Department of Mining, Metallurgical and Materials Engineering

College of Engineering

Corrosion of Metals

Introduction, Types of Corrosion

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Definition
destructive and unintentional attack in a metal due to
an electrochemical reaction which usually starts at the
surface

http://www.midwaymetals.com.au/stainless-steel-plate/ https://en.wikipedia.org/wiki/File:Rust_and_dirt.jpg

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Effects of Corrosion
Loss of:
aesthetic value
functionality

http://www.thesaharian.com/education/how-does-corrosion-happen-and-what-are-its-different-types/ https://commons.wikimedia.org/wiki/File:Corroding_iron_machinery_at_old_White_Island_sulphur_mine_2.jpg

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Effects of Corrosion
metal failure
contamination

http://www.monkeywrenchps.co.uk/wp-content/uploads/2012/08/Corrosion_Steel1.jpeg http://flintwaterstudy.org/tag/drinking-water/

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Electrochemical Reaction
a chemical reaction in which there is transfer of
electrons from one chemical species to another
composed of two half-cell reactions: oxidation and
reduction

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Reduction
characterized by gaining of electron/s
species with a strong affinity for electrons are called
oxidizing agent
occurs at the cathode
+
+
Example:
2 + + 2 2()

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Oxidation
characterized by losing of electron/s
species with a strong affinity to lose electrons are
called reducing agent
occurs at the anode
+
+
Example:
3+ + 3

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Nature of Corrosion
metals generally occur in the combined state in nature
almost all metals tend to oxidize (tendency differs from
one metal to the next)
Oxidation
process or chemical reaction by which refined metal returns
to its natural state

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Refining vs Oxidation
REFINING

https://www.tomra.com/~/media/Images/Sorting%20solutions/Mining/Segments_Ferrous%20meta http://www.tutorvista.com/content/chemistry/chemistry- http://jameksteel.com/product/steel-rods/

ls%20sorting/Categorie%20Picture_Ferrous%20Metals_Iron%20Ore_723x366.ashx ii/metals/iron.php
OXIDATION

http://jameksteel.com/product/steel-rods/ http://www.rgbstock.com/bigphoto/mif3yxY/reinforcement+steel+bar+series

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Rusting of Iron

http://www.machinerylubrication.com/Read/29116/inhibiting-rust-corrosion

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Cell Potential,
measure of the potential difference between two half
cells in an electrochemical cell

Standard Cell Potential,
resulting potential when the reactants and products are
in standard state (the activities of the reactants and
products are all unity)

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Standard Cell Potential

0 0 0
= , ,

or

0 0 0
= , + ,

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

First Semester AY 2017-2018
Standard EMF Series

MetE 143: Elements of Materials Science

Callister, William D., and David G. Rethwisch. Materials Science and Engineering: An Introduction. John Wiley &
Sons, 2014.
JLPBuquiz
Relationship to Standard Gibbs Free Energy

0 0
=
Note:
More positive , lower free energy, more spontaneous towards the forward reaction
More negative , higher free energy, more spontaneous towards the backward
reaction

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Standard Cell Potential Calculation: Example

2+ 2+ +
Half Cells:
2+ + 2 0 = +0.340
2+ + 2 0 = 0.440

0
= 0.340 0.440 = +0.780

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Effect of Temperature and Concentration
Nernst Equation
consider the following chemical equation
+ +
the electrode potential is related to the standard
electrode potential by

0

=

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Relationship to Gibbs Free Energy

= =
Note:
More positive , lower free energy, more spontaneous towards the forward reaction
More negative , higher free energy, more spontaneous towards the backward
reaction

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

First Semester AY 2017-2018
Galvanic Series

MetE 143: Elements of Materials Science

Callister, William D., and David G. Rethwisch. Materials Science and Engineering: An Introduction. John Wiley &
Sons, 2014.
JLPBuquiz
Corrosion Cells
describe the conditions at which corrosion occurs
also called corrosion couples

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Components of Corrosion Cells
Anode Electrolyte
where oxidation occurs medium for ion
high oxidation potential movement
metal is consumed
Cathode Electrical Contact
where reduction occurs medium for electron
low oxidation potential movement
electron is consumed
First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz
Composition Cell
corrosion due to a
difference in the
composition of metals
the less noble metal
will corrode
also known as
Galvanic corrosion
http://www.open.edu/openlearnworks/mod/page/view.php?id=41376

