The Dangers of Corrosion: How It Can Harm Both Human Safety and Equipment

What are the main causes of corrosion?

While many factors can contribute to corrosion, there are three primary causes: poor ventilation, high temperatures, and electrolytic action. Inadequate ventilation can occur when corrosion-prone metals are enclosed such that airflow is prevented from reaching it. This lack of airflow speeds up the corrosion process by allowing condensate moisture to remain on metal surfaces. High temperatures can also accelerate corrosion by causing metal to expand and contract, which weakens its structure, particularly where two metallic bodies make contact, such as at joints and fasteners. Finally, electrolytic action occurs when two dissimilar metals are in contact with each other in an electronically conductive solution. This can create a current that flows between the metals, causing one of them to corrode. Given the many potential causes of corrosion, it's important to take steps to prevent it from occurring. By understanding the root causes of this destructive process, we can take measures to protect metal surfaces from their effects.

Understanding the dangers that corrosion imposes on equipment and their operators

Operators of all types of equipment potentially face dangers from corrosion every day. The danger isn't always obvious, but the risk is always present. Understanding corrosion's dangers to equipment and operators is the first step in preventing accidents and injuries. 

Corrosion can weaken the structure of industrial equipment, such as buckets, pump components, tanks and piping, compressors, and valve gates, and making them more likely to fail. This can lead to mechanical failures that can cause injuries to operators and/or damage to the equipment itself. Even small levels of corrosion can have a substantial impact on the safety of equipment. 

Corrosion can also create electrical hazards. When metal corrodes, it can create conductive paths that allow electricity to flow where it shouldn't, and can weaken conductors causing them to fail. If the electrical current that is flowing through the corrosive material is strong enough, it can lead to shock hazards for operators or even fires and explosions. 

In addition, corrosion can lead to other problems that can be just as dangerous. For example, corrosion can cause leaks in pipes and tanks. These leaks can allow hazardous materials to escape, posing a danger to both operators and the environment. Corrosion can also block drains and vents, leading to flooding and the release of harmful gasses.

The financial impacts of corrosion

The impact of corrosion reaches far beyond the physical damage it causes to equipment. This destructive process also takes a toll on human safety, as well as the economy. In the United States, the cost of corrosion is estimated to be about $276 billion per year. This includes the expense of repairing or replacing damaged equipment, as well as the cost of lost productivity due to corrosion. The financial impact of corrosion is felt by businesses of all sizes, from small manufacturers to large utility companies and governments. In addition, corrosion can cause environmental damage, contaminate soil and water supplies and release harmful toxins into the air. Given the far-reaching effects of corrosion, it is clear that this is a serious problem that needs to be addressed. Thankfully, there are numerous ways of preventing or mitigating corrosion. By understanding the causes and effects of corrosion, we can take steps to protect ourselves, our equipment, and our environment from this destructive force.

What are the main types of corrosion?

In general, there are four main types of corrosion: chemical, electrochemical, galvanic, and environmental. Each type of corrosion occurs under specific conditions and can have different effects on metal.

Chemical Corrosion

Chemical corrosion occurs when the metal comes into contact with a substance that reacts with it, such as an acid. This type of corrosion can cause the metal to weaken or even break down completely.

Electrochemical Corrosion
Electrochemical corrosion occurs when the metal is exposed to an electrical current. This type of corrosion can cause the metal to become oxidized, which can also weaken it or cause it to break down completely.

Galvanic Corrosion
Galvanic corrosion occurs when two metals are in contact with each other in the presence of an electrolyte. This type of corrosion can cause one of the metals to deteriorate while the other remains unchanged.

Environmental Corrosion

Environmental corrosion occurs when the metal is exposed to a combination of environmental factors, such as air, water, and temperature. This type of corrosion can cause the metal to become pitted or rusted.

Preventing Corrosion

The most common method used in preventing corrosion is surface protection, including thermal spray coatings. Thermal spraying involves the application of a protective coating of non-corroding or corrosion resistant metals or ceramics to metal surfaces. The coating can be applied to new surfaces to prevent corrosion from occurring, or it can be used to repair existing damage by restoring dimension. Thermal spraying, especially in conjunction with sealers, is an effective way to protect against corrosion because it creates a physical barrier between metal and the environment. This barrier prevents moisture and other corrosive agents from coming into contact with the metal surface, which in turn prevents rusting and other forms of degradation. Thermal spraying is a cost-effective way to prevent corrosion, and it can extend the life of metal surfaces by years. In one study of thermal sprayed steel plates coated with aluminum and zinc and left exposed to outdoor marine and industrial environments, corrosion levels were so low that the study was stopped after 19 years of observation.

At Hayden Corp, we understand the importance of extending the life of your parts. Whether you are operating in a corrosive environment or simply looking to prevent wear and tear, our thermal spray coatings can give your parts the protection they need. The resulting coating is extremely durable, providing excellent protection against abrasion, corrosion, and high temperatures. Contact us us at Hayden Corp to learn more about our US thermal Spray services and how our spray coatings can help extend the life of your parts.