University of Salahaddin-Hawler

College of Engineering
Chemical and Petrochemical Department

Corrosion & Corrosion Controls

Lecturer: Ahmed A. Zardoey

[Link]. Mechanical Engineering
Contact:
Email: Ahmed.ahmed3@[Link]
Mr. Ahmed A. Zardoy 1
Textbooks:

 R. Winston Revie ; Herbert H. Uhlig, Corrosion and

Corrosion Control ,4th edition , 2008.
 Philip A. Schweitzer, Fundamentals of Corrosion, 2010.
 E. Mc Cafferty, Introduction to Corrosion Science, 2010.
 Zaki Ahmad, Principle of corrosion engineering and
corrosion control, September 2006.
 R. Winston Revie, Uhlig’s corrosion handbook, 3rd
edition 2011.

Mr. Ahmed A. Zardoy 2

*- Corrosion (Vol.1&2), [Link], 3rd edition -
2000

*- Corrosion and protection, Einar Bardal, 2003

*- Electrochemistry and corrosion science, Nestor
Peres, 2004

*- Fundamentals of metallic corrosion, Philip

Schweitzer, 2007
Mr. Ahmed A. Zardoy 3
:COURSE SPECIFICATION
This Course Specification provides an introductory
level course in corrosion and its definitions in
addition to know thermodynamic and kinetic of
corrosion. Corrosion types have been reviewed in
this course

Mr. Ahmed A. Zardoy 4

 Aims of the Course
 1- Understanding the basic of corrosion.
 2- Understanding the behavior of materials in
different environments (Dry and Wet corrosion).
 3- Recognize to nature of cathodic and anodic
reactions.
 4- Calculate thermodynamic and kinetic parameters
for corrosion process.
 5- Determine the lifetime of equipments.
 6- Recognize to causes the corrosion forms.
 7- Identify the causes and inspection. .
Mr. Ahmed A. Zardoy 5
:Topic Title
 . Definitions, classification, thermodynamic and
kinetic, Electrochemical cells, Polarization and its
types, passivity,, reactions and Fe/H2O system,
Types of corrosion: uniform, galvanic,
thermogalvanic, Crevice, Pitting corrosion, selective
leaching ,Erosiong, Fretting corrosion, Stress
corrosion cracking SCC,wear. Corrosion prevention
methods

Mr. Ahmed A. Zardoy 6

Objective

 What is corrosion
 Classification of corrosion
 Mechanism of corrosion
 Types of corrosion
 Corrosion prevention methods
 Corrosion tests

Mr. Ahmed A. Zardoy 7

 Corrosion Science
Corrosion Science : is an all-purpose area embracing
chemistry, materials science, and mechanics. The study of
aqueous corrosion processes involves the interaction of
chemistry and materials science. It’s a link between chemical
and mechanical engineering

Mr. Ahmed A. Zardoy 8

 Corrosion Engineering
Corrosion Engineering is the application of science and art
to prevent or control corrosion damage economically and
safely.
Corrosion Engineer protect corrosion of various metallic
structures, e.g.: corrosion protection of Ships, Pipe Lines,
Industries …etc. Corrosion Engineering is supposed to have
the knowledge of Metallurgy, Electro-Chemistry, Mechanical
behaviors of Materials, Electrical Engineering, corrosion
test, the nature of corrosive environments and the knowledge
of Cost analysis.
Click here for a video
Mr. Ahmed A. Zardoy 9
 What would be expected from Corrosion Scientist

Several important timely challenges to the corrosion scientist can

be listed
1. The development of protective surface treatments and
corrosion inhibitors to replace inorganic chromates, which are
environmentally objectionable.
2. An improved conservation of materials through the
development of corrosion-resistant surface alloys which
confine alloying elements to the surface rather than employing
conventional bulk alloying.
3. The formation of a new generation of stainless steels
containing replacement for chromium and other critical metals.

Mr. Ahmed A. Zardoy 10

 What would be expected from Corrosion Scientist

4. An improved understanding of passivity so as to use our fundamental

knowledge to guide the development of alloys having improved
corrosion resistance.
5. Understanding the mechanism of the breakdown of passive oxide
films by chloride ions and subsequence pitting of the underlying metal.

