27/9/2014

Diploma in Mechanical Engineering (Material)

JF 302 MATERIAL TECHNOLOGY 1

www.pis.edu.my

CLO 3 : Show various principles of material testing and

material defects.

Week 12

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definition

Describe the corrosion process

Describe non-ferrous metals

types of corrosion

corrosion control

oxidation

Definition:
Corrosion is defined as the destructive of a material by chemical,
electrochemical or metallurgical interaction between the
environment and material.

Corrosion
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definition

types of corrosion

corrosion control

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oxidation

Factors that influence the corrosion:

i. Difference in electrical potential of dissimiliar metals when coupled
together and immersed in an electrolyte
ii. Residual stresses
iii. Voids, inclusions and dissolved gases
iv. Concentration and temperature of corrodant
v. Presence of impurities

definition

types of corrosion

corrosion control

oxidation

Describe the following corrosion reaction.

Think critically 5.0

Zn
e-

Zn2+
e-

acid solution
H+
H+

H2

Corrosion
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27/9/2014

definition

types of corrosion

corrosion control

oxidation

Describe the following corrosion reaction.

Think critically 5.0

Zn
e-

Zn2+
e-

acid solution
H+
H+

The electrochemical action associated with the

corrosion of zinc in an acid solution containing H+
ions.

H2

2H+

Zn
+ 2e-

Zn2+ + 2eH2

definition

types of corrosion

Fe

Cu

Fe2+
Solution

Cu2+
Solution

Oxidation
Reduction

oxidation

What will happen to iron and copper if the iron

and copper electrodes are connected
Think critically 5.1
electrically?

Fe

Cu

Fe2+
Solution

Cu2+
Solution

definition

types of corrosion

Zn2+
Solution

Fe2+
Solution

oxidation

Think critically 5.2

Cu2+ ions will deposit (electrodeposit) as metallic

copper on the copper electrode.
Iron dissolves (corrode) and goes into solution as
Fe2+ ions.

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corrosion control

Zn
Fe2+ + 2e-

Fe

corrosion control

Fe2+ + 2e- Oxidation

Cu
Reduction

What will happen to iron and zinc if the iron

and zinc electrodes are connected
electrically?

Zn

types of corrosion

What will happen to iron and zinc if the iron

and zinc electrodes are connected
electrically?

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definition

oxidation

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corrosion control

Fe
Cu2+ + 2e-

corrosion control

What will happen to iron and copper if the iron

and copper electrodes are connected
Think critically 5.1
electrically?

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definition

types of corrosion

oxidation

definition

types of corrosion

corrosion control

oxidation

Why does this happen?

Think critically 5.2

Think critically 5.3

Zn2+ + 2e- Oxidation

Fe
Reduction

Fe2+ ions will deposit (electrodeposit) as metallic

iron on the iron electrode.
Zinc dissolves (corrode) and goes into solution as
Zn2+ ions.

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27/9/2014

definition

types of corrosion

corrosion control

oxidation

The emf Series

Think critically 5.3

definition

types of corrosion

corrosion control

oxidation

Types of corrosion:
1. Uniform corrosion
i. galvanic corrosion
2. Localised corrosion
i. crevice corrosion
ii. pitting corrosion
iii. intergranular corrosion
iv. stress corrosion
v. selective leaching
vi. erosion corrosion

Corrosion
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definition

types of corrosion

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corrosion control

oxidation

definition

types of corrosion

corrosion control

oxidation

The galvanic Series

Galvanic corrosion occurs when two metals or alloys having
different compositions are electrically coupled while exposed to an
electrolyte. The less noble or more reactive metal will experience
corrosion.
The galvanic series will indicates the relative reactivities.

Galvanic corrosion

Galvanic corrosion

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definition

types of corrosion

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corrosion control

oxidation

definition

types of corrosion

corrosion control

oxidation

The rate of galvanic attack depends on the relative anode to

cathode surface areas that are exposed to the electrolyte. For a given
cathode, a smaller anode will corrode more rapidly than a larger one.

The reason for this is that corrosion rate depends on current density.
Thus, a high current density results for the anode when its area is
small relative to that of cathode.

Why?

Why?

Galvanic corrosion
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Galvanic corrosion
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27/9/2014

definition

types of corrosion

corrosion control

oxidation

Failure of a brass ( unlikely to be bronze) skin

fitting on a 2004 fast motor cruiser, discovered
on the pre sea trial check.

Sail drive leg corroded due to a stray current

from ground plate (used as 12 volt earth) on
the same yacht.

definition

types of corrosion

corrosion control

Measures to reduce the effects of galvanic corrosion:

1. If coupling of dissimiliar metals is necessary, choose two that are
close together in the galvanic series
2. Avoid an unfavourable anode to cathode surface area ratio; use
an anode area as large as possible.
3. Electrically insulate dissimiliar metals from each other
4. Electrically connect a third, anodic metal to the other two; this is a
form of cathodic protection.

