Introduction to Corrosion

Lecture#01

Definition

Corrosion may be defined as the destruction of a metal or an alloy because of chemical or electrochemical reaction with its surrounding environment or medium

1Sheir,

Environments in Corrosion1
L.L., R.A. Jarman, and G.T. Burstein, eds. Corrosion. 3rd ed. Vol. 1. 2000, Butterworth-Heinemann: Oxford. 3

Corrosion: Metallurgy in

2 Reverse

2Fontana,

M.G., Corrosion Engineering. 3rd ed. 1986, New York: McGraw-Hill. 4

Some Corrosion 3 Failure Examples

3Corrosion

Doctors Website. Homepage: http://www.corrosion-doctors.org

Aloha Incident

Aloha Incident (Contd..)

Bhopal Accident

Carlsbad Pipeline Explosion

Flow Accelerated Corrosion

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Nuclear Reactor with a Hole in the Head

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Losses due to

4 Corrosion

4Uhlig,

H.H. and R.W. Revie, Corrosion and Corrosion Control. 3rd ed. 1985, New York: John Wiley & Sons. 12

Cost of Corrosion

Which cost more?

Corrosion Fire Flooding Earthquake

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Cost of Corrosion(2004) in billion US$5

Country
USA Japan

Direct Cost
303.76 59.02

Indirect Cost
200 (approximately)

Former USSR
Germany UK Australia Belgium India Poland Canada .....

55.01
49.26 8.51 7.32 6.75 3.78 3.53 3.38

.....
..... Global
5Bhaskaran,

510.14

940 (approximately)

R., N. Palaniswamy, and N.S. Rengaswamy, Global Cost of CorrosionA Historical Review, in Corrosion: Materials, Vol 13B, ASM Handbook. 2005, ASM International.

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Example of

3 Overdesign

An 8" in. dia oil pipeline 225 miles long with a in. wall thickness was installed with no corrosion protection system With appropriate protection namely cathodic protection, it would have a thin wall thickness which would

save 3,700 tons of steel (worth more than one million dollar) increase internal capacity of the pipeline by about 5%.
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SoWhy Study Corrosion?

Materials are precious resources Engineering design is incomplete without knowledge of corrosion Applying knowledge of corrosion protection can minimize disasters Corrosion contaminate products such as pharmaceutical, food and dairy products or luxury items like soap Corrosion products threat to the environment Artificial implants for the human body!!!
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Distribution of disciplines in which active corrosion engineers have graduated

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So .. What would be expected from You (a Corrosion Engineer)?

Ensuring maximum life of new equipment Preservation of existing equipment Protecting or improving the quality of a product in order to maintain or improve a competitive position. Avoiding costly interruptions of production. Reducing or eliminating losses of valuable products by spillage or leaks. Refitting of equipment withdrawn from service because of corrosion. Reducing hazards to life and property that might be associated with corrosion: Explosions of pressure vessels or piping systems release of poisonous or explosive gases or vapors are a few examples.
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