The 8 most common types of corrosion
Detect corrosion damage at an early stage: Efficient inspection using drone technology
1. surface corrosion: the most common threat to industrial plants
Surface corrosion attacks metal surfaces evenly over a large area. This widespread type of corrosion is characterised by typical rust formation and matt discolouration. Exposed metal surfaces are particularly at risk in Industrial plants:
Critical areas:
- External steel structures
- Unprotected metal panelling
- Exposed pipework systems
Effective prevention:
- Industrial protective coatings
- Galvanic finishing
- Use of corrosion-resistant materials
Drone inspection:
- Thanks to high-resolution cameras and LED lighting, the Elios 3 recognises even early stages of surface corrosion. Regular drone inspections document the development and enable protective measures to be taken in good time.
2. pitting corrosion: the insidious danger for industrial plants
Pitting corrosion is one of the most dangerous forms of corrosion. It develops at certain points and eats deep into the material - often unnoticed from the outside. Stainless steel is particularly at risk if its protective layer is damaged.
Danger zones:
- Chemical plants with chloride exposure
- Maritime industrial plants
- Process vessels with aggressive media
Prevention strategies:
- Special anti-corrosion coatings
- Installation of sacrificial anodes
- Systematic monitoring of vulnerable areas
Drone-based detection:
The Elios 3 enables detailed inspections of Tanks and containers. Its high-resolution camera and LED lighting make even the smallest pitting visible. The Inspector 5 system documents the size and depth of corrosion spots for precise damage assessment.
3. crevice corrosion: hidden damage at joints
Crevice corrosion develops insidiously in narrow gaps where a lack of oxygen creates aggressive corrosion conditions.
Joints and overlaps in industrial plants are particularly critical.
Risk areas:
- Screwed pipe connections
- Flange connections
- Overlapping metal constructions
- Sealing areas
Targeted prevention:
- Constructive avoidance of narrow gaps
- Use of special sealing materials
- Regular cleaning of the crevices
Innovative inspection:
Thanks to its compact design, the Elios 3 can even reach narrow gaps. Its thermal imaging camera identifies moisture build-up - a major cause of crevice corrosion. The precise 3D mapping documents critical joints for systematic monitoring.
4. intercrystalline corrosion: danger in the microstructure
Intergranular corrosion destroys metals along their grain boundaries and thus jeopardises the structural integrity of industrial plants. This microscopic form of corrosion is particularly insidious as it is difficult to recognise from the outside.
Main risks:
- Weld seams on stainless steel structures
- Heat-treated metal components
- Highly stressed aluminium constructions
Preventive measures:
- Optimised heat treatment processes
- Stabilised steel alloys
- Regular material testing
Drone-based detection:
The Elios 3 combines high-resolution video images with thermal imaging for comprehensive inspection. The precise imaging enables early damage detection, especially at weld seams and heat-affected zones. The Inspector 5 software documents changes over time for targeted maintenance planning.
5. stress corrosion cracking: when stress and corrosion come together
Stress corrosion cracking (SCC) is caused by the dangerous interaction of mechanical stress and corrosive attack. This combination can lead to sudden material failure - particularly critical in the case of Pressure vessels and pipelines.
Endangered plants:
- High pressure vessel
- Chemical process plants
- Loaded pipework systems
- Load-bearing constructions
Preventive measures:
- Voltage-optimised design
- Use of SpRK-resistant materials
- Corrosion protection
- Coatings
- Regular voltage measurements
Drone-based surveillance:
The Elios 3 enables detailed crack inspection even in high-risk areas. Its LiDAR system creates precise 3D models for stress analysis, while the high-resolution camera documents the finest cracks. Regular inspections track crack development and enable timely maintenance interventions.
6 Galvanic corrosion: When dissimilar metals meet
In a humid environment, contact between different metals leads to galvanic corrosion. The less noble metal becomes the 'victim' - a process that can cause massive damage to industrial plants.
Critical combinations:
- Aluminium-steel connections
- Copper-zinc contacts
- Stainless structural steel transitions
- Metallic flange connections
Protection strategies:
- Electrical insulation between metals
- Targeted installation of sacrificial anodes
- Coating of vulnerable contact points
Drone inspection:
The Elios 3 identifies galvanic corrosion by combining visual and thermal images. The high-resolution camera enables early damage detection, especially at metal transitions. The Inspector 5 software documents corrosion progress for targeted maintenance planning.
7 Microbially induced corrosion: Biological attack on industrial plants
Microbially induced corrosion (MIC) is caused by aggressive metabolic products of microorganisms. This biological form of corrosion is a particular threat to systems in humid environments.
Main risk areas:
- Oil and gas pipelines
- Industrial water systems
- Tank farms and containers
- Maritime installations
Targeted prevention:
- Systematic cleaning concepts
- Biocide treatment of endangered areas
- Antimicrobial coatings
- Regular biofilm control
Drone-assisted early detection:
The Elios 3 uses HD cameras and thermal imaging technology to recognise typical MIC patterns. Even in tanks that are difficult to access, it enables regular inspections for biofilm control. The systematic documentation provided by Inspector 5 supports effective prevention strategies.
8. erosion-corrosion: the destructive double effect
Erosion corrosion combines mechanical wear with chemical attack. This combination leads to aggressive material removal, particularly in high-speed flow systems.
Areas at risk:
- Turbines and pump systems
- High-pressure pipework
- Valves and control fittings
- Heat exchanger
Effective countermeasures:
- Flow-optimised design
- Wear-resistant coatings
- Speed reduction at risk areas
- Regular material thickness measurement
Drone-based inspection:
The Elios 3 enables detailed inspections of pipe systems and turbines. Its high-resolution cameras precisely document erosion damage. The integrated ultrasonic module measures remaining wall thicknesses for targeted maintenance planning.
Conclusion
Corrosion manifests itself in many forms - from obvious surface corrosion to hidden stress corrosion cracking. Thanks to innovative drone technology such as the Elios 3, even areas that are difficult to access can now be systematically monitored. The combination of precise early detection, professional prevention and regular inspection effectively protects industrial plants from corrosion damage.
If you are looking for more information on the subject of corrosion, we recommend the book "Principles of Corrosion Engineering and Corrosion Control" by Zaki Ahmad to the heart.
Preventing corrosion damage: free advice on drone inspections
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