Many times, you may have come across metals in your facility or home that have lost their luster or covered with a blackish brown colored layer. Do you ever wonder what's this layer covering the metal or why it is losing its lustier?
Every year, approximately 2.5 trillion US dollars is lost due to corrosion worldwide. This is over 3% of the global gross domestic product (GDP). The concern of a metal corrosion is more than just a financial issue. It is a critical safety and health issue as well.
Corroded metallic bars and surfaces can affect the structural integrity of warehouses and other structures that use metal. It also causes and danger to people who use all live within the vicinity of the metal. You have probably heard of cases where corroded bridges and buildings collapsed killing people. Corroded water pipes are more susceptible to leaking and poisoning water that people use.
Given these facts, it's accurate to say nothing good can come from metal corrosion. This is why you should use a corrosion inhibitor or other ways of preventing corrosion. Read on to learn more about the impact of rusting or corrosion and what you can do to prevent it.
What's metal corrosion?
Corrosion is the process of mental deterioration due to various chemical reactions between the metallic surface and the surrounding environment. The rate of corrosion depends on the specific type of metal and the environmental conditions, particularly the gases that are likely to come into contact with the metallic surface.
Do all metals corrode? This is a question among many people who own or work with metallic equipment. Corrosion can happen to most types of metals. Keep in mind that some metals like pure iron are more likely to corrode than others. On the other hand, the combination of iron and other stable alloys to create stainless steel can considerably slow down the rate of corrosion.
It's important to mention that there is a group of metals that are considered less reactive compared to other metals. Such metals are commonly referred to as noble metals and include silver, gold, palladium, platinum, and rhodium. These metals really corrode even when exposed to weather elements.
To ensure the practical use of steel and other essential metals in the construction and manufacturing environment, corrosion control is an important process that should never be ignored. Otherwise, corrosion will still catch up with your pieces of metal equipment or structure and compromise its integrity and efficiency. This could escalate the cost of maintenance. Here are effective tips to control and prevent corrosion.
Consider corrosion inhibitors
Generally, corrosion inhibitors prevent or slow down the process of corrosion by reacting with the metallic surface and the surrounding gases to successfully subdue electrochemical reactions that facilitate and catalyze corrosion. These chemicals usually form a highly protective film on the metal surface, preventing the surface from coming into contact with moisture and other elements that accelerate corrosion.
You can apply a corrosion inhibitor in the form of a protective barrier through dispersion technique. These inhibitors are also available in solution form. The entire process of applying corrosion inhibitors is commonly referred to as passivation. Unless you are an expert in corrosion inhibitors, it's best to first discuss the corruption issue with an expert then choose the specific type of corrosion inhibitor that best suits your needs.
Protective coatings
According to experts, applying a coat of paint is one of the most cost-effective techniques of preventing corrosion. The paint usually acts as a barrier that prevents rust-causing electrochemical charges from coming to contact with a metallic surface underneath the coating.
It's also possible to apply a powder coating to the metallic surface and heat it to form a highly protective and smooth film on the metal surface. Some of the common and popular powder compositions include acrylic, urethane, epoxy, polyester and nylon.
Take the appropriate environmental measures
You already know what that corrosion happens whenever there is a chemical reaction between a metal and water or gases in the environment around it. Thus, it follows that if you can successfully control the environmental elements, you can slow down the rate of corrosion by reducing or eliminating unwanted reactions that lead to corrosion.
Some of the simple ways you can control the environment include minimizing exposure to seawater and moisture. Other complicated measures include controlling the level of chlorine, Sulphur, and oxygen in the environment around the metallic objects.
Sacrificial metals
You can protect you steel by placing it adjacent to a dissimilar metal. For instance, magnesium or zinc can be placed in direct contact with the steel and successfully protect the steel from rusting. In this case, magnesium or zinc serve is a sacrificial metal that can protect the area of immediate conduct and beyond the metal in each direction.
Keep in mind that protection from rust by sacrificial metal is commonly used in different forms including:
- Magnesium or zinc blocks are usually used to protect water tank interiors, ship hulls, and other metallic surfaces submerged in water.
- It's also possible to completely cover steel with the sacrificial metal. For instance, galvanized steel is usually covered with zinc.
- Zinc-rich coatings can be applied to steel surfaces to offer cathodic protection.
Note that sacrificial metal technique of preventing corrosion is complicated and not everyone can apply it. If you must use this technique, it's in your best interest to consult with an expert to ensure that the sacrificial metal is perfectly placed or applied to maximize its corrosion prevention benefits.
Preventing metal corrosion is never easy. It will always be a fact of life for every manufacturing firm or person who uses metal. Understanding causes of rusting and preventive measures can help you take the right corrosion-preventive measures long before the corrosion becomes an inconvenience.
Exposed metallic surfaces are the most vulnerable. So do your best to preventing rusting instead of waiting until it's too late to start controlling the corrosion process.