How to Make the Metal Parts More Corrosion Resistant

Corrosion can be a major problem for metal parts, causing damage and failure over time if left unchecked. Whether you’re an engineer, or designer, understanding how to prevent and mitigate corrosion is crucial to ensuring the longevity and performance of your products.

In this post, we’ll explore the various factors that contribute to corrosion and provide practical strategies for making metal parts more corrosion resistant. From selecting the right materials to applying protective coatings and treatments, we’ll cover everything you need to know to keep your metal parts in top condition. So, let’s dive in!

CNC Machining

Common Types of Corrosion

General Corrosion:
General corrosion is the most common type of corrosion and occurs when metal is uniformly attacked across its surface. This type of corrosion typically occurs due to exposure to moisture or air, and can result in a reduction in the thickness of the metal over time.

Pitting Corrosion:
Pitting corrosion is a localized type of corrosion that creates small pits or craters in the metal surface. This type of corrosion can occur when a small area of the metal surface is exposed to a corrosive environment, such as a saltwater spray or acidic solution. Pitting corrosion can be particularly dangerous as it can cause rapid and severe damage to the metal.

Crevice Corrosion:
Crevice corrosion occurs in tight spaces or gaps, such as between two metal parts or under a washer or gasket. This type of corrosion can occur when stagnant water or other corrosive fluids become trapped in these crevices, leading to localized corrosion of the metal.

Galvanic Corrosion:
Galvanic corrosion occurs when two different metals are in contact with each other in a corrosive environment, such as seawater. This can create a galvanic cell, with one metal acting as the anode and the other as the cathode. The anode metal will corrode more rapidly, leading to localized corrosion.

Stress Corrosion Cracking:
Stress corrosion cracking is a type of corrosion that occurs when a metal is under stress in a corrosive environment. This can cause cracks to form in the metal, which can lead to failure over time. This type of corrosion is often seen in metals that are used in high-stress applications, such as aircraft components or pipeline systems.

Why It Is So Important to Make the Metal Parts More Corrosion Resistant?

Corrosion can have a number of negative effects on metal parts, which is why it’s important to prevent it whenever possible. Some of the main reasons why preventing corrosion is important include:

Safety:
Corrosion can weaken metal parts, making them more prone to failure and potentially causing safety hazards. For example, a corroded part in a car engine or aircraft could fail unexpectedly, leading to an accident.

Durability:
Corrosion can shorten the lifespan of metal parts and reduce their durability. This can result in more frequent replacement or repair of the parts, which can be costly and time-consuming.

Performance:
Corrosion can also affect the performance of metal parts. For example, a corroded pipe in a plumbing system could reduce water pressure and flow rate, while a corroded component in an electrical system could affect its functionality.

Appearance:
Corrosion can also impact the appearance of metal parts. This can be particularly important in industries such as automotive or consumer electronics, where aesthetics are an important factor.

Environmental impact:
Finally, corrosion can have a negative environmental impact. For example, corroded parts in machinery could lead to oil or chemical leaks, which could harm the environment and wildlife.

How to Make the Metal Parts More Corrosion Resistant?

Choose the right metal:
Choosing the right metal is the first step in preventing corrosion. Some metals are more resistant to corrosion than others. For example, stainless steel is more resistant to corrosion than regular steel. Other metals that are known for their corrosion resistance include aluminum, brass, bronze, and copper. So, make sure to choose the right metal for your application.

Coat the metal:
Coating the metal with a protective layer is another way to prevent corrosion. There are different types of coatings that you can use depending on the application. Some common types of coatings include electroplating, anodizing, and powder coating. Electroplating involves applying a thin layer of metal onto the surface of the metal part. Anodizing is a process where a layer of oxide is formed on the surface of the metal. Powder coating involves applying a layer of dry powder onto the metal part and then curing it in an oven.

Keep the metal clean and dry:
One of the main causes of corrosion is moisture. So, it’s important to keep the metal clean and dry. Make sure to remove any dirt or debris from the metal surface. Use a dry cloth to wipe the surface of the metal. If the metal is exposed to water, make sure to dry it off as soon as possible.

Use inhibitors:
Inhibitors are chemicals that can be added to the metal to prevent corrosion. Some common inhibitors include chromate, phosphate, and molybdate. These chemicals work by forming a protective layer on the surface of the metal, which prevents corrosion.

Control the environment:
The environment can also play a role in corrosion. So, it’s important to control the environment around the metal. For example, if the metal is exposed to saltwater, it’s more likely to corrode. So, you may need to take extra measures to prevent corrosion in this type of environment. This could include using a special coating or inhibitor.

Use sacrificial anodes:
Sacrificial anodes are another way to prevent corrosion. These are metals that are more reactive than the metal part that you’re trying to protect. By attaching a sacrificial anode to the metal part, the anode will corrode instead of the metal part. Zinc is a common sacrificial anode that’s used in marine environments.

Proper storage:
In addition to controlling the environment, it’s important to store the metal parts properly to prevent corrosion. For example, storing metal parts in a humid environment can cause them to corrode. So, make sure to store them in a dry place with proper ventilation.

Use cathodic protection:
Cathodic protection is a technique used to prevent corrosion on metal parts. It involves connecting the metal part to a more reactive metal (such as zinc) through an electrical circuit. This causes the reactive metal to corrode instead of the metal part, providing protection against corrosion.

Choose the right fasteners:
When attaching metal parts together, it’s important to choose the right fasteners. Using fasteners made of the same material as the metal parts can help prevent galvanic corrosion. Additionally, using fasteners with a protective coating can also help prevent corrosion.

Consider the application:
The type of application the metal parts will be used in can affect the level of corrosion resistance required. For example, metal parts used in marine environments will require a higher level of corrosion resistance than those used in a dry environment.

Quality control:
Ensuring the quality of the metal parts is also important in preventing corrosion. This may include using high-quality materials, testing the parts for defects, and ensuring proper manufacturing processes are followed.

Design considerations:
The design of the metal parts can also affect their corrosion resistance. For example, designing parts with smooth surfaces and rounded edges can reduce the buildup of moisture and debris, which can lead to corrosion. Additionally, designing parts with adequate drainage and ventilation can help prevent moisture buildup.

Proper installation:
Proper installation is important to ensure that metal parts remain corrosion-resistant. This may include using the right tools and techniques to install the parts, using proper fasteners and connectors, and ensuring that the parts are installed in a dry and clean environment.

Monitoring and testing:
Regular monitoring of metal parts can help identify any signs of corrosion early on. This may include visual inspections, non-destructive testing methods, and corrosion rate measurements. By identifying corrosion early, you can take steps to prevent it from spreading and causing further damage.

Environmental considerations:
Finally, it’s important to consider the environmental impact of the metal parts and their corrosion resistance. Using environmentally friendly coatings and inhibitors, and properly disposing of any hazardous materials, can help reduce the environmental impact of metal parts.

Conclusion

Preventing and mitigating corrosion is essential for ensuring the durability and reliability of metal parts. By understanding the various types of corrosion and employing the appropriate prevention strategies, engineers, and designers can extend the lifespan and performance of their products.

Beska’s Metal Machining Capability

As a CNC machining service provider, the Beska team produces high-quality metal parts that are designed to withstand the effects of corrosion. We get expertise in selecting the right materials, applying protective coatings and treatments, and utilizing state-of-the-art manufacturing techniques to produce parts that are resistant to corrosion and other forms of wear and tear.

If you’re in need of corrosion-resistant metal parts for your next project, you can contact us to learn more about our CNC machining capabilities and how we can help you achieve your goals.

Scroll to Top