Danube University of Galati

Faculty of Engineering
Sustainable development and security industry

Project: Effect of galvanic

corrosion.Hydrogen induced cracking.

Stud

Supervisor Lidia Be

Contents:
1. Introduction
2. Denition
3. Material factors
3.1. Effects of coupled materials
3.2. Effect of area
3.3. Effect of surface condition
4. Environmental factors
4.1. Effects of solution
5. Preventive measures
6. Benecial effects of galvanic corrosion
7. Hydrogen induced cracking
8. Hydrogen induced cracking detection

Introduction

Corrosion is the deterioration of a material,

which results from a reaction with its environment. This
environment comprises the physical, chemical and
mechanical conditions or surroundings of the material.
The corrosion of ferrous metals in ground water may be
caused by electrochemical or physical processes. The various types
of corrosion that can be generated from contact between water well
components and ground water include electrochemical, crevice,
and galvanic corrosion as well as stray electrical current or
microbial induced corrosion. Physical processes may also corrode
metals through fluid or particle impact.
the material.

Galvanic corrosion
Galvanic corrosion is either a chemical or
an electrochemical corrosion. The latter is
due to a potential difference between two
different metals connected through a
circuit for current flow to occur from more
active metal (more negative potential) to
the more noble metal (more positive
potential)
Galvanic coupling is a galvanic cell in
which the anode is the less corrosion
resistant metal than the cathode.

 Galvanic corrosion can be predicted by

using the electromotive force (emf) or
standard potential series for metal
reduction listed in Table at the next slide
In selecting two metals or two alloys for
a galvanic coupling, both metals should
have similar potentials or be close to each
other in the series in order to suppress
galvanic corrosion

Effects of Coupled Materials

As listed in Figure 1, all the factors affecting the electrode properties,
such as those under categories (a)(g), have an influence on galvanic
action between any two metals.
For example, titanium has a very negative reversible electrode potential
and has an active position in the emf series. However, titanium occupies
a noble position in the galvanic series in many practical environments
due to passivation of the surface.

Galvanic coupling can be used for

cathodic protection purposes

Other types of galvanic coupling are

batteries and fuel cells
Lithium Ambient-Temperature
Batteries (LAMBS)
Lead-Acid Battery
Dry-Cell Battery
Sintered Nickel Electrode in
Alkaline Batteries

MICROSTRUCTURAL
EFFECTS
mechanically deformed metal or

A
alloy can experience galvanic
corrosion due to
differences
in
atomic
plane
distortion and a high dislocation
density

Effect of Area
The effect of anode and cathode areas on galvanic corrosion depends
on the type of control in the system. If the galvanic system is under
cathodic control, variation in the anode area has little effect on the total
rate of corrosion, but variation of the cathode area has a signicant
effect. The opposite is true if the system is under anodic control.
Galvanic currents in many situations are proportional to the surface
area of the cathode .

FIGURE 2. Effect of area of mild steel

cathode on weight loss of Zn anode
(area of 100 cm2) and on number of
coulombs flowing between Znsteel
couple over a 96-h period in 1N NaCl
solution at 25C

Effect of Surface
Condition

The surface of metals in contact with an

electrolyte is gene- rally not bare but is
covered with a surface layer, at least an
adsorption layer, but often a solid surface lm.

This is the most important factor that

causes the difference between the intrinsic
polarity and apparent polarity and between the
difference in potentials and the extent of
galvanic corrosion.

Formation of a surface lm, whether a salt

lm or an oxide lm, may signicantly change
the electrochemical properties of the metal
surfaces, resulting in very different galvanic
action.

ENVIRONMENTAL FACTORS
A corrosive environment is characterized
by its physical and chemical nature, which
may affect the electrochemical properties.
Given that the electrochemical
properties of each metal are distinctive in a
given electrolyte, galvanic corrosion is
essentially unique for each metal couple in
each environment.
The combination of metal couples and
environmental conditions is, thus, limitless, as
can be appreciated from Table 1.

PREVENTIVE MEASURES
The essential condition for galvanic corrosion to
occur is two dissimilar metals that are both electrically
and electrolytically connected.
Theoretically, prevention of galvanic corrosion can
be achieved by avoiding the use of dissimilar metals in
an assembly, by electrically separating the dissimilar
metals with an insulating material or by physically
insulating the environment from the metal surface with a
coating impermeable to water. In reality, however,
complete prevention is often not practical, as dissimilar
metals need often to be used in direct contact and
exposed to a corrosive environment and there is no
absolutely impermeable coating.
Thus, measures to minimize the possibility and
extent of galvanic corrosion must be implemented All the
factors listed in Figure .1 can be considered and
controlled in order to reduce galvanic corrosion.

Some practical approaches are as

follows:
(a) Avoid combinations of dissimilar metals that
are far apart in the galvanic series applicable to
the environment.
(b) Avoid situations with small anodes and large
cathodes.
(c) Isolate the coupled metals from the
environment.
(d) Reduce the aggressiveness of the
environment by adding inhibitors.
(e) Use cathodic protection of the bimetallic
couple with a rectier or a sacricial anode.


BENEFICIAL EFFECTS OF GALVANIC
CORROSION
As a result of galvanic corrosion of the anodic metal,
the corrosion of the cathodic, coupled metal or alloy
is generally reduced (i.e., cathodically protected).
This effect has been well utilized in the application
of sacricial anodes, coatings, and paints for
corrosion protection of many metal components and
structures in various environments.
Sacricial anodes, mainly made of zinc, aluminum,
and magnesium and their alloys, are widely used in
corrosion prevention underwater and underground
for structures such as pipelines, tanks, bridges, and
ships.

Hydrogen induced cracking

Hydrogen-induced cracking (HIC) refers to the internal

cracks brought about by material trapped in budding
hydrogen atoms. It involves atomic hydrogen, which is the
smallest atom, that diffuses into a metallic structure. In the
case of a crystal lattice becoming saturated or coming into
contact with atomic hydrogen, many alloys and metals may
lose their mechanical properties.
In case the buildup of molecular H is repressed, the
emerging atomic H can disperse into the metal rather than
forming a gaseous reaction. This, in turn, produces a crack
in the metal or material. Certain chemical elements may
contribute to this like selenium, antimony, arsenic and
cyanides. However, the topmost species is H2S, or
hydrogen sulde.

HYDROGEN INDUCED CRACKING

DETECTION

CrHydrogen Induced acking (HIC) is a failure mechanism

resulting in sudden exposures and cracks due to growing
laminations inside the base material and welds.
Hydrogen Induced Cracking is a mechanical fracture
caused by penetration and diffusion of atomic hydrogen
into the internal structure of steel, which changes into
molecular hydrogen at internal interfaces between nonmetallic inclusions and the base material.

APPLICATIONS
Pipelines, towers, vessels, heat exchangers in aqueous
sulphide environment of oil industry facilities, petrochemical
plants and oil transportation
Parts where HIC has occurred and accurate testing is needed
Possible testing geometries: pipe, curved pipe, spherical
surface and flat plate (diameter > 150 mm)
ADVANTAGES
Very high resolution equipment giving clear data
presentation
Test speed: 150 mm/sec
Scanner accuracy: Maximum 0.5 mm
Possibility to print an image of real defect size
Quantitative analysis, permanent integrity of data, periodic
monitoring and side by side analysis
Identies the need to apply further NDT to conrm or
increase integrity