COURSES OF STUDY

2008-2009

M.Tech. & Ph.D.

in

Corrosion Science & Engineering

I.I.T. Bombay
 M.Tech. Programme

Corrosion Science and Engineering

CREDIT STRUCTURE

CREDITS
Course Work Sem. I Sem. II Sem. III Sem. IV Total Credits
(Incl.
Summer)
Core Courses 2x8=16 8 - - 36
2x6=12
Elective 1x6=6 6 1x6=06 - 26

Ins. Elective - 6 - - 06

Outside Dept - - - - 00
Courses (**)
Lab. Course - - - - --

Seminar - 1x4=04 - - 04

R&D Project 0 - - - 00

Communication 4 - - - 04
Skills#

Training - - - - 00

Course Total 34+4 12 - 72+4

24
Project - 24 26 40 90

Total Credits 34+4 48 38 40 162 (+4)

(**) No outside department course is proposed as compulsory. However, the candidate may
choose courses from outside the department as a part of the electives in consultation with
the Guide.

# PP/NP only
 CORROSION SCIENCE & ENGINEERING

List of Courses and Course Requirements

Semester I

Core Courses

Course Course Name L T P C

No.
CR 601 Thermodynamics and Kinetics of Corrosion Processes 3 0 0 6
CR 605 High Temperature Corrosion 3 0 2 8
CR 607 Materials Science for Corrosion Engineers 3 0 0 6
CR 617 Aqueous Corrosion and its Control 3 0 2 8
CR 694 Seminar 0 0 4 4
HS 699 Communication and Presentation Skills 2 0 0 4#
Elective I 3 0 0 6
Total Credits 38+4

II Semester

Core Courses

CR 602 Protective Coatings 3 0 2 8

CR 696 Project Stage-I 24
Elective II 2 0 0 4
Elective III 2 0 0 4
Elective IV 3 0 0 6
Total Credits 46

III Semester

Elective V 3 0 0 6
Institute Elective 3 0 0 6
CR 697 Project Stage-II 26
Total Credits 38

IV Semester

CR 698 Project State-III 40

Electives :

Course Course Name L T P C

No.
CR 603 Introduction to Corrosion Science & Engineering 3 0 0 6
CR 604 Corrosion Control Practice for Industries 2 0 0 4
CR 608 Advances in Design for Corrosion Control 3 0 0 6
CR 609 Characterization of Materials for Corrosion Control 3 0 0 6
CR 610 Control of Erosion and Wear in Corrosive Environment 3 0 0 6
CR 611 Destructive and Non-destructive evaluation for Corrosion 3 0 0 6
Studies
CR 612 Cathodic Protection Engineering 1 0 0 2
CR 613 Surface Engineering of Engineering Materials 3 0 0 6
CR 614 Fracture Mechanics and Non-Destructive Evaluation 3 0 0 6
CR 615 Materials for Corrosion Prevention at High Temperatures 3 0 0 6
CR 619 Fracture and Failure Analysis of Composites 3 0 0 6
MM 680 Welding Science & Technology 3 0 0 6
MM 453 Engineering Polymers and Composites 3 0 0 6
COURSE CONTENTS:

CR 601 : Thermodynamics and Kinetics of Corrosion Processes 3 0 0 6

Difference between chemical and electrochemical reaction, fundamentals of ion solvent interactions and
their transport in aqueous, fused salt and solid electrolytes. Electrode (conducting and semi-
conducting)/electrolyte double layer interface. Concept of chemical potential, Electrode potentials.
Nerns’t Theory. Reference electrodes, their principles of working and construction. The concept of
reversible and irreversible electrodes and exchange current density. Theory of adsorption and zero
charge potentials. EH-pH (Pourbaix) diagrams their construction form basic thermodynamic data and
their applications in understanding different electrochemical phenomena.
Fundamental electrochemical systems viewed as energy producer, energy converter and energy
destroyer. Concept of different types of over voltages in an electrochemical cell and their relation to net
reaction rate at either of the electrodes. Butler Volmer relation, development of Tafels equation and its
linear approximation. Theory of mixed potential and its relation to corrosion potential. Important half
reactions like hydrogen evolution, oxygen reduction and active metal dissolution. Dimensionally stable
electrodes.
Concept of passivity and its breakdown. Origin of electrochemical noise and its applications to
studies in corrosion and its control.
Electrochemical instrumentation to study different electrochemical reactions.

