Study of Corrosion Deterioration in Industrial Machinery and Equipment: A Comprehensive Review

Corrosion deterioration is one of the most significant challenges affecting the reliability, safety, and service life of industrial machinery and equipment. It causes gradual degradation of metallic materials through chemical and electrochemical reactions with the surrounding environment, leading to equipment failure, production losses, increased maintenance costs, and safety hazards. Corrosion affects a wide range of industries, including manufacturing, oil and gas, power generation, chemical processing, marine engineering, mining, transportation, and infrastructure. Traditional corrosion management relies on periodic inspections, protective coatings, cathodic protection, and corrosion inhibitors. However, the emergence of Industry 4.0 technologies has introduced intelligent corrosion monitoring systems that integrate sensors, the Internet of Things (IoT), Artificial Intelligence (AI), Machine Learning (ML), Digital Twins, robotics, and predictive analytics for real-time corrosion assessment and maintenance planning. This review comprehensively discusses corrosion mechanisms, types of corrosion, influencing factors, conventional corrosion assessment techniques, modern monitoring technologies, corrosion prevention and control strategies, industrial applications, current challenges, and future research directions. The review highlights the importance of integrating advanced sensing technologies with intelligent maintenance systems to improve equipment reliability, reduce operational costs, and achieve sustainable industrial asset management.