Corrosion and Materials Protection

Week-1; February 19-23, 2024

Abdul Wadood (PhD),

Head of Department (HoD)
Department of Materials Science and
Engineering
Visiting Hours: 13:00 – 15:00

Attendance: 80% as per Institute policy

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 Corrosion and Materials Protection
• Grading Policy:

 Quizes: 5 (15%)

 Presentation: 1 (5%)

 Class Participation: 2%

 2 OHTs: 28%

 Final: 50%
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 Some Corrosion Researchers
• Dr. Akhlaq UET Lahore
• Dr. M. Shahid, SCME NUST
• Dr. Shahzad, PINSTECH
• Dr. Akbar Niaz But, King Faisal University, KSA
• Dr. Atiq, IST
• Dr. Ameeq Farooq, Punjab University
• Mr. Khalil, PhD scholar, IST
• Worked in the corrosion lab, FMSE, GIKI
2000-2008.

• MS Thesis related to Corrosion of NiTi and

NiTi-Ag biomaterials.

• During post-doc work, I also did some work

related to oxidation behavior of Titanium
based shape memory alloys.
• Taught this course, 2017 and 2018
Reference Book
Text Book
PLO 1: Engineering Knowledge
PLO 2: Engineering Problem Analysis
PLO 4: Investigation
PLO 7: Environment and sustainability
OBE Learning Domains
• Instructional designers, trainers, and educators
often refer to these three categories as KSA:
(Knowledge [cognitive], Skills [psychomotor],
and Attitudes [affective]).

• This taxonomy of learning behaviors may be

thought of as “the goals of the learning process.”

• That is, after completion of course, , the learner

should have acquired a new skill, knowledge,
and/or attitude.
Bloom’s Taxonomy
 Cost of Corrosion in USA
Cost of Corrosion
According to the current U.S. corrosion study, the direct cost of metallic corrosion is $276 billion on an
annual basis. (30 billion dollar is suggested by Fontana)

 About 15 - 25% of this expense could be avoided if currently available corrosion

technology were effectively applied.
 Cost of corrosion in U. S. about $ 276 billion
 Cost of corrosion to oil and gas producers in U. S.  $ 2 billion that are increasing because of deeper
wells and more hostile environment (500 F, H 2S).
 Automobile industry  $ 2 billion /yr
 Nuclear industry $ 0.25 billion /yr in U.S.

 Indirect loss
 Plant shutdown.
 Loss of product.
 Loss of efficiency
 Contamination.
 Over design.
 Appearance
 Effects of safety and reliability
 Maintenance costs

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 Effects of corrosion
Losses are economic and safety:
• Reduced Strength
• Downtime of equipment
• Escape of fluids
• Lost surface properties
• Reduced value of goods

The consequences of corrosion are many and varied and

the effects of these on the safe, reliable and efficient
operation of equipment or structures are often more serious
than the simple loss of a mass of metal.

Failures of various structures and the need for expensive

replacements may occur even though the amount of metal
destroyed is quite small.
• Deep well, hostile environment
• Oil and gas sector
• Highly paid jobs for corrosion engineers
• Corrosion of bridges---replacement cost
• One company spending 4 Lac $/year as
maintenance cost for corrosion protection
• Another spend 2 million dollars to paint
steel to protect from rust
• Corrosion cost of automobiles, fuel system,
batteries etc.

• Production of corrosion resistance metals—

increase the cost,

• National energy consumption

• Stainless steel for corrosion resistance

 Role of Corrosion Engineer
• Mg can save steel from corrosion
• Washing of car will increase its life
• Proper selection of materials
• Good maintenance painting program
• Corrosion engineering: Application of science
to control corrosion economically and safely

• Corrosion Engineering: Different disciplines

combine together: Thermodynamics,
Chemical, Electrical, design (Mechanical)

• Corrosion is not always the evil

• Ignorance to corrosion can lead to

catastrophic failure
Corrosion is the deterioration of materials by
chemical interaction with their environment. The
term corrosion is sometimes also applied to the
degradation of plastics, concrete and wood, but
generally refers to metals.
 -- Cost: 4 to 5% of the Gross National Product (GNP)*
-- this amounts to just over $400 billion/yr**
* H.H. Uhlig and W.R. Revie, Corrosion and Corrosion Control: An Introduction to
Corrosion Science and Engineering, 3rd ed., John Wiley and Sons, Inc., 1985.
**Economic Report of the President (1998).
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Underground corrosion

Buried gas or water supply pipes can suffer

severe corrosion which is not detected until
an actual leakage occurs, by which time
considerable damage may be done.
In electronic equipment it is very important
that there should be no change in
resistance with time.
 Safety of aircraft

The lower edge of this aircraft skin panel has

suffered corrosion due to leakage from a wash
basin in the toilet. Any failure of a structural
component of an aircraft can lead to the most
serious results.
 Influence of corrosion on value

A very slight amount of corrosion may not interfere with the

usefulness of an article, but can affect its commercial value. At
the points where these scissors were held into their plastic case
some surface corrosion has occurred which would mean that the
shop would have to sell them at a reduced price.

Silver bridge failure due to stress corrosion in Ohio state USA: Loss of 40 lives