TOPICS
GROUP 4
4. Fracture Toughness and Fatigue and Engineering
materials
4.1 impact Testing
4.2 Destructive Testing
4.3 Fatigue Testing
MATERIAL SCIENCE & ENGINEERING
5. Corrosion Prevention and Control
5.1 Significance and Purpose
5.2 Electrochemical nature of aqueous corrosion
5.3 Corrosion rate determinates
5.4 Galvanic and concentration cell corrosion
Description
Our Team
Nilo Dexter Edrianne John Peter
4.0
Fracture Toughness
& Fatigue
More Infromation
Fracture Toughess
This property refers to a material's ability to resist breaking when it contains a crack, and it
is one of the most crucial characteristics for many design applications.
Fatigue
This condition occurs when a material fractures or fails due to repeated (cyclic) stresses
that are applied at levels below its ultimate strength.
Types of Fatigue
Failure occurs over millions of cycles due to stresses
High-Cycle Fatigue
- lower than yield strength.
-
Occurs within thousands or hundreds of cycles due to
Low-Cycle Fatigue
stresses exceeding yield strength.
induced by cyclic thermal loads causing material to
Thermal Fatigue
- expand and contract leading to stress build-up and
cracks.
4.1
Impact Testing
1
The goal of impact testing is to assess an object's capacity to withstand rapid force application,
typically involving two objects colliding at high relative velocities.
2
A material or component's ability to withstand impact is often a key factor in determining its
lifespan or its suitability for a specific application.
3
Impact resistance is often one of the most challenging properties to measure. Being able to
quantify it provides a significant advantage in terms of product safety and liability.
What are the Different Types of Impact Testing?
Charpy Impact Test
It is a standardized test used to measure the
toughness of a material, particularly its ability
to absorb energy during fracture.
Izod Impact Test
The Izod impact test is another standardized
test used to measure a material's resistance
to impact or its toughness.
Drop-Weight Impact Test
The Drop-Weight Impact Test is a type of test used to
assess a material's toughness or resistance to fracture
when subjected to sudden, high-energy impacts.
Dynamic Tear Test
The Dynamic Tear Test (DT Test) is a materials testing method used to evaluate a
material's resistance to crack propagation and toughness under dynamic or high-
speed loading conditions.
4.2
DESTRUCTIVE TESTING
Destructive Testing methods analyze
mechanical properties like strength and
toughness by breaking down materials. This
helps assess the quality of welds and
materials under extreme conditions.
More Infromation
More commonly used destructive testing methods
Corrosion Testing
Metals are used extensivelyin many
industries due tobtheir tensile strength and
versatility.However they are also prone to
common.Rust on iron based
materials,tarnish or silver,and patina on
copper and copper alloys are common
examples of common.This is a problem
More Infromation
because corrosion decreases the tensile
strength and file of these metals
4.3 Fatigue Testing is used to determine how many load
cycles a material can sustain or the failure load level
Fatigue Testing for a given number of cycles. The results of fatigue
testing vary dramatically depending on the material.
EX.
What is the purpose of Fatigue Testing
Usually the purpose of a fatigue test is to determine the
lifespan that may be expected from a material subjected to cyclic
loading, however fatigue strength and crack resistance are commonly
sought values as well. The fatigue life of a material is the total number
of cycles that a material can be subjected to under a single loading
scheme. A fatigue test is also used for the determination of the
maximum load that a sample can withstand for a specified number of
cycles. All of these characteristics are extremely important in any
industry where a material is subject to fluctuating instead of constant
forces.
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CORROSION TOPICS:
PREVENTION 5.1 SIGNIFICANCE AND PURPOSE
5.2 ELECTROCHEMICAL NATURE OF AQUEOUS CORROSION
& CONTROL
PRESENTED BY: JOHN PETER C. SIOSON
2
CORROSION
The deterioration of a material, usually a metal,
that results from a chemical or electrochemical
reaction with its environment.
