:Corrosion:

Self-Potential :
When one gram of any material is dipped into its 1gm of ions there will be some potential
difference developed b/w ions called Self potential.
Self Potential of H (Hydrogen) is very insignificant so it is taken as reference ( ∵emf = 0).

Suppose Zn is immersed in Hcl solution so due to the potential difference b/w the Zn and the
environment, e(-)s (electrons) will come out of the material. These e (-)s after combining with H2 / H+ ; emf = 0
hydrogen ions produces hydrogen gas but this circuit is incomplete. To complete the circuit Zn
ions are coming to the solution, the rate at which Zn ions are coming to the solution is called
“Corrosion Rate”.

Hcl --> H(+) + Cl(-)

2H(+) + e(-) --> H2

To complete the circuit: Zn --> Zn+2 + 2e(-)

Fig: Zn - Hcl Solution
Polarization :
When the surrounding is concentrated, flow of ions towards the metal surface will slow down, this will decrease the
corrosion rate.
Suppose some turbulence appears in the surrounding atmosphere, again flow of ions will increase and this will in-turn
increase the corrosion rare and this phenomenon is call Polarization.

Passivity:
Oxidizing power of any material can be increased by increasing the flow of Nescent oxygen. By increasing the oxidizing
power, corrosion rate will also be increased but in some materials like Al (Aluminium), initially the corrosion rate
increases but it forms Al-Oxide (Al2O3) which is a ceramic. We know ceramics are highly corrosion resistance this
decreases the corrosion rate further and the phenomenon is call Passivity. (As shown below)

Forms Of Corrosion

1. Uniform Attack: This type of corrosion appears on the surface uniformly and the only way to take care of this
corrosion is by providing allowance.

2. Galvanic Corrosion:

> To control corrosion b/w 2 materials, both material should be selected from the closed proximity in the galvanic Series
because voltage difference will be less and hence corrosion will be less. (Galvanic series scale show below)
cathode Pt ; Au ; Graphite ; Ti ; Ag ; Ni ; C ; Bronze; Cu ; Sn ; Pb ; Co Io ; Steel ; Cd ; Al ; Zn ; Mg anode

Ti-Al shows high potential difference

> When we have to select 2 materials, large difference in the galvanic series, since corrosion will be more, so a thin layer
of insulating material is kept b/w the 2 material like gasket. This equally distribute the corrosion burden on both the
materials otherwise anode material will corrode faster.

> suppose we want to protect a single material from corrosion, small piece of anode material is taken from galvanic
series and attached with it. Anode material will corrode faster but it will protect the cathode after certain time period,
this anode material needs to be replaced.

> Corrosion is taken place in the material because e (-) are coming out of it. Corrosion is controlled when we supply e(-)s
back to the material and this will do it by connecting the material to the battery.

3. Area Effect: Suppose a anodic material is coated over a cathodic material and if there is small hole in the coating,
concentration of e(-)s though the hole is very high. So, Rate of at which anodic material is consumed will be large.
(Note: Never coat cathodic material over anodic materials).

Anodic Coating

Anodic Coating Cathodic Coating

4. Crevice Corrosion: When reveted and bolted joints are used all around these fasteners, dust will be accumulated, this
creates acetic environment which lead to corrosion. Crevice is a localized corrosion and it can be avoided only by welded
joints.

5. Stress Corrosion: Upon over stressing the material by fastening, some micro cracks will appear near fasteners. These
cracks will corrode first under acidic environment.
Ex: NH3 environment for brass material, gradually size of crack keeps on increasing and once crack reaches a particular
value sample will fail.

Note:
# To see the micro-structure of any material after polishing, it is dipped into some etchant or chemical. This creates
corrosive environment to the material. Grain boundaries will corrode more then grain the grain because of their larger
bond lengths and different phase extent of corrosion will be different. This variation in corrosion rate can be seen in the
form of from of microstructure under inverted optical microscope(1600X).