Texts/References:

• Seansbury, R.A. Buchanan, Fundamentals of Electrochemical Corrosion, ASM International, USA,

2000.
• A.J. Bard and L.R. Faulkner – Electrochemical Methods: Fundamentals and Applications, John
Wiley & Sons, New York, 1980.
• M. Pourbaix, Atlas of Electrochemical Equilibria in Aqueous Solutions, Pergamon Press, New York,
1966.

CR 602 : Protective Coatings 3 0 2 8

Requirement of protective coatings, classification of organic, polymeric and inorganic coatings,

conversion coatings, metallic coatings, electrodeposition and elecotroless coatings. Paint coatings for
corrosion protection, role of resins, pigment, additives and solvents. Application techniques: Surface
preparation and its importance in coating, role of coating selection & design of coating, failure
mechanism , maintenance coatings, industrial paint systems, modern paint coating systems and specific
examples. Coatings for underground pipelines, storage tanks, overhead pipelines, offshore structures,
ship hulls, risers, reinforced bars and concrete structures. Testing and evaluation.

Texts/References:

• R. Lambourne and T.A. Strivens, Paint and Surface Coatings, Ellis Horwood D, Chichster, 1987.
• C.G. Munger, Corrosion Prevention by Protective Coatings, NACE Pub., Houston, 1984.
• Surface Finishing, Cleaning & Coatings, ASM Handbook, Vol. 5, 1994.
• J. Biesiek and J. Weber Portcullis, Electrolytic and Chemical Conversion Coatings, Red Hill Press,
1976.
• F.A. Lowenheim, Electroplating: Fundamentals of Surface Finishing, McGraw-Hill, New York, 1978.

CR 603 : Introduction to Corrosion Science & Engineering* 3 0 0 6

Importance and cost of corrosion, computation of corrosion rates, thermodynamics of corrosion,

passivation, mixed potential theory of corrosion and its application to understand the influence of
oxidizers, effect of velocity of the medium, galvanic corrosion: area relationship in both active and
passive states of metals.
Different forms of corrosion and their control viz., uniform corrosion, galvanic corrosion, selective
leaching, crevice corrosion, filliform corrosion, pitting corrosion, intergranular corrosion, erosion
corrosion, fretting damage, stress corrosion cracking, corrosion fatigue, hydrogen embrittlement and
microbes induced corrosion.
Elementary treatment of corrosion testing procedures, inhibitors and corrosion of steels.

Texts/References:

• Mars G. Fontana, Corrosion Engineering, McGraw-Hill, 3rd Ed., Singapore, 1987.

• H.H. Uhlig and R.W. Revie, Corrosion and its Control, 3rd Ed., John Wiley, Singapore, 1991.

(*The course contents of this course are same as that of theoretical contents of the course CR 617)

CR 604 : Corrosion Control Practice for Industries 2 0 0 4

Component design consideration, corrosion consideration in fabrication techniques, materials selection,

environmental review in industries, cooling water system, boiling water systems, inhibitors Case studies
from aerospace automobile, petrochemical, pharmaceutical, paper and pulp industries, Nuclear and
thermal power plant. Corrosion of off-shore structures.

Texts/References:

• Corrosion: Environment and Industries, Metals Handbook, Vol. 13c, Park Ohio, 1984, 10th Ed., ASM
Metals, Ohio, 1987.
• Failure Analysis and Prevention, Metals Handbook, Vol. 11, 9th Ed., Ohio, 1986.

