Best Practices for Preventing Corrosion in Industrial Components

Best Practices for Preventing Corrosion in Industrial Components

Manufacturing Technology Insights | Thursday, January 13, 2022

The most fundamental method of corrosion prevention is to ensure that components are constructed of corrosion-resistant materials.

FREMONT, CA: Corrosion costs the manufacturing and manufacturing production industries around 17.6 million dollars per year. Corrosion is a significant problem. People see it everywhere; on kitchen knives and in vehicle wheel wells. Corrosion happens when metals react with naturally occurring elements in the environment, forming oxides, hydroxides, and sulfides. Iron oxide is the most often encountered corrosion agent in manufacturing components. Corrosion can also occur in ceramics and polymers, but it rarely occurs before the onset of other forms of degradation. If people want to extend the life of machine components and avoid corrosion, there are some approaches to do it.

Select Materials That Are Corrosion-Resistant

The most fundamental method of corrosion prevention is to ensure that components are constructed of corrosion-resistant materials. Typically, these materials are metal alloys such as nickel aluminim or 310 stainless steel. The disadvantage of this technology is that manufacturing a component entirely from these materials is expensive. It is frequently difficult to justify the expense due to the component's limited service life. Additionally, these materials are often unable of being hardened to a high enough hardness to avoid wear, implying that corrosion protection is sacrificed for wear resistance. While the item will resist corrosion, it may fail due to the normal wear and tear of the manufacturing environment.

Defend Against the Elements

Corrosion happens when metals are exposed to natural elements, most commonly water and air. To avoid corrosion, keep machine components away from sources of excessive water and in a climate-controlled environment. This can be particularly challenging in the manufacturing business since most components are exposed to hostile industrial environments. Water or other corrosive chemicals and materials are present in most industrial situations. While down-hole tooling does not usually come into direct contact with water, it will come into touch with drilling muck and soil, which both contain water and other corrosive compounds, likewise for pump components. This solution is not always applicable in all work environments.

Maintain Clean Components

While keeping components clean, dry, and stored in a climate-controlled environment is usually a good idea, this is not always achievable. Apart from completely shielding it from hostile industrial settings, keeping components clean also helps prevent corrosion. Eliminating exterior corrosion-causing elements can help delay the chemical reactions that generate corrosion. Maintaining clean components necessitates frequent maintenance programs and time away from production. Keeping numerous components on hand enables a component to be cycled out of service for cleaning. This reduces downtime, but it can be costly to have spares on the shelf.

Thermal Mist

People cannot always keep components away from corrosive surroundings or clean them thoroughly after each usage. The ideal approach would be to acquire corrosion-resistant components; however, this is not always financially feasible or meets all performance requirements. Thermal spray is a more cost-effective solution. Thermal spraying can be used to coat low-cost components in corrosion-resistant materials. Coating machine components with a protective layer makes it possible to avoid corrosion and even postpone wear and erosion damage. Even if a component has already begun to corrode, thermal spray can be utilized to restore the surface or prevent further deterioration. The damaged material can be removed and replaced with a corrosion-resistant surface using machining and grinding procedures. Thermal spray is used to coat new components with a protective coating or repair and refit already corroded ones.

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