spraycorrosion

Spray corrosion is a form of localized corrosion that occurs when a liquid or slurry impacts a metal surface, leading to progressive material degradation. This type of corrosion is commonly observed in industrial settings where fluids, such as seawater, acidic solutions, or abrasive slurries, are sprayed or splashed onto metal components. The process typically involves both mechanical erosion and chemical corrosion, often accelerating the deterioration of the material more rapidly than uniform corrosion.

The mechanism of spray corrosion generally begins with the impact of droplets or particles onto the metal surface, causing localized deformation and surface roughening. This disruption of the protective oxide layer exposes fresh metal, making it more susceptible to chemical attack from the surrounding environment. Over time, repeated impacts can lead to the formation of pits, grooves, or even perforations, depending on the material properties and the severity of exposure.

Factors influencing spray corrosion include the velocity, composition, and temperature of the impacting fluid, as well as the material’s resistance to erosion and corrosion. High-velocity impacts, particularly with abrasive particles, exacerbate mechanical wear, while corrosive chemicals accelerate chemical degradation. Environmental conditions, such as humidity and temperature, can also play a role by influencing the formation of corrosive byproducts or promoting electrochemical reactions.

Preventive measures against spray corrosion include the use of corrosion-resistant materials, such as stainless steels or alloys with high hardness, as well as protective coatings like ceramics, polymers, or metallic overlays. Design modifications, such as shielding vulnerable surfaces or redirecting fluid flow, can also mitigate exposure. Regular maintenance, including inspection and cleaning, helps detect early signs of corrosion and prolongs the service life of affected components. Understanding and addressing the specific conditions contributing to spray corrosion is essential for maintaining structural integrity in industrial applications.