Galvanic corrosion

Galvanic corrosion

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definition

types of corrosion

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corrosion control

oxidation

Crevice corrosion occurs when a solution becomes stagnant in

crevices and there is localised depletion of dissolved oxygen.

definition

types of corrosion

corrosion control

Crevice corrosion

types of corrosion

oxidation

After the oxygen has been depleted within the crevice, oxidation of
the metal occurs at this position. It occurs inside the crevice that has
lower concentration of ions or dissolved gases.

Crevice corrosion

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definition

oxidation

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corrosion control

oxidation

The driving force of this type of corrosion is the difference in

level of oxygen between the internal crevice and the external
surface. The crevice is depleted of oxygen and becomes the
anode. This creates a highly corrosive environment inside the
crevice. The low-oxygen area corrodes, acting as the anode,
while the high oxygen area is protected, acting as the
cathode.

definition

types of corrosion

corrosion control

oxidation

Failed powder coating on a handrail post

base, with crevice corrosion penetrating under
the failed coating and propagating it further.

Stainless T-bolt hose clamps are usually very

strong, however, the folded design traps
water, creating an ideal environment for
crevice corrosion.

Crevice corrosion
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Crevice corrosion
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27/9/2014

definition

types of corrosion

corrosion control

oxidation

Pitting corrosion occurs when small pits or holes form. They

ordinarily penetrate from the top of a horizontal surface downward in
a nearly vertical direction.

definition

types of corrosion

corrosion control

The mechanism for pitting is that oxidation occurs within the pit itself,
with the reduction at the surface. The gravity causes the pits to grow
downward; thus, the solution at the pit tip becoming more
concentrated.

Pitting corrosion

Pitting corrosion

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definition

types of corrosion

oxidation

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corrosion control

oxidation

definition

types of corrosion

corrosion control

oxidation

Quick intro into corrosion

Pitting corrosion on the bottom of a tank.

Diesel engine's cylinder piston liners with

pitting corrosion.

Pitting corrosion

If two dissimilar materials are

in contact, a corrosion cell
can be formed where one
material acts as the anode
and the second as a
cathode.
When a protective coating is
damaged, corrosion pockets
can be formed under the
coating, resulting in pits,
rather than wide spread
corrosion.

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definition

types of corrosion

corrosion control

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oxidation

definition

types of corrosion

corrosion control

oxidation

Quick intro into corrosion

If two dissimilar materials are
in contact, a corrosion cell
can be formed where one
material acts as the anode
and the second as a
cathode.
When a protective coating is
damaged, corrosion pockets
can be formed under the
coating, resulting in pits,
rather than wide spread
corrosion.
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Intergranular corrosion occurs along grain boundaries for some

alloys and in specific environment. It is found in the welding of
stainless steel when heated to temperature between 500 to 800C for
sufficiently long time periods.

Why?

Intergranular corrosion
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27/9/2014

definition

types of corrosion

corrosion control

oxidation

It is believed that this heat treatment permits the formation of small

precipitate particles of chromium carbide by reaction between the
chromium and carbon in the stainless steel.
Both the chromium and carbon must diffuse to
grain boundaries to form the precipitates, which
leaves a chromium depleted zone adjacent to
the grain boundary.

definition

types of corrosion

A small section of the spring seat of a strut

that has under gone intergranular corrosion,
as can be seen this type of corrosion forms
layers and has the consistency of brittle
toffee.

Intergranular corrosion

types of corrosion

Intergranular corrosion
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corrosion control

oxidation

Stress corrosion, sometimes termed stress corrosion cracking,

results from the combined action of an applied tensile stress and a
corrosive environment.

definition

types of corrosion

corrosion control

Stress corrosion

types of corrosion

oxidation

When a stress is applied, small cracks form and then propagate in a

direction perpendicular to the stress with the result that failure may
occur.

Stress corrosion

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definition

oxidation

A carrier ring for soldered on tungsten carbide

rings destroyed by intergranular corrosion.

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definition

corrosion control

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corrosion control

oxidation

definition

types of corrosion

corrosion control

oxidation

A chain plate that failed due to stress cracking

corrosion.
What are the differences between dry and wet
corrosion?

A hanger with large stress corrosion cracks

that couldnt be seen until it was removed.

Stress corrosion
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27/9/2014

cold
definition
work

types
hot work
of corrosion castingcorrosion
processcontrolHeat treatment
oxidation
of steels

cold
definition
work

What are the differences between dry and wet

corrosion?

Compare between emf series and galvanic

series.

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cold
definition
work

types
hot work
of corrosion castingcorrosion
processcontrolHeat treatment
oxidation
of steels

types
hot work
of corrosion castingcorrosion
processcontrolHeat treatment
oxidation
of steels

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cold
definition
work

types
hot work
of corrosion castingcorrosion
processcontrolHeat treatment
oxidation
of steels

Discuss the corrosion control methods.

Galvanic series
It predicts the corrosive tendencies of metal
alloy
Positioning of metal or alloy may change
The metal or alloy are immersed in the sea
water for study
Electrode potentials are measured for both
metal and alloy

emf series
It predicts the relative displacement
tendencies
Position of metal is fixed. Hydrogen
electrode is used as reference
Concentration of salts of the same metal
that was being used
Electrode potential measured only for metal
and non metal

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