CR 605 : High Temperature Corrosion 3 0 2 8

Low temperature vs high temperature corrosion. Introduction to oxidation, thermodynamics of gas/metal

reaction, stability of oxides/sulphides. Ellingham diagrams; oxidation kinetics – linear, parabolic, cubic,
logarithmic rate laws, Wagner’s theory of oxidation. Types of oxidation: general oxidation, selective
oxidation, internal oxidation, breakaway and catastrophic oxidation; defects in oxides (p&n type),
Wagner Hauffe Rules, Kroger Vink notations; oxidation vs sulphidation, hot-corrosion, oxidation of
important metals and alloys; Use of electron-optical techniques in assessing oxidation damage and
understanding oxidation mechanism. Practical examples of high temperature oxidation – power plants,
gas turbines, petrochemical plants etc.

Texts/References:

• Per Kofstad, High Temperature Corrosion, Elsevier Applied Science, 1988.

• U.R. Evans, Corrosion and Oxidation of Metals, Arnold Publ., London, 1981.
• N. Birks and G.H. Meier, Introduction to Oxidation of Metals, Edward Arnold, London, 1983.
• A.S. Khanna, Introduction to High Temperature Oxidation and Corrosion, ASM International,
Materials Park, Ohio, 2002.

CR 607 : Materials Science for Corrosion Engineers 3 0 0 6

Classification of materials, Bonding in materials and crystal structure, Phase diagrams : General concepts
in binary diagrams, Fe-Cr, Fe-Ni-Cr classification of alloys, ferrous and non-ferrous alloys, Heat
treatment: concept of hardening, annealing, quenching, tempering, Thermomechanical treatment etc.,
surface hardening treatment. Solidification and its effect.
 Mechanical behaviour of materials; Stress strain concept of deformation; true stress true strain
dislocations, Frank-read source, elastic and plastic behaviour, role of defects in mechanical properties,
treatment of various mechanical tests such as hardness, impact, tensile tests with theoretical principles.
Strengthening mechanism, solid solution strengthening, precipitate strengthening, work hardening
etc.
Fatigue of materials: Types and mechanism of creep, Development of creep resistant materials, low
and high cycle fatigue and mechanism of fatigue.
Fracture of materials: Griffith’s theory and fracture mechanics, fracture toughness, Analysis of
fractographs in relation to mode of fracture.

Texts/References:

• L.H. Van Vlack, Elements of Materials Science and Engineering, 6th Ed., Addison-Wesley, 1989.
• S.H. Avner, Introduction to Physical Metallurgy, 2nd Ed., McGraw-Hill, 1974.

CR 608 : Advances in Design for Corrosion Control 3 0 0 6

Design of field and laboratory experiments, Galvanic, Pitting and Crevice Corrosion, Intergranular
corrosion, Stress corrosion cracking and corrosion fatigue. Application of optical, scanning electron and
transmission electron microscopes, x-ray diffraction, EPMA, Auger and photoelectron spectroscopy.
Influence of composition and microstructure and their control and materials selection.
Design involving geometry, fabrication such as welding, piping system and plant layout for
corrosion prevention.
Treatment of water for recirculating systems and boilers.
Cathodic Protection: principle, sacrificial and impressed current systems, soil surveys, life estimation
of anodes, rectifiers – selection criteria, stray current corrosion, monitoring of CP of pipeline, tank
bottoms and offshore structures.
Anodic protection : Principles and applications
Failure analysis : Principles and detailed methodology, case studies from various industrial failures.

Texts/References:

• C.R. Pludek, Design and Corrosion Control, Macmillan, London, 1977.

• S.K. Coburn, Corrosion Source Book, ASM Metals.
• Corrosion, Metals Handbook Vol.13, Park Ohio, 1984 9th Ed., ASM Metals, Ohio, 1987.
• Failure Analysis and Prevention, Metals Handbook, Vol. 11, 9th Ed., Ohio, 1986.

CR 609 : Characterization of Materials for Corrosion Control 3 0 0 6

Mechanisms of various corrosion scale formation, thick layer and thin layer. Chemical analysis,
Principles and method of analysis of various electron optical techniques : optical microscopy, SEM,
EDAX, EPMA, SIMS, AES/ESCA, XRD, TEM, X-ray fluorescence, atomic force microscopy. Use of
these techniques to analyse corrosion products, insitu corrosion scale analysis. Analysis of passive layers,
thin tarnishing layers. Examples of analysis from corrosion case histories.

Texts/References:

• Materials Characterization, Metals Handbook Vol. 10, ASM, Ohio, 1994.

