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uniform corrosion of metal surface due to lack of nickel chrome plating

Uniform Corrosion

What is Uniform Corrosion?

Learn Key Variable and Mitigation Tips for Uniform Corrosion

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The Basics of Uniform Corrosion

Uniform corrosion is a type of general corrosion that occurs evenly across the entire surface of a metal or alloy. At first glance, the corrosion mechanism can cause an unwanted appearance, leading to the gradual loss of material and potential weakening of the material structure. This corrosion mechanism is often observed in mechanical systems exposed to a variety of environments, such as automotive, construction, and chemical processing applications.
Uniform corrosion can be defined as the process of metal loss that occurs at a uniform rate over the entire exposed surface, resulting in a reduction of material thickness and potentially compromising the structural integrity. Synonymous terms for uniform corrosion include general corrosion and even corrosion.

Several factors influence the occurrence and progression of uniform corrosion in industrial applications and mechanical systems, such as:

  • Surface Condition: The condition of the exposed surface, such as cleanliness, roughness, and presence of surface defects, can impact the uniformity of the corrosion process.
  • Electrochemical Factors: The electrochemical properties of the material, such as galvanic potential and corrosion potential, can influence the rate of corrosion by determining the electrochemical reactions that occur on the surface.
  • Environment: The chemical composition, temperature, humidity, and pH of the environment can affect the aggressiveness of the corrosion process, influencing the extent of corrosion.
  • Protective Surface Films: The presence and stability of protective surface films, such as oxide layers, can affect the uniform corrosion rate and the material’s resistance to corrosion.

To reduce the progression of uniform corrosion in machined components, the mitigation strategies outlined below should be taken into consideration:

  • Material Selection: Work with materials that have suitable properties, such as high corrosion resistance and appropriate chemical compatibility, to reduce the propensity for corrosion.
  • Protective Coatings: Apply functional coatings with high corrosion resistance, such as electroless nickel, thin dense chrome, or organic based coatings to provide a protective barrier to corrosion. Hybrid coatings that combine nickel and chromium, such as Armoloy Bi-Protec, can be even more effective at protecting components against corrosive forces.
  • Surface Preparation: Ensure proper surface preparation, including cleaning, degreasing, and removal of surface defects, to promote uniformity of the protective films and reduce the likelihood of localized corrosive attack.

Armoloy's Solution to Corrosion

Armoloy offers multiple metal surface treatments with varying levels of protection from the common causes of corrosion. Offering both broad-spectrum and industry-specific applications, our protective metallic coatings add significant value through increased performance and decreased revenue losses from unplanned maintenance and downtime.

Our protective coatings ensure a thin, precise coat that won’t impact production, but will improve surface hardness and prevent environmental defects. Beyond increasing wear life, Armoloy tailors our metallic coatings based on the specific requirements of your application and industry.

While uniform corrosion is a widespread and detrimental failure mechanism, it’s fairly easy to accurately predict and employ mitigation techniques to effectively control. Understanding the key variables that impact corrosion, along with choosing the right materials and protective surface coatings, can dramatically reduce the likelihood of machined components experiencing failure from corrosive actions.

Beyond the Lab: Metal Failures in Narrative Form

Other Metal Failure Modes

Other common metal failures include:

Corrosion can also result from, or be a precursor to, other potential metal failures

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