-:Polymers:-
Polymer are building blocks of monomers. Polymer are long C-C Chain structure and C-C bond can be taken different 3D
Shapes by maintaining the same Bond angle. This phenomenon is call confirmation. Due to which polymers are soft,
otherwise C-C bond is one of the strongest know bond.

Conformation / Bond rotation

Degree of Polymerization (n):Number of monomer connected in
chain
Atomic weig h t of c h ain
n=
Atomic wig h t of 1 monomer
Length of Chain: (Lc)

From theory of randomness

Lc= √ n L

Where,
L --> Step length
n --> no. Of monomers connected in chain

#Plastics:

Thermo Plastics : Can be recycled because upon heating and cooling it become soft and hard interchangeably. Both in
the ceramics and polymers it is a long chain structure and unless and until this structure is broken material is not going
to become soft.
Some Thermoplastics are : 4 Thermoplastics are call BIG 4 (80-90%) in nature.

1. Polyethylene (PE) - 3. poly vinyl Chloride (PVC) Other thermoplastics are

-> PTFE or Teflon

-> ABS ( Acrylo Butadyne Styrene )

2. Polypropylene (PP) 1. Polystyrene
it is a CD material
terplymer
(C8H8)x (C4H8)y (C3H3N)z

-> Aeroplane Window materials is a plastic :

PMMA (Poly methyl meta acrylate )

2. Thermo-setting Plastics: Since there is an cross linking of C-C bond and no matter how much is the temperature this
cross linking doesn’t open up so thermo-setting plastics will burn but I will not become soft.

- Bakelite : Manufacturing Electric Switches

- Epoxy : is used as a matric material in composites.

-:Ceramics:-
Metals Non-Metals

- At Room temperature, they are solids - At room temperature they are Gas
- Good conductors of heat & electricity - Bad conductor of electricity
- By combining with other material, they form alloy - By combining with other materials, they do not form alloy
Ceramics : Whatever is not a Metal, Non-Metal or organics polymers is called a Ceramics Ex: Stone, Glass
Properties of ceramics:
1. Very high temperature resistance
2. Very Hard & Brittle
3. Very High compressive strength
4. Very high corrosion resistance
5. Very low tensile strength

Ceramics : SiO2 (Silica) , Al2O3

Every material when it is cooled from the liquid, it exhibits TTT

diagram for crystallization.

-When Liquid silica is cooled slowly it will enter into TTT

diagramm this produces crystalline Silica called “Quartz”. It is
used in Piezoelectric crystals, manufacturing of optical flats,
watches etc.,

-When the cooling rate is equal to or greater than the critical

cooling rate, then viscosity of the liquid metal will keep on
increasing and after certain temperature, it appears like solid
but there are no crystals on it, this amorphous state of silica is
called Glass. Glass is unstable sate and after certain time period
it’s going to convert into crystalline form and the process is
called Devitrification of glass

- Larger is the ceramics specimen size more is the probability having large size crack so when a ceramics specimen
loaded in tension, large size crack normal to load starts increasing in size. The moment when crack reaches a critical
value, entire specimen divide into two parts. So strength of ceramic is size dependent.

Silica Tetrahedra Quartz Glass

Building block for both Quartz and Glass is Silicatetrahedra. When terahedras are connected in an organized structure, it
is called “Quartz”.But when silica tetrahedras are connected randomly it is called “Glass”.
Since, each silica tetrahedra can be connected with 4 other silica tetrahedras, it forms very long chain structure. Upon
heating an amorphous material unless and until long chain structure is broken, materal is not going to become soft so
processing temperature of pure silica glass is high this increases cost of glass.
To decrease the processing temperature of the glass, with the help of NaO and CaO this silica tetrahedra chain is broken
into smaller pieces, this decreases the processing temperature and hence the cost of the glass. since, Sodium (Na)
having only one valency so whenever sodium get connected silica terahedra, chain will brake. It is called “Soda-lime
Glass”
Toughened Glass:

Toughening is the process of introducing compressive stresses in the surface of glass specimen so when a tensile load is
applied, these compressive stresses will be neutralized first before the tensile stress go towards the crack. This increase
the strength of glass specimen, due to the residual stresses if this glass break in many pieces due to compressive stresses
there will be tendency in the material to move towards center. This makes the sharp edge blunt.

