ENGINEERING

MATERIALS

Lecturer: Muhammad Sulaiman

m.sulaiman@uet.edu.pk
1
Department of Chemical, Polymer and Composite Materials Engineering
University of Engineering & Technology, Lahore(KSK Campus)

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 CORROSION & DEGRADING OF
MATERIALS

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 MATERIALS Vs ENVIRONMENT
Most materials experience some type of interaction with a large
number of diverse environments.
This interaction results in the deterioration of their material
properties including:

1. Mechanical Properties (ductility, strength)

2. Material Appearance

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CORROSION
Defined as the destructive and unintentional attack of a metal resulting
in a slow or continuous eating away of metallic and non-metallic
components by chemical or electrochemical attack”.
Metals: In metals, there is actual material loss either by dissolution
(corrosion).
Ceramics: Ceramic materials are relatively resistant to deterioration,
which usually occurs at elevated temperatures or in rather extreme
environments; the process is frequently also called corrosion.
Polymers: For polymers, mechanisms and consequences differ from
those for metals and ceramics, and the term degradation is most
frequently used.

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ELECTROCHEMICAL CONSIDERATIONS

For metallic materials, the corrosion process is normally

electrochemical, that is, A chemical reaction in which there is
transfer of electrons from one chemical species to another.
Metal atoms characteristically lose or give up electrons in what
is called an oxidation reaction.
For example, the hypothetical metal M that has a valence of n (or n
valence electrons) may experience oxidation according to the
following reaction:

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ELECTROCHEMICAL CONSIDERATIONS
The site at which oxidation takes place is called the anode; oxidation is
sometimes called an anodic reaction.

The electrons generated from each metal atom that is oxidized must be
transferred to and become a part of another chemical species in what is
termed a reduction reaction. For example, some metals undergo corrosion
in acid solutions, which have a high concentration of hydrogen (H) ions;
the H ions are reduced as follows and hydrogen gas (H2) is evolved.

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ELECTROCHEMICAL CONSIDERATIONS
The location at which reduction occurs is called the cathode.
An overall electrochemical reaction must consist of at least one
oxidation and one reduction reaction, and will be the sum of them;
often the individual oxidation and reduction reactions are termed half-
reactions.

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ELECTROCHEMICAL
CONSIDERATIONS

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ELECTROCHEMICAL CONSIDERATIONS

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ELECTROCHEMICAL
CONSIDERATIONS

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FORMS OF CORROSION

1. Dry corrosion

2. Wet corrosion

3. Galvanic corrosion

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 Dry Corrosion

Direct oxidation of metals OR Corrosion due to atmospheric gases.

 Freshly cut surface reacts with the oxygen(no moisture or water to aid
the corrosion.

Wet Corrosion
Oxidation in the presence of air and moisture.
 Rusting of ferrous metals
 Involving oxidation and reduction process.

Galvanic Corrosion
Occurs when two metals or alloys having different compositions are
electrically coupled while exposed to an electrolyte. Here one metal acts as
Anode and the other one acts as Cathode. The Anode metal will be active in
a particular series and the Cathode metal will be acting as a noble metal.
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GALVANIC CORROSION OR TWO METAL CORROSION

Passive
Active Component
Component (Cathodic)
(Anodic)

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GALVANIC CORROSION
The less noble or more reactive metal in the particular environment
will experience corrosion;
The more inert metal, the cathode, will be protected from corrosion.
When galvanic couple is formed, one of the metal in the couple
becomes anode and corrodes faster than it would alone, while other
become cathode and corrodes slower than it would alone.
The electrolyte is provided in the form of rain, dew, humidity, or
chemicals.

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GALVANIC CORROSION
Galvanizing
In the case of galvanized iron (zinc-coated mild steel), steel base
acts as cathode and zinc coating as anode.
The zinc corrodes away whilst protecting the steel.
This is termed as “SACRIFICIAL CORROSION”.

Galvanic Corrosion-Prevention
 If coupling of dissimilar metals is necessary, choose two that are
close together in the galvanic series.
 Avoid an unfavorable anode-to-cathode surface area ratio; use an
anode area as large as possible.
 Electrically insulate dissimilar metals from each other.
 Electrically connect a third, anodic metal to the other two; this is a
form of cathodic protection, discussed presently.
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GALVANIC SERIES…..

