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Corrosion Failure Analysis: Understanding the Causes and Solutions

Corrosion is a common problem in many industries, from oil and gas to manufacturing and construction. It occurs when a material reacts with its environment and undergoes deterioration, resulting in damage or failure. If left unchecked, corrosion can cause significant safety hazards, expensive downtime, and costly equipment repairs and replacements. In this article, we’ll take a closer look at corrosion failure analysis, its causes, and the best ways to prevent and manage it.

What is Corrosion Failure Analysis?

Corrosion failure analysis is a process of identifying, understanding and mitigating the factors that contribute to corrosion-related failures. It involves examining the affected material, analyzing the corrosion mechanisms, and determining the root cause of the failure. The goal of failure analysis is to prevent similar failures from happening in the future by implementing appropriate mitigation measures.

Understanding Corrosion Mechanisms

To conduct an effective corrosion failure analysis, it’s important to understand the different mechanisms that cause corrosion. Here are some of the most common types of corrosion:

Uniform Corrosion – This type of corrosion occurs when a material is exposed to a corrosive environment and corrodes evenly across its surface. It’s often caused by exposure to moisture, acids, or salts.

Galvanic Corrosion – Galvanic corrosion occurs when two dissimilar metals are in contact in a corrosive environment, leading to an electrochemical reaction. The more reactive metal corrodes while the less reactive metal remains unaffected.

Pitting Corrosion – Pitting corrosion is a localized form of corrosion that creates small holes or pits on the surface of a material. It’s often caused by exposure to chloride ions in seawater or industrial environments.

Crevice Corrosion – Crevice corrosion occurs in tight spaces where a material is exposed to moisture or corrosive chemicals. Examples include gaps between metal sheets or under gaskets.

Intergranular Corrosion – Intergranular corrosion occurs along the grain boundaries of a material, often caused by exposure to high temperatures or chemical contamination during manufacturing.

Stress Corrosion Cracking – Stress corrosion cracking occurs when a material is exposed to a corrosive environment while under stress, leading to cracks or fractures. It’s often caused by exposure to hot alkaline solutions or acidic environments.

Identifying the Root Cause of Corrosion Failure

Once you understand the different mechanisms of corrosion, you can start to identify the root cause of failure. Here are some common factors that contribute to corrosion failure:

Inadequate material selection – Using the wrong type of material for a specific application can increase the risk of corrosion. For example, choosing a material that’s not resistant to a particular chemical or temperature can lead to rapid failure.

Improper design – Poor design choices such as sharp corners, crevices, or uneven surfaces can trap moisture and chemicals, leading to corrosion.

Poor maintenance – Lack of proper cleaning or corrosion prevention techniques can lead to the buildup of corrosive chemicals and accelerate the corrosion process.

Environmental factors – Exposure to moisture, salt, acids, or other corrosive chemicals can cause rapid corrosion.

Preventing Corrosion Failure

Preventing corrosion failure starts with identifying the factors that contribute to corrosion and addressing them proactively. Here are some best practices for preventing corrosion:

Choose the right materials – Select materials that are resistant to the specific environment and application.

Ensure proper design – Avoid sharp corners, crevices, or uneven surfaces that can trap moisture and chemicals.

Implement regular maintenance – Clean and treat surfaces regularly to prevent the buildup of corrosive chemicals.

Use protective coatings – Apply protective coatings, such as paint or chemical inhibitors, to prevent direct contact between the material and the corrosive environment.

Use cathodic protection – Install a cathodic protection system, such as sacrificial anodes or impressed current, to protect the material from galvanic corrosion.

Implement corrosion monitoring – Regularly monitor the material’s condition and corrosion rate to detect any changes or unexpected failures.


Corrosion failure analysis is an important process for identifying and mitigating the factors that contribute to corrosion-related failures. By understanding the different mechanisms of corrosion and addressing the root causes of failure, you can prevent costly downtime, equipment repairs, and replacements. Implementing best practices such as proper material selection, design, maintenance, protective coatings, and corrosion monitoring can help you prevent corrosion failure and ensure the longevity of your assets.

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