Mr. Ahmed A. Zardoy 11

 What is Corrosion

 “The deterioration of a material or its properties due to a

reaction of that material with its chemical and physical
environment”. Corrosion is a general term used to describe
various interactions between a material and its environment
leading to degradation in the material properties.
 The word corrosion is as old as the earth, but it has been
known by different names. Corrosion refers to the
degradation of metal by its environment other materials
such as plastics, concrete, ceramics and composite materials
all undergo destroyed when placed in some environment.
Mr. Ahmed A. Zardoy 12
Mr. Ahmed A. Zardoy 13
 What is Corrosion

 Corrosion is known commonly as rust, an undesirable

phenomena which destroys the luster and beauty of
objects and shortens their life. The word “rusting”
applies to the corrosion of iron and plain carbon steel.
Rust is a hydrated ferric oxide which appears in
familiar color of red or dark brown see Figure 1.

Figure 1: An example of red rust showing the

corrosion of a ship near the waterline.
Thus, steel rusts (and corrodes), but ferrous
metals such as aluminum, copper, and zinc
corrode (but do not rust).

Mr. Ahmed A. Zardoy 14

 Why study Corrosion

There are three main reasons to study corrosion.

(i) human life and safety, ???

(ii) the cost of corrosion, and
(iii) cost of materials.
.

Mr. Ahmed A. Zardoy 15

Losses due to Corrosion

Mr. Ahmed A. Zardoy 16

FIVE GOOD REASONS TO STUDY CORROSION
(1) Materials are precious resources of a country. Our material
resources of iron, aluminum, copper, chromium, manganese,
titanium, etc. are dwindling fast. Some day there will be an acute
shortage of these materials. An impending metal crisis does not
seem anywhere to be a remote possibility but a reality.
(2)Engineering knowledge is incomplete without an understanding of
corrosion. Aero planes, carriers cannot be designed without any
recourse to the corrosion behavior of materials used in these
structures.
(3) Several engineering disasters, such as crashing of civil and
military aircraft, naval and passenger ships, explosion of oil
pipelines and oil storage tanks, collapse of bridges and decks and
failure of drilling platforms and tanker trucks have been witnessed in
recent years.

Mr. Ahmed A. Zardoy 17

(4) The designing of artificial implants for the human body
requires a complete understanding of the corrosion science and
engineering. Surgical implants must be very corrosion-resistant
because of corrosive nature of human blood.
(5) Corrosion is a threat to the environment. For instance, water
can become polluting by corrosion products and unsuitable for
drinking. Corrosion prevention is integral to stop pollution of air,
water and soil.

Mr. Ahmed A. Zardoy 18

Cost of Corrosion
In all world cost of corrosion is calculated to be in billion
dollars/year. This cost involves the cost of material lost and
the cost for preventing corrosion . Almost all the metals and
alloys would corroded in various environments , some
environments are more corrosive than the others .

Mr. Ahmed A. Zardoy 19

What would be expected from Corrosion Engineer.

Ensuring maximum life of new equipment.

Protection of existing equipment.
Protecting or improving the quality of a product
Avoiding costly of production.
Reducing or eliminating losses of valuable products by threads (bolt
and nut )or leaks in joinings (pit welding)
Refitting of equipment parts because of corrosion.
Reducing hazards to life and property that might be associated with
corrosion:
√ Explosions of pressure vessels or piping systems release of
poisonous or explosive gases or vapors.

Environments : Practically all environments are corrosive to some

degree. Examples are air and moisture . Environment means the
condition of corrosion e.g.: Water , Water + Air , Water + Cl2 ,
Water + H2S . Water + soil

Mr. Ahmed A. Zardoy 20

Mr. Ahmed A. Zardoy 21
Mr. Ahmed A. Zardoy 22
Corrosion and
Degradation of
Materials

Mr. Ahmed A. Zardoy 23

Significance of Corrosion
on Infrastructure

Mr. Ahmed A. Zardoy 24

Mr. Ahmed A. Zardoy 25
Engineer finds corrosion in collapsed bridge at North
Carolina speedway (2012)

Click here for a video

Click here for a video

Mr. Ahmed A. Zardoy 26

Corrosion & Catastrophic Failure.

Mr. Ahmed A. Zardoy 27

A Concrete bridge failure

Mr. Ahmed A. Zardoy 28