3
CAUSES OF CORROSION
LOW PH HIGH PRESENCE OF
TEMPERATURE ELECTROLYTE
4
TYPES OF
CORROSION
BASED ON
MECHANISM
5
DRY
CORROSION
Dry corrosion, also known as atmospheric
corrosion, refers to the deterioration of
metals in a dry environment, typically due to
the presence of gases and pollutants in the
air.
6
WET
CORROSION
Unlike dry corrosion, wet corrosion occurs
in the presence of moisture or a liquid
environment. It is often associated with the
exposure of metals to water, saltwater, or
other aqueous solutions.
7
TYPES OF CORROSION BASED
ON CORRODED SURFACE
8
METHODS OF
PREVENTION FOR
CORROSION
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BARRIER
COATING
One of the easiest and cheapest ways to prevent
corrosion is to use barrier coatings like paint,
plastic, or powder.
10
HOT-DIP
GALVANIZATION
The corrosion prevention method involves dipping
steel into molten zinc.
11
ALLOYED STEEL
(STAINLESS)
Alloyed Steel is one of the most effective corrosion
prevention methods around, combining the
properties of various metals to provide added
strength and resistance to the resulting product
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SIGNIFICANCE OF CORROSION
PREVENTION & CONTROL
ECONOMY FACTOR MATERIAL DESIGNING PRESERVATION OF MATERIALS
Corrosion has a significant Studying corrosion is crucial in Understanding corrosion is crucial for
economic impact as it damages engineering to design materials that preserving metals like iron, aluminum,
materials linked to people’s wealth. minimize corrosion, thereby and copper. Corrosion engineers use this
knowledge to reduce material losses and
Studying corrosion can help reducing material loss. This
boost economic growth, protecting
preserve these materials, thereby knowledge can also enhance
structures such as piping, tanks,
preventing economic decline. efficiency, decrease contamination,
machines, ships, bridges, and marine
and prevent equipment shutdowns. structures.
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PURPOSE OF CORROSION
PREVENTION & CONTROL
SAFETY COST SAVINGS OPERATIONAL EFFICIENCY
Corrosion can lead to structural Corrosion can be expensive to Corrosion can cause equipment to
failures, which can be dangerous. repair and can shorten the malfunction or become less
Preventing corrosion helps ensure lifespan of equipment and efficient. By preventing corrosion,
the safety of structures, vehicles, structures. Effective corrosion systems can operate more reliably
and machinery by maintaining control reduces maintenance and efficiently, reducing
their integrity. costs and extends the life of downtime and improving
assets performance.
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5.2
ELECTROCHEMICAL
NATURE OF AQUEOUS
CORROSION
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15
AQUEOUS
CORROSION
It is an electrochemical reaction of materials due
to a wet environment, resulting in the
deterioration of the material and its vital
properties.
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AQUEOUS CORROSION
IS ELECTROCHEMICAL
IN NATURE
RUSTING OF IRON NAIL
This occur when two metals with different electro
positivity come into contact with an electrolyte (liquid
medium).
The more electropositive element is corroded, and the
less electropositive element is protected from
corrosion by the more electropositive element.
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It involves flow or exchange of electrons
which constitutes a REDOX (Reduction and
Oxidation) process - Anodic and Cathodic
reactions.
ELECTROCHEMICAL
IN NATURE
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ANODIC
REACTION
SOLUBLE CORROSION PRODUCT
Does not protect the surface of the metal.
SOLID CORROSION PRODUCT
TWO MAIN TYPES May or may not slow corrosion of the
metal.
Is an oxidation process through which the valence of a metal
increases from 0 to a more positive value.
There is a loss or release of electrons.
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ANODIC REACTION
20
CATHODIC
REACTION
HYDROGEN EVOLUTION REACTION (HER)
In this reaction 2H* accept electrons to
become Hydrogen Gas (H2)
TWO CATHOD REACTIONS
OYGEN REACTION REDUCTION (ORR)
IN NATURAL ENVIRONMENT
In this reaction Oxygen (O2) in water is
reduced to Hydroxyl Ions (OH)
Is a reduction process during which the valence of the element is
reduced.
There is a gain of electrons.