• D. Cullity, Elements of X-ray Diffraction, Addison Wesley, Mass, 1956.
• J.J. Hren, J.I. Goldstein (Eds.), Introduction to Analytical Electron Microscopy, Plenum Press, New
York, 1979.
CR 610 : Control of Erosion and Wear in Corrosive Environment 3 0 0 6

Principles of friction and wear. Mechanism of adhesive and abrasive, corrosion and erosive wear.
Rebinder effect Fretting and fatigue, fundamentals of erosion and erosion-corrosion and corrosion
resistance, requirements for high temperature coatings, principles of CVD, PVD, plasma spraying,
carburizing, and nitriding, ion implantation, laser surface alloying, life prediction of coated surface,
economic consideration and future coatings requirements.

Texts/References:

• Friction, Lubrication and Wear Technology, Vol. 18, 9th Ed., ASM Metals Handbook, Ohio, 1992.
• I.M. Hutchings, Tribology-Friction & Wear of Engineering Materials, Edward Arnold – Great Britain,
1992.

CR 611: Destructive and Non-Destructive Evaluation for Corrosion Studies 3 0 0 6

Microscopy and crystallography techniques. Chemical & microchemical analysis. Introduction to NDT,
Surface examination methods, visual, liquid penetrant testing, magnetic particle testing, eddy current
testing, volumetric examination methods, radiography (X-rays). Ultrasonics, advanced NDT
methods/Ultrasonic time of flight diffraction methods, acoustic emission testing, NDT methods for the
measurement of residual stresses, NDT methods for characterization of microstructures. NDT for
uniform corrosion, localized corrosion (local wall thinning, crack type flaws due to CF, SCC, HE)
Interaction of fracture mechanics & NDE for assessment of corrosion damage. Role of NDE in corrosion
failure analysis, linear polarization & AC impedance for online monitoring. Surface Chemical
characterization.

Texts/References:

• Materials Characterization, Metals Handbook, Vol.10, ASM, Ohio, 1994.

• Baldev Raj, T. Jaikumar and M. Thavasimuthu, Practical Non-destructive Testing, Narosa Pub., New
Delhi, 1997.
• Non-destructive Evaluation and Quality Control, ASM Handbook, Vol. 17, 1989.

CR 612 : Cathodic Protection Engineering 1 0 0 2

Fundamentals of cathodic protection, types of cathodic protection systems and anodes. Surveys, design
of anode ground beds, Life time calculations, rectifier selection. Stray current corrosion problems and its
prevention. Coating for various cathodic protection system and their assessment.

Texts/References:

• J. Morgan, Cathodic Protection, NACE, Houston, 1987.

• A.W. Peabody, Control of Pipeline Corrosion, 2nd Ed., NACE International, Houston, 2001.

CR 613 : Surface Engineering of Engineering Materials 3 0 0 6

Significance, design of surface layers based on mathematical modeling, rational application of surface
layers, significance of the surface, the surface – physico-chemical concepts, interphase surface – a
physical surface, surface energy, surface phenomenon, the superficial surface structure, potential
properties, stereometric-physico-chemical parameters, residual stresses, adsorption, tribological
properties, types of friction, the role of surface in the friction process, electrochemical nature of surface
layers – electrical structure of surface layer, corrosion resistance, anti corrosion properties, structure of
metallic coatings, adhesion, hardness, ductility (elasticity), service properties, anti corrosion properties,
porosity, bulging, permeability, prevention – coatings and formation of technological surface layers,
techniques of formation (mechanical, thermo-mechanical, thermal, thermo-mechanical, electrochemical
and chemical), electron beam technology, laser technology, implantation techniques (ion implantation),
glow discharge methods and CVD technology, vacuum deposition by physical techniques (PVD) for
surface modification.

Text/References:

• T. Burakowski and Wierzchon, Surface Engg. of Metals - Principles, Equipments, Technologies, CRC
Press, Boca Raton, London, New York, Washington, 1999.
• J.O.M. Bockris, A.K.N. Reddy, Modern Electrochemistry, Plenum, New York, 2000.
• M.G. Fontana, Corrosion Engineering, 3rd Ed., McGraw-Hill, New York, 1986.

