What Is Corrosion and How to Prevent It

Corrosion is the gradual deterioration of metal caused by chemical reactions with its surroundings. Understanding what is corrosion and how to prevent it helps industries protect equipment, reduce costs, and maintain long-term performance.

What is Corrosion in its Basics

Corrosion happens when metal reacts with its environment, gradually breaking down through contact with oxygen, moisture, or salts. Knowing what is corrosion and how it starts is key to understanding why metals weaken and how to prevent it.

In simple terms, it’s what causes steel to rust, copper to tarnish, or aluminum to pit. These visible changes might seem minor at first, but over time they can reduce strength and reliability, leading to costly repairs or replacements.

Common Types of Corrosion in Metals

Corrosion doesn’t appear in just one form. Different environments and conditions create different types of damage, each affecting metals in their own way. The most common types of corrosion found in industrial settings include:

• Uniform corrosion: Affects the entire surface evenly, often seen on unprotected steel exposed to moisture.
• Galvanic corrosion: Occurs when two different metals are in contact in the presence of an electrolyte, such as saltwater.
• Pitting corrosion: Forms small, deep holes that can severely weaken components, even if the rest of the surface looks intact.
• Crevice corrosion: Develops in narrow gaps where oxygen is limited, such as under gaskets or between joined parts.
• Stress corrosion cracking: Happens when metal under tension reacts with a corrosive environment, leading to sudden and dangerous failure.

Recognizing these types of corrosion helps with choosing the right materials, designs, and maintenance routines to prevent costly damage.

A metal surface deteriorated due to strong corrosion

Factors That Influence Corrosion

Several factors influence how corrosion forms and progresses. Knowing these conditions helps explain why certain metals last longer than others in specific environments.

• Moisture and humidity: Water is one of the main triggers of corrosion, especially where condensation or seawater is present.
• Temperature: Heat speeds up chemical reactions, often making corrosion appear faster and more severe.
• Chemical exposure: Acids, salts, and industrial pollutants attack metal surfaces and weaken their natural protection.
• Material composition: Alloys containing copper, aluminum, or nickel tend to resist corrosion more effectively than pure metals.
• Design and surface finish: Gaps, crevices, and rough finishes can trap moisture, allowing corrosion to develop in hidden spots.

Each of these factors plays a role in how metals age and perform, which is why preventive planning needs to start even before equipment enters service.

A heavily corroded metal pipe joint

How to Prevent Corrosion: Practical Measures

Preventing corrosion starts with understanding where and how it occurs. While it’s impossible to stop the natural reactions entirely, the right choices in materials, design, and maintenance can greatly slow down the process and protect valuable equipment.

• Material selection: Choosing corrosion-resistant alloys, such as bronze or copper-based materials, offers strong protection in harsh or humid conditions.
• Protective coatings: Applying paints, sealants, or plating adds a barrier between the metal and its environment.
• Design improvements: Avoiding tight crevices, ensuring good drainage, and allowing air circulation all help reduce moisture buildup.
• Regular maintenance: Cleaning, inspection, and timely repairs prevent small issues from developing into serious corrosion damage.
• Environmental control: Managing humidity, temperature, or chemical exposure where possible further limits corrosion risks.

In practice, prevention is about combining these measures to match the environment and application, balancing protection, performance, and cost efficiency.

Final Thoughts

Even though corrosion can’t be avoided completely, understanding what is corrosion and how it develops and how to manage it helps keep equipment reliable and long-lasting. Each application requires a different approach, and informed material selection is key to success.

Those who want to explore this topic in more depth will find useful resources and technical insights on the AMPCO Academy, including articles on corrosion behavior, material performance, and prevention methods.