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CORROSION BY OTHER GASES (BY HYDROGEN)

Hydrogen Embrittlement
Loss in ductility of a material in the presence of hydrogen is known as hydrogen
embrittlement.
This type of corrosion occurs when a metal is exposed to hydrogen environment.
Iron liberates atomic hydrogen with hydrogen sulphide in the following way.
Fe + H2S → FeS + 2H
Hydrogen diffuses into the metal matrix in this atomic form and gets collected in
the voids present inside the metal. Further, diffusion of atomic hydrogen makes
them combine with each other and forms hydrogen gas.
H + H → H2↑
Collection of these gases in the voids develops very high pressure, causing
cracking or blistering of metal.
Hydrogen embrittlement is similar to stress corrosion.

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 EROSION CORROSION
It arises from the combined action of chemical attack and
mechanical abrasion/wear as a consequence of fluid motion.
The nature of the fluid can have influence on the corrosion behavior.
Increasing fluid velocity normally enhances the rate of corrosion.
Also, a solution is more erosive when bubbles and suspended
particulate solids are present.
Erosion–corrosion is commonly found in piping, especially at bends,
elbows, and abrupt changes in pipe diameter-positions where the fluid
changes direction or flow suddenly becomes turbulent.
Propellers, turbine blades, valves, and pumps are also susceptible to
this form of corrosion.

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 EROSION CORROSION
Elbow fitting that was part of a steam condensate line under
Erosion Corrosion.

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 EROSION CORROSION-PREVENTION

Change the design to eliminate fluid turbulence.

Other materials/coatings may also be utilized that inherently resist

erosion.
Removal of particulates and bubbles from the solution will less its
ability to erode.

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STRESS-CORROSION CRACKING(SCC)

It results from the combined action of an applied tensile

stress and a corrosive environment.
Small cracks form and then propagate in a direction perpendicular to
the stress, with the result that failure may eventually occur.
Most alloys are susceptible to stress corrosion in specific
environments, especially at moderate stress levels.
Probably the best measure to take in reducing or totally eliminating
stress corrosion is to lower the magnitude of the stress.
For example, most stainless steels stress corrode in solutions
containing chloride ions, whereas brasses are especially vulnerable
when exposed to ammonia.
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 MICROBIAL CORROSION
Corrosion promoted by microorganisms.
It can apply to both metals and non-metallic materials, in both the
presence and lack of oxygen.
Sulfate-reducing bacteria are common in lack of oxygen; they
produce hydrogen sulfide, causing sulfide stress cracking.
In presence of oxygen, some bacteria directly oxidize iron to iron
oxides and hydroxides.

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CORROSION FURTHER TYPES
Uniform Corrosion
 Corrosion that occur at the same rate over the exposed metal surface.
Pitting corrosion
 Corrosion  by which cavities are produced in the material.
 Chloride ions(liquid) are damaging to the passive films and can make pit
formation auto-catalytic.
 The area covered by the drop of salt solution acts as anode.
Crevice Corrosion
 Corrosion occurred in the crevice between two joining surface.
 Accumulation of liquid(chlorides) inside crevice will aggravate damage.
 The crevice becomes anodic region and undergoes corrosion
 Bolts, nuts, rivets, joints are examples for this type of corrosion.

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CREVICE CORROSION
Electrochemical corrosion may also occur as a consequence of
concentration differences of ions or dissolved gases in the
electrolyte solution, and between two regions of the same metal
piece. For such a concentration cell, corrosion occurs in the locale
that has the lower concentration. A good example of this type of
corrosion occurs in crevices and recesses or under deposits of dirt
or corrosion products where the solution becomes stagnant and
there is localized depletion of dissolved oxygen. Corrosion
preferentially occurring at these positions is called crevice
corrosion.
Bolts, nuts, rivets, joints are examples for this type of corrosion.

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INTERGRANULAR CORROSION(IGC)

 The boundaries of crystallites of the

material are more susceptible to
corrosion than their insides.
 Occurs in corrosion-resistant alloys,
when the grain boundaries are depleted
of the corrosion-inhibiting compound.
 Also occurs when there are impurities
and/or stress concentrations are present
at the grain boundaries.
  It is as a result of chromium depletion,
mainly due to the precipitation of
chromium carbides in the grain
boundaries.
 Such intergranular corrosion is common
in stainless steel welded structures.
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INTERGRANULAR
CORROSION(IGC)

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SELECTIVE LEACHING
Selective leaching is found in solid solution alloys and occurs
when one element or constituent is preferentially removed as a
consequence of corrosion processes. The most common example is
the dezincification of brass, in which zinc is selectively leached
from a copper–zinc brass alloy.

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FACTORS INFLUENCING CORROSION

1. Structural design

2. Environment

3. Applied or Internal stresses

4. Composition

5. Temperature

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Thank You

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