21
CATHODIC
REACTION
1
5.3 Corrosion
Rate
Determinates
2
What is
Corrosion
Rate?
Corrosion rate is the speed at which any
metal in a specific environment deteriorates.
The rate, or speed, is dependent upon
environmental conditions as well as the type,
and condition, of the metal.
3
Why Corrosion
Rate matter?
Corrosion rates determine the lifespan of
metal-based structures. This dictates the
choice of metals used for different purposes,
and in different environments.
It also determines the maintenance
requirements for structures: a metal
structure in a wet and/or polluted
environment may require more frequent
maintenance than a similar structure in a
drier or unpolluted environment .
Two Commonly Existing Corrosion Rate calculations are Short
4
Term Corrosion Rate (SCR) and Long Term Corrosion Rate
(LCR)
Short term Corrosion Rate (SCR) Long Term Corrosion Rate (LCR)
The rate of metal loss as The rate of metal loss calculated
calculated from the most over full length of time during
recently or previous measured which thickness measurements
thickness values. were taken.
STCR= Short Term Loss/Total Interval LTCR= Long Term Loss / Total Interval
The corrosion rate used in remaining life is usually the greater of short term and long
term rates.
5
Short term Corrosion Rate (SCR)
t previous = thickness, in inches(millimeters), at the same location as t actual measured during a
previous inspection.
t actual = the actual minimum thickness, in inches determined at the time of inspection for a
given location or component.
STCR= Short Term Loss/Total Interval
6
Long term Corrosion Rate (SCR)
t initial = the thickness, in inches(millimeters), at the same location as t actual measured at the
initial installation or at the commmencement of a new corrosion rate environment.
t required = the required thickness in inches at the same location or component as the t actual
measurement computed by the design formulas(e.g, pressure and structural) before corrosion
allowance and manufacturer's....
LTCR= Long Term Loss / Total Interval
7
Example 1: Calculate the short term and long term Corrosion Rate
THICKNESS DATA(MM)
CML# DEC 1995 DEC 1997 DEC 2000 DEC 2005
10 12.70 12.19 11.81 11.18
8
Example 1: Calculate the short term and long term Corrosion Rate
STEP 1: Calculate the short term corrosion rate
STEP 2: Calculate the long term corrosion rate
Important: Pick the controlling corrosion rate the highest one for remaining life
calculation.
9
Example 2: Calculate the short term and long term Corrosion Rate
THICKNESS DATA(MM)
CML# MAR 1995 JUN 1997 OCT 2000 DEC 2005
10 12.70 12.19 11.81 11.18
10
Example 2: Calculate the short term and long term Corrosion Rate
Firs of all convert the months into years ( since months not same as in
previous example)
Fractional Decimal
DATE Month #
Year Year
March 1995 3 3/12 0.25 1995.25
June 1997 6 6/12 0.5 1997.5
October
10 10/12 0.83 2000.83
2000
Dec 2005 12 12/12 1 2006
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Example 1: Calculate the short term and long term Corrosion Rate
STEP 1: Calculate the short term corrosion rate
STEP 2: Calculate the long term corrosion rate
Important: 1. Convert the months (if not the same) into years for accurate
corrosion rate determination 2. Pick the controlling corrosion rate the highest one
for remaining life calculation.
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5.4 Galvanic and
Concentration cell
corrosion
13
Galvanic Corrosion
There are two primary types of galvanic cells
that cause corrosion: the bi-metallic couple and
the concentration cell. A bi-metallic couple is
like a battery, consisting of two dissimilar
metals immersed in an electrolyte solution. An
electric current (flow of electrons) is generated
when the two electrodes are connected by an
external, conductive path.
14
Concentration Cell Corrosion
Concentration cell corrosion is the
deterioration of parts of a metal surface
at different rates, due to the parts of the
surface coming into contact with different
concentrations of the same electrolyte.
These differing concentrations result in
some parts of the metal acquiring different
electric potentials.
It is due to an electrochemical attack on the
metal surface exposed to an electrolyte of
varying concentration or varying aeration.
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