WELCOME TO ME 575

(Advanced Corrosion Engineering)

(6.30~7.45 PM / MW)

Instructor: Dr. Ihsan-Ul-Haq Toor

Office: 63-358/Phone:7493
Office Hours: 12.30~1.30 (UTR)
or appointment via E-mail:
ihsan@kfupm.edu.sa

Lecture Contents

Why Study Corrosion?

Economic impact of corrosion?
Environmental factors for corrosion?
Corrosion Basics (what, why and how)
Electrochemical nature of corrosion
Forms of Corrosion

ADVANCED CORROSION ENGINEERING

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What is Corrosion?
The destruction of a metallic material by chemical,
electrochemical, or metallurgical interaction with the
environment

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Why Study Corrosion?

Almost every engineer/scientist will at one time or another be

exposed to MATERIALS (design, synthesis, application etc)
Examples: gear, building, oil refinery component, or an integrated
circuit chip, oil and gas etc, desalination, power, nuclear, etc

Metals are the most abundant and each has different

properties (80 known elements are metals)
These different elements have been combined to develop
roughly > 40000 different alloys and still going on

ADVANCED CORROSION ENGINEERING

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Importance of this subject?

Human life and safety

ALOHA incident 1998/ Pilot managed to land the plane on the island of
Maui, Hawaii (one flight attendant was died)

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Silver Bridge connecting Ohio and West

Virginia over the Ohio River
collapsed,1967

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Importance of this subject?

The oil-drilling rig that burned for 36 hours in the Gulf of Mexico sank
Thursday, April 22, 2010/ 11 ppl died and major oil spill occured

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Importance of this subject?

Economic Impact of Corrosion

3~5% of GNP of Developd country

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Economic Impact of Corrosion

Direct Cost:
Capital costs cost of replacement parts, e.g., automobile mufflers, water lines, hot
water heaters, sheet metal roofs.

Control costs maintenance, repair, painting.

Design costs extra cost of using corrosion-resistant alloys, protective coatings,
corrosion inhibitors.

Indirect loss

Plant shutdown.

Loss of product.

Loss of efficiency

Contamination.

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Economic Impact of Corrosion

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Materials & Environment

Corrosion is an interdisciplinary area

embracing chemistry, materials science,
and mechanics

The study of aqueous corrosion

processes involves the intersection of
chemistry and materials science.
But the science of mechanics must be
added to understand mechanically
assisted corrosion processes (SCC, HIC,
FAC, CF)

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Defining the environment is very important

Some environments are more corrosive than others,
but there can be exceptions
Moist air is more corrosive than dry air

Hot water is more corrosive than cold water

Polluted air is more corrosive than clean air

Acids are more corrosive than bases (alkalies) to steels

Salt water is more corrosive than fresh water
No corrosion will occur in a vacuum, even at very high temperatures

ADVANCED CORROSION ENGINEERING

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Challenge for Corrosion Engineers

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Challenge for Corrosion Engineers

1. The development of protective surface treatments and corrosion inhibitors to replace inorganic chromates,
which are environmentally objectionable.
2. An improved conservation of materials through the development of corrosion-resistant surface alloys which
confine alloying elements to the surface rather than employing conventional bulk alloying.
3. The formulation of a new generation of stainless steels containing replacements for chromium and other
critical metals.
4. An improved understanding of passivity so as to use our fundamental knowledge to guide the development
of alloys having improved corrosion resistance.

5. Understanding the mechanism of the breakdown of passive oxide films by chloride ions and subsequent
pitting of the underlying metal.
6. The development of smart organic coatings which can detect a break in the coating and automatically
dispatch an organic molecule to the required site to both heal the coating and inhibit corrosion.
7. The ability to predict the lifetime of metals and components from short-term experimental corrosion data.

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Why Corrosion?

Corrosion is natural process and it returns the metal to its oxidized state or combined state in the form of
chemical compounds that are similar to the minerals from which they are extracted

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How Corrosion Takes Place?
Corrosion process requires a complete corrosion cell/circuit, which
includes;

1.
2.
3.
4.

Anode
Cathode
Electrolyte
Electrical path

Electrochemical Cell

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How Corrosion Takes Place?
Anodic reactions/Oxidation reaction takes place at anode
(generation of electrons)

General Reaction (metal oxidation)

MMn+ + ne- (gives off electrons))
Zn Zn2+ + 2eFe Fe2+ + 2eAl Al3+ + 3eFe2+ Fe3+ + e-

(Zn corrosion)
(Fe corrosion)
(Al corrosion)
(Ferrous ion oxidation)

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How Corrosion Takes Place?
Cathodic reactions/reduction reaction:
O2 + 2H2O + 4e- 4OH- (oxygen reduction in water/bases)

O2 + 4H+ + 4e- 2H2O (oxygen reduction in acids)

2H2O + 2e-

H2 + 2OH- (hydrogen evolution in water/bases)

2H+ + 2e- H2 (hydrogen evolution in acids)

Cu2+ + 2e- Cu (metal deposition=>copper plating)

Fe3+ + e- Fe2+ (metal/ferric ion reduction)

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Electrochemical nature of Corrosion

Consider what happens when Zn is placed in aerated dilute HCl solution
(acidic solution):

CR or ?

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Corrosion of Metals
Behavior of Active and Passive metals

Passive
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Active
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Corrosion Types

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Corrosion Types

SCC in DSS

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