Department of Mechanical Engineering

Chittagong University of Engineering and Technology

Corrosion: Corrosion is the degradation of the materials because of the chemical reactions with the
environments.
Definitions of Corrosion from different perspective
 From Science perspective: The reaction of a solid with its environment (1)
 From engineering perspective: The reaction of an engineering constructional metal with its
environment with a consequent deterioration in properties of the metal (1)

Corrosion Engineering: Corrosion engineering is the application of science and arts to prevent or
control corrosion damage economically and safely

Why we have to understand corrosion?

1. Save material
2. Same money
3. Avoid product contamination
4. Avoid loss of life

ME 6351 Introduction to Corrosion Page # 1

 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

Physical degradation processes

 Fracture: Failure of a metal under an applied stress

 Fatigue: Failure of a metal under an applied repeated cyclic stress

 Wear: Rubbing or sliding of materials on each other

 Erosion or cavitation erosion: Mechanical damage caused by movement of a liquid or the

collapse of vapor bubbles against a metal surface

 Radiation damage: Interaction of elementary particles with a solid metal so as to distort the
metal lattice.

All physical degradation processes are assisted by corrosion

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

Figure 1: Factors increase or decrease cost of Corrosion [2]

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

Table: Opportunities of corrosion [2]

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

Ion: An atom with electrical charge

Anion: Ion with negative charge
Cation: Ion with positive charge
Oxidation or Anodic reaction: An increase in valance charge or production of electrons

Zn Zn2+ + 2e- (Oxidation or Anodic reaction)

2H+ + 2e- H2 (Reduction or Cathodic reaction)

Reduction or Cathodic reaction: A decrease in valance charge or consumption of electrons

Dissociation: Breakup of ionic solid into discrete ions

Ionization: Ionization is the process of adding electrons to or removing electrons from atoms
or molecules, creating ions. High temperatures, electrical discharges, and nuclear radiation
can cause ionization. Many metals have a tendency to lose electrons to atoms or ions that have
a tendency to gain electrons. Current can be conducted by the movement of these ions. The
compounds that conduct electric current by ion movement are called electrolytes, and this ionic
motion is call electrolytic conduction.

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

Electrolysis: Electrolysis is the decomposition by electric current (in the context of corrosion the
use of electrical current to bring about chemical change
Electrolyte: An electrolyte is defined as an electricity-conducting fluid; that is, it has positive and
negative ions that can move and constitute an electrical current.
Acid: A solution in which the concentration of hydrogen ion exceeds the concentration of hydroxyl
ion
Alkali: A solution in which the concentration of hydroxyl ion exceeds the concentration of
hydrogen ion
Ohm’s Law: Voltage is directly proportional to resistance

Free Energy: The portion of substances internal energy which is available to perform work

Current: Current is the flow of electrons through a medium. An electric current can flow through
a metal conductor, and the metal will not show any obvious chemical changes. This type of
conduction of electricity is called metallic conduction.
Conductivity: Conductivity is a measure of the ability of a substance to allow electron flow. In the
context of corrosion, conductivity indicates the amount of ions in solution, which relates directly to
the potential of corrosion taking place.

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

Classification
of Corrosion
Based on Forms
Uniform or General Attack Corrosion Based on Temperature
Galvanic or Two Metal Corrosion
Crevice Corrosion High-temperature
Pitting Corrosion
Intergranular Corrosion Corrosion
Selective leaching or Parting
Erosion corrosion Low-temperature
Stress Corrosion
Filiform Corrosion Corrosion

Based on
Based on liquid
combination
Dry Corrosion
Oxidation
Wet Corrosion Electrochemical

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

Figure 4: Macroscopic versus Microscopic forms of localized corrosion [2]

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

 Uniform or General Attack Corrosion: The corrosion that takes place uniformly or
thoroughly the surface is called uniform corrosion.

 Galvanic or Two Metal Corrosion: The corrosion that occurs due to the cell potential
developed between to dissimilar metals.

 Crevice Corrosion: The corrosion that develops inside the crevice or near the joints of a
metal surface.

 Pitting Corrosion: The corrosion that causes small pits on the metal surface

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

 Intergranular Corrosion: The corrosion that occurs between the grains of metals

 Stress Corrosion: The corrosion that occurs due the stress generated or residual stress inside the
metals.

 Selective leaching or Parting: The corrosion that occurs due to the selective attack on the
surface of the metals.

 Erosion corrosion: This is a special type of corrosion that occurs due to the flow or motion of
the fluid over the surface of the metals.

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

NACE International Technical Committee [2]

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

ASTM committee G -1 on corrosion of metals [2]

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

Practice problems:

1. What is the molecular weight of hydrated Copper (II) sulphate (CuSO4. 5H2O), ZnO, Al2O3

and Cu3O?

2. How do you make a solution of CuSO4. 5H2O which is 0.5 M?

3. The elements of Ni and O2 both have a valency of 2. When Ni is heated in air with O2 to form
the ionic material, Nickel Oxide. Write equations to describe the process.
4. Write a corrosion reaction for iron
5. Under standard condition what is the concentration of a) Hydrogen ions b) Hydroxyl ions in a
solution of pH 8.4?
6. A source of emf of 0.2 volts drives an electrical current of 2 mA through a solution of NaCl for
1 hour.
a) How much charge has been passed?
b) Assuming there is no resistance elsewhere in the circuit, what is the resistance
represented by the solution?
c) By what means the charge pass through the solution?

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

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