CR 614 : Fracture Mechanics and Non-destructive Evaluation 3 0 0 6

Deformation, defects & fracture, Detection & characterization of defects using, NDT Techniques.
Introduction to LEFM & EPFM: Micro-structural aspects of fracture toughness. Environmental assisted
cracking, Determination of toughness parameters. Quantitative NDE & analysis of Engg. failures, fitness
for purpose and life extension.

Text/References:

• T.L. Anderson, Fracture Mechanics: Fundamentals and Applications, CRC Press, USA, 1995.
• D. Hull, Fractography, Cambridge Univ. Press, U.K., 1999.
• Rechard W. Hertzberg, Deformation & Fracture Mechanics of Engineering Materials, John Wiley &
Sons, 1989.
• NDE and Quality Control Metals Handbook, Vol. 17, ASM, Metals Park, Ohio, 1989.

CR 615 : Materials for Corrosion Prevention at High Temperatures 3 0 0 6

Choice of materials based on their mechanical strength, creep, fatigue and toughness. Microstructural
stability and corrosion resistance.
General properties and application of various steels, ODS alloys, rapidly solidified materials, single
crystals, intermetallics, refractories and composite materials.
Need for protective coatings at high temperature, Diffusion coatings, PVD and CVD coatings, ion-
plating ion sputtering, electron beam coatings, laser glazing and laser alloying.

Texts/References:

• E. Bullock et al, Research and Development of High Temperature Materials for Industry, Elsevier
Sci., 1989.
• O. Van Der Biest, Analysis of High Temperature Materials, Appl. Sci. Pub., 1986.
• E. Lang, Editor, Coatings for High Temperature Applications, Appl. Sci. Pub., 1983.

CR 617 : Aqueous Corrosion and its Control* 3 0 2 8

Importance and cost of corrosion, computation of corrosion rates, thermodynamics of corrosion,

passivation, mixed potential theory of corrosion and its application to understand the influence of
oxidizers, effect of velocity of the medium, galvanic corrosion: area relationship in both active and
passive states of metals.
Different forms of corrosion and their control viz., uniform corrosion, galvanic corrosion, selective
leaching, crevice corrosion, filliform corrosion, pitting corrosion, intergranular corrosion, erosion
corrosion, fretting damage, stress corrosion cracking, corrosion fatigue, hydrogen embrittlement and
microbes induced corrosion.
Elementary treatment of corrosion testing procedures, inhibitors and corrosion of steels.

(*The body of this course is the same as that of CR 603, but includes practical)

Texts/References:

• Mars G. Fontana, Corrosion Engineering, 3rd Ed., McGraw-Hill, Singapore, 1987.

• H.H. Uhlig and R.W. Revie, Corrosion and its Control, 3rd Ed., John Wiley, Singapore, 1991.

CR 619 : Fracture and Failure Analysis of Composites 3 0 0 6

Processing of composite materials. Fabrication processes for metal matrix composite, ceramic matrix
composite and polymeric matrix composites, Applications of composites, NDT for production
applications, Interface strength and toughness of composites, modes & micro-mechanisms of Fracture,
Fatigue & fracture behaviour of composites, Environmental effects, Fractography and failure analysis of
composites. Case studies.

Text/References:

• B.Z. Jang, Advanced Polymer Composites : Principles and Applications, ASM International,
Materials Park, Ohio, USA, 1994.
• K.K. Chawla, Composite Materials Science & Engineering, Springer Verlag, New York, 1987.
• M.M. Schwartz, Composite Materials : Processing Fabrication and Applications, Vols. I & II,
Prentice-Hall, PTR, New Jersey.
• E.E. Goloutos et al, Failure Analysis of Industrial Composite Materials, McGraw-Hill, New York,
2000.
• S. Suresh, Andreas Mortensen and Alan Needleman, Fundamentals of Metals Matrix Composites,
Butterworth-Heinemann, USA, 1993.
• R.C. Prasad and P. Ramakrishnan (Eds.), Composites: Science and Technology, New Age
International, Delhi, 2000.