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Stress Cells
corrosion occurs at sites
which are the most
stressed or plastically
deformed
becomes a concern if
corrosion leads to loss of
load bearing capability
http://www.climbcaymanbrac.com/safety/

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Concentration Cell
corrosion occurs due to a difference in concentration of
electrolyte
occurs when two or more areas of a metal surface are in
contact with different concentrations of the same
solution

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Types of Corrosion
uniform attack
galvanic
crevice
pitting
intergranular
selective leaching
erosioncorrosion
stress corrosion
First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz
Uniform Attack
oxidation & reduction
occur uniformly over the
surface
chemical control and the
use of protective coatings
are most commonly used
protection against
uniform corrosion

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Galvanic Corrosion
corrosion between dissimilar metals physically joined,
where the more anodic metal corrodes

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Crevice Corrosion
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 Callister, William D., and David G. Rethwisch. Materials Science and Engineering: An Introduction. John Wiley & Sons, 2014.

dissolved oxygen

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Pitting Corrosion
localized corrosion attack
downward propagation of small pits & holes

https://www.comsol.com/blogs/strategy-designing-corrosion-resistant-materials/ http://www.keyword-suggestions.com/cGl0dGluZyBjb3Jyb3Npb24/

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Intergranular Corrosion
occurs preferentially along grain boundaries for some
alloys and in specific environments

http://www.ssina.com/corrosion/igc.html

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Selective Leaching / Dealloying
found in solid solution alloys and occurs when one
element or constituent is preferentially removed as a
consequence of corrosion processes
e.g. dezincification, denickelification, decobaltization

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Erosion-Corrosion
result of the combined action of
chemical attack and mechanical
abrasion or wear as a
consequence of fluid motion

Callister, William D., and David G. Rethwisch. Materials Science and Engineering: An
Introduction. John Wiley & Sons, 2014.

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

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

Callister, William D., and David G. Rethwisch. Materials Science and Engineering: An
Introduction. John Wiley & Sons, 2014.

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Hydrogen Embrittlement
significant reduction in ductility and tensile strength
when atomic hydrogen (H) penetrates into the material

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Corrosion Prevention
control of electrochemical reaction
formation of a mechanical barrier between the metal
and environment

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Corrosion Prevention
Use of Corrosion-Resistant Metals
Stainless steels
Copper-based alloys (brass)
Nickel-based alloys (Hastelloys)
Titanium Alloys

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Corrosion Prevention
Use of Corrosion-Resistant Metals
Passivation
formation of very thin films formed on the metals surface
(transparent)
films are hard and impermeable and protects the surface from
corroding

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

First Semester AY 2017-2018
Passivation

http://earjhschemistry.pbworks.com/w/page/65448714/O
xidation%20Reduction%20SL

MetE 143: Elements of Materials Science

http://www.j4stainless.com/info.html

http://wonderopolis.org/wonder/why-is-the-statue-of-
JLPBuquiz

liberty-green/
Corrosion Prevention
Cathodic Protection
this technique involves making the metal to be
protected to act as a cathode
e.g. sacrificial anode, impressed current

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Corrosion Prevention
Cathodic Protection
Sacrificial Anode
protection technique employs a galvanic couple: the metal to
be protected is electrically connected to another metal that is
more reactive in the particular environment

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

Sacrificial Anode

Callister, William D., and David G. Rethwisch. Materials Science and Engineering: An Introduction. John Wiley &
Sons, 2014.
http://www.cathodicprotection101.com/

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

First Semester AY 2017-2018
Sacrificial Anode

MetE 143: Elements of Materials Science

Callister, William D., and David G. Rethwisch. Materials Science and Engineering: An Introduction. John Wiley &
Sons, 2014.
JLPBuquiz
Corrosion Prevention
Cathodic Protection
Impressed Current
impressing a direct current
between an inert anode
and the structure to be
protected Callister, William D., and David G. Rethwisch. Materials Science and Engineering: An Introduction. John Wiley & Sons, 2014.

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz

References
[1] Callister, William D., and David G. Rethwisch. Materials Science and Engineering: An Introduction.
John Wiley & Sons, 2014. eBook.

First Semester AY 2017-2018 MetE 143: Elements of Materials Science JLPBuquiz