperature changes, or residual stress accumulated during a manufacturing process.

Signs of stress cracking are often hard to detect, as a majority of the metal surface stays intact. However, during this corrosion process, fine cracks begin to progress through the structure, which ultimately wears down the metal and leads to failure. Selecting the proper material that can handle specific corrosive environments, such as high temperatures or heavy external loads, can minimize the potential for failures caused by stress cracking.

While these are only a few of the most common types of corrosion, there are many different forms that can have a major impact on metal parts and devices. In order to ensure the best protection against corrosion, metal materials should be consistently monitored for any signs of wear and proper material selection should be enforced to avoid chemical reactions.

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