1. Air Quenching: When liquid SiO2 is cooled rapidly, viscosity if material will keeps on increasing and after some time
the material appears like solid. The temperature at which we are not able to decide whether it is liquid or solid is called
Glass transition temperature (Tg).
Glass specimen is heated to a temperature slightly less then glass transition temperature and then it is placed in the
steam of cooled air since outer surface come in contact with quenching medium immediately it comes to room
temperature and become rigid but center is still hot having slightly higher specific volume. After certain time period
when core comes to room temperature, its volume will shrink and it will also try to pull the surface which is rigid. This
introduces compressive stress in surface.
These compressive stress makes the crack propagation difficult so glass will become strong in tension. Also due to
residual stress when the glass break it brake in small pieces. There will be a tendency in glass material to move towards
center this makes the shape edges blunt.

2. Ion Exchange : Soda line glasses are toughened by this process. These glasses are placed in hot KNO 3 bath, whatever
Na ions present on the surface of the glass will be replaced by potassium (K) atoms. Since K atoms is bigger in size
surface wants to expand but core restrict it motion. This introduces very high compressive stress in the surface but the
thickness of toughened layer will be in microns.
 -:Composites Material:-
1. Metals
2. Polymers Mixing any two --> Composites
3. Ceramics

A) Matrix Material : Matrix - Main ingredient (high Quantity) and Dispersed phase (low quantity)

i) Metal Matrix composites : Matrix -metal dispersed - ceramics

Ii) Polymer Matrix composites : Matrix -polymer dispersed - ceramics

- CFRP (Carbon fiber reinforced plastics )
- GFRP ( Glass Fiber reinforced plastics )

Iii) Ceramic matrix composites : Matrix -RCC -dispersed -Steel

- RCC

B) Orientation of Fibers:

i) Long continuous fiber: used for uni axial loading & weaker in transfers load

ii) Short Discontinuous Fiber: Used when loading is varying in one plane

iii) Short Randomly orientation fiber: Same strength throughout, any direction

-:Nano-Materials:-
For any materials if one of its physical dimension or the maximum grain size is less than 100nm is called a nanomaterial.
(<100nm)

Figure shows line = 3 grain/length --> grain density

Yield strength by hall patch equation

K
Y.s = σo +
√d
Where, D-> size of Grain

Because of very fine grain structure, material will have larger surface area that is very prone to reaction and at very high
temperature. Since grain boundary have tendency to flow so material will exhibit a great degree of ductility.

Application of Nanomaterials
1. Due to larger contact area there will be uncontrolled combustion of solid fuel and these nano fuels are used in rockets
and missiles. ( these produce high thrust)
2. Bio Medical engineering, Manufacturing of artificial bone.
3. Nano-Material honey comb, catalytic converter.
4. Computer Chips, Sunscreen lotion (TiO2)
5. HD TV’s to increase resolution

Classification of Nano-Materials
1. Zero Size: Some of the example in this category are particle, cluster of particle and dia if this particle will less than
100nm.

2. 1D : ex: Nano Tubes, used in artificial bones

3. 2D : Ex: Thin films

4. 3D : any bulk material ( Max. Grain size <100nm)

Processing of Nano-material / How to manufacture Nano material

When bulk material is converted in nano-size particle it is called Top-Down Approach & when atoms of any material
synthesized and grouped together to produce nano material is called Down to top Approach.

Methods:
1. Mechanical Grinding: (Top to Down approach)

If the material is extremely brittle we can directly put into the drum to
convert to powder and when there is little bit ductile, Initially it will be
dipped in the liquid nitrogen (N2)and placed in drum. By repeated
impact b/w material & steel balls, material will convert to nano-powder
but it is a time consuming process.

2. Sol Gel (Hydrolysis) : (Down to Top approach)

Different atoms are synthesized to convert into nano material

3. Chemical Vapour deposition (CVD)

In CVD, initially material is vaporized and by synthesis process atoms are grouped together to form nano-materials