Online Syllabus - ES464

ES464 Corrosion Engineering
Spring 2002

Catalog Description: Corrosion Engineering R-3, C-3 (ChE). The nature of corrosion and the means by which it can be controlled. The behavior of ferrous and non-ferrous metals and alloys in various environments is related to the theory of corrosion. Control measures such as alloy selection, equipment design, cathodic protection, protective coating and inhibitors. (Even Springs)

Prerequisites: CM132 (Chemistry II). Even though Chemistry II is the only prerequisite, knowledge of Gibb's free energy from a thermodynamics or physical chemistry course is helpful.

Textbook: D.A. Jones, Principles and Prevention of Corrosion, 2nd edition, Prentice Hall 1996.

References: 1. Mars G. Fontana, Corrosion Engineering, McGraw Hill (1986). 2. H.H. Uhlig and R.W. Revie, Corrosion and Corrosion Control, John Wiley (1985).

Instructor: Der-Tau Chin (CAMP 246, 268-7930, chin@clarkson.edu)

Office Hours: Mondays, Wednesdays, Fridays 1:30 p.m. - 3:00 p.m. or by appointment.

Course Site: http://www.clarkson.edu/~chengweb/curricula/syllabi/es464.html

Learning Objectives:

  1. Understand the principles of corrosion chemistry, including redox reactions, electrochemical cell voltage, electrode potential, Nernst equation, activation polarization, Tafel equation, concentration polarization, passivity, mixed potential theory, corrosion potential and corrosion current density. Know to predict the corrosion tendency of a metal or an alloy in a given environment and to estimate the corrosion rate using the Tafel kinetic parameters.
  2. Understand various forms of corrosion, their relation to the metallurgical structures, and their mitigation measures.
  3. Learn the corrosion measurement and monitoring methods, including the linear polarization, Tafel extrapolation, and AC impedance techniques.
  4. Learn the characteristics of various corrosion environments and corrosion control measures, including material selection, equipment design, coatings and linings, corrosion inhibitors, and anodic and cathodic protections.
  5. Learn the principles of high temperature corrosion and corrosion resistance of metals and alloys in a high temperature environment.

Learning Outcomes*:

  1. Students will be familiar with the principles of corrosion chemistry, including the thermodynamics and kinetics aspects of electrochemistry. [1,2,3,4,5] (1)
  2. Students will learn to identify various forms of corrosion and their mitigation measures. [1,2,3,5] (1,3)
  3. Students will learn to plan corrosion experiments and to monitor the corrosion rate of a metal or alloy using modern electrochemical instruments. [4,5] (1,3,4)
  4. Students will become knowledgeable of various corrosion environments and prevention of corrosion with proper material selection, equipment design, use of coatings, corrosion inhibitors, anodic protection and cathodic protection. [2,3,5] (1,2)

Evaluation Methods:

  1. Mid-term Exam (25%) - Friday March 1 in class
  2. Final Exam (40%) - Date to be scheduled by SAS
  3. Project #1 Failure Analysis (15%) - Students locate a corroded metallic object, analyze it, determine its failure/corrosion mechanism, and recommend corrosion mitigation measures. A written and an oral report are required at the end of the semester. Instructions will be given in a separate sheet. (3 students per project)
  4. Project #2 Experiment on Corrosion Rate Measurement (10%) - A laboratory experiment begins in the week of March 25th to measure the corrosion rate of a metal with an electrochemical corrosion measurement instrument and compare the results with the weight loss measurement. A written report is due one week after the completion of the experiment. Instructions will be given in a separate sheet. (3 students per project)
  5. Homework (10%)

Exam Policy: All exams are close book and close notes.

Homework Policy: Homework problems will be assigned on a need basis. Students are required to submit homework on the designated due date. Each homework assignment will be given a grade of 0 - 3 (0-1 for poor; 1-2 for acceptable; and 2-3 for good to excellent). The grade will be based on the neatness and efforts demonstrated on the submitted homework. Homework solution will be posted at library's curriculum support desk after the due date. No late homework will be accepted.

Attendance Policy: Class attendance will be taken on a regular basis, although not necessarily in each class meeting. If you are consistently absent from the classes without a valid excuse, you will be reported to the appropriate Deans and your final course grade will be affected.

Course Outline:

  1. Corrosion Principles (Chapter 1): introduction, social and environmental effects of corrosion, corrosion chemistry; etc.
