8 Key Symptoms of Corrosion You Should Never Ignore
Corrosion is a slow process that can cause extensive damage in different materials, especially metals. Early detection is very important to avoid major damage and expensive repairs. Here are some detailed tips to help you identify the symptoms of corrosion:
Look for Discolouration or Stains
Discolouration is often one of the first visual indicators of corrosion. Thus, when the metal surfaces start to corrode, they appear with colors like red, brown, or yellower stains. For instance, iron and steel appear with reddish-brown rust color; if one observes properly, corroded copper appears green in color. Indeed, it is important to regularly check for color changes as signs of deeper corrosion issues may not yet be visible from a quick glance. Such symptoms of corrosion can be caught early with regular visual inspections before more severe structural problems develop.
Checking for Surface Pitting
Surface pitting is a type of pitting corrosion characterized by small, isolated, and well-defined holes or pits found on the surface of metals. This form of corrosion is particularly devious because it may not be easily noticed, especially on smooth surfaces. Pitting can also occur in other metals, like stainless steel or aluminium, especially when chlorides or other aggressive agents are present. The pits could deepen and widen over time and cause structural weaknesses and failure in the structure. Inspections must be conducted close to surfaces with signs of pitting, especially at areas where moisture tends to collect.
Check for Cracks or Blisters
Presence of blisters or cracks on coatings is an obvious indication that corrosion might be taking place underneath the surface. The blisters form when moisture or corrosive agents penetrate the protective layers and force the coating away from the substrate. Cracks lead to further deterioration of the metal below as they open up more surface areas to elements. Regularly inspecting coatings for signs of failure, especially in harsh environments, can help detect corrosion early and enable timely repairs or replacements.
Notice Texture Changes
Changes in surface texture can indicate that corrosion is affecting the material. A smooth surface may develop a rough, flaky, or powdery appearance as corrosion progresses. For example, while a smooth surface of metal was initially present, oxidation or corrosion may make this surface appear rough or granular. This occurs most commonly on metals like aluminium and copper due to oxidation leading to a dulled appearance. Conducting sensory inspections in combination with visual analysis can be applied to identify surface texture changes much earlier and lead to the possibility of prevention in such structures.
Fractured Structures or Brittle Materials
As corrosion advances, it can significantly weaken the structural integrity of the material. Some of the signs of weakness include bends, flexes, or fractures in otherwise stable structures. In heavily corroded components, brittle failure can lead to catastrophic failure. Regular assessments of structural integrity, including mechanical strength testing, can help identify weaknesses before they result in serious accidents or damage. Load-bearing structures, such as beams and supports, should be closely monitored for safety.
Check for Leaks in Pipes or Tanks
Corrosion usually affects pipelines, storage tanks, and containers. This causes leakage or seepage. Leakage may be minor and undetectable initially but can develop into a serious problem later on. Some common places to check include joints, seams, and welds. These are usually the first points of failure in case corrosion occurs. A routine inspection schedule can help detect leaks early on, preventing spills, environmental damage, or costly repairs. Fluid levels and unusual drops can also signal internal corrosion issues.
Detect Odour or Taste Changes in Liquids
In systems that involve the transportation of water or other liquids, changes in taste or smell may indicate corrosion in the pipes. For example, a metallic taste in drinking water can be an indication that metal pipes are corroding and leaching into the water supply. Such symptoms of corrosion can become a health risk and indicate the advancement of corrosion. Regular tests for water quality and monitoring for any unusual changes will catch these problems early, thereby ensuring the safety of the system and its users.
Listen for Unusual Noises
Unusual noises, such as creaking, groaning, or popping sounds, can indicate internal corrosion affecting the integrity of structures or systems. These noises may arise as materials expand and contract or as components shift due to corrosion-related degradation. Regular audits and inspections of mechanical systems and structures can help identify these sounds early. By addressing the root cause of the noise, potential structural failures can be avoided, ensuring safety and longevity.
Preventive Measures
To effectively run a corrosion management regime, preventive measures are essential. Regular inspections and maintenance schedules allow early symptoms of corrosion to be caught and also reduce long-term damage. The effective use of corrosion-resistant materials and protective coatings helps to reduce risk. Proper ventilation and monitoring the environmental factors associated with humidity as well as the exposure to chemicals also play important roles in lowering the corrosion potential.
Frequently Asked Questions
How can I visually identify corrosion on metal surfaces?
You can identify corrosion by looking for changes such as rust (reddish-brown stains), greenish discolouration on copper, or powdery white residue on aluminium. Inspect surfaces closely for pits, cracks, or flaky textures that indicate material degradation.
What causes corrosion to occur?
Corrosion is caused by the reaction of metals with environmental factors such as oxygen, moisture, salt, chemicals, or pollutants. Factors like poor ventilation, high humidity, and exposure to corrosive agents accelerate the process.
Closing Insights
CORCON Institute of Corrosion was established in 2014. Since then, it has led the way for corrosion awareness and protection across the industries. Its focus is on training, certification, and education programs to overcome corrosion challenges both in India and worldwide.
For more information and solutions on corrosion identification, protection, and prevention, join hands with CIC and explore their workshops, certifications, and expert guidance. Enhance your approach to corrosion management with the trusted expertise of CIC!
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