Irrespective of any industries, metal corrosion is a predominant problem every manufacturer faces every other day. It shows up as rust on iron, a greenish layer on copper, or dull patches on aluminium. While it may start small, it can seriously weaken a metal’s strength and appearance over time. While it can not be eliminated entirely, with the right method and coating, the manufacturers can build a safety shield for their products and systems.
Why Metal Corrodes
When metal comes into contact with oxygen, water, or chemicals in the environment, corrosion starts. If an iron rod is exposed to air and water for a long time, it forms Fe?O?, or iron oxide. This is called rust. While irons are most prone to rusting, things are a bit different with metals like copper and aluminium. These metals develop protective layers. But in harsh conditions, even these layers are of no use.
Factors like salty air, acids, or pollution increase the chance of corrosion. In a country like India, where each of these factors is present in high amounts, corrosion becomes quite a common issue. The main problem is that while we know that the metals are catching rust, we don’t know how to prevent it. That not only destroys the structure but also increases our budget severely.
Types of Corrosion
Metals don’t all corrode the same way. For iron, there is a different method, while for aluminium and copper, the corrosion method is something else. There are, in total, 5 types of corrosion.
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Uniform Corrosion
This is the simplest type. The metal surface corrodes evenly over time. You can usually spot it because the damage spreads across the entire surface. It’s predictable, but most of us ignore it. This results in completely destroying the structure. However, the good thing is that the Uniform corrosion can easily be fixed.
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Pitting Corrosion
Small, deep holes form in the metal surface. It’s more like pores we get to see on different things, such as soil, leaves, etc. Unlike uniform corrosion, these pits are dangerous in nature. These pits concentrate stress inside and cause failure even if most of the metal looks fine.
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Galvanic Corrosion
When two different metals touch in a moist environment, one of them corrodes faster. This is common in joints or fasteners made from mixed metals.
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Crevice Corrosion
Moisture trapped in tight spaces like bolts, rivets, or under gaskets can attack the metal. The corrosion can spread quickly inside these hidden areas.
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Intergranular Corrosion
This targets the boundaries between metal grains. Steel often suffers from this, as most of the steels are improperly heat-treated, leading to brittle, weak spots.
What Are the External and Internal Factors Impacting Metal Corrosion?
Corrosion doesn’t just depend on the metal type. There are several external and internal factors impacting metal corrosion. The external factors like humidity, temperature, salt, and pollution work in sync in faster corrosion. For this reason, metals which are exposed to the coastal regions or industrial environments are more prone to catch rust.
Similarly, there are internal factors. Impurities, micro-cracks, and uneven alloy composition create weak points that corrode faster. Surface roughness, welding defects, or scratches can also act as starting points for corrosion.
Corrosion Tester: Checking Metal Resistance
Before metals, be they iron or aluminium, go for sale, testing their resistance to corrosion is common. Corrosion testers create harsh environments and predict how long a metal or coating will last. These testers are widely used in industries such as automotive, aerospace, construction, and marine engineering.
Salt Spray Testing Procedure
Salt spray testing is one of the most common methods for checking metal durability. It’s straightforward but effective:
- Metal samples are placed inside a salt spray chamber.
- The chamber produces a continuous mist of saltwater, replicating harsh conditions like coastal air.
- Over time, the samples react, showing rust, pits, or other corrosion signs.
- Observers note the time it takes for corrosion to appear, comparing materials or coatings.
Types of Metal Corrosion in Real Life
Corrosion appears in many situations. That's why testing becomes essential. Steel bridges may show uniform corrosion on open surfaces and pitting around bolts. Ships often deal with galvanic corrosion where different metals meet in seawater. Factory machinery can face crevice corrosion near seals and fasteners.
Salt Spray Chamber and Test Applications
A Salt Spray Chamber is a specialised testing instrument used to evaluate the corrosion resistance of metals, coatings, and other material. The PrestoGroup salt spray tester is designed to evaluate the corrosion resistance of materials under accelerated conditions. This testing equipment simulates a saline fog environment to assess the durability of coatings, metals, and other materials exposed to corrosive conditions.
Key Features
- Meets ASTM B117 and JIS Z 2371 standards for corrosion testing.
- Equipped with an HMI-based touchscreen for easy operation and monitoring.
- Panel-type sample holding fixtures
- FRP hanging rods holding fixtures for thick samples
- V-Grooved tray for Fasteners
Salt spray tests are common in
- Automotive parts
- Paints
- Metal coatings
- Hardware.
FAQs
Q1. How much does a standard salt spray chamber cost?
A: Prices for salt spray chambers depend on the size, capacity, and automation features. The ones with the highest level of accuracy cost around INR 10 lakhs, while small, tabletop units start from INR 1.5 Lakhs.
Q2. Are there additional costs beyond the initial purchase of a corrosion tester?
A: Yes, there are some additional running costs. Running costs include salt solutions, water, electricity, and occasional replacement of spraying nozzles or sensors. Regular calibration and maintenance contracts can also add to the total cost over time.
Q3. Is it worth investing in a high-end corrosion tester for small-scale testing?
A: It depends on the frequency and type of testing. For occasional or small sample testing, a mid--range model is often sufficient. High-end testers are ideal for industries that need continuous testing or handle multiple metals and coatings regularly, where accuracy and speed justify the higher price.
Corrosion Tester Price – Get Your Quote Today
Looking for a reliable Corrosion Tester at the best corrosion tester price? Presto Group offers high-quality corrosion testing instruments to ensure accurate and long-term corrosion resistance testing for metals and coatings.
Call us: +91 9210 903 903
Email: info@prestogroup.com
Request Your Corrosion Tester Price Now and Ensure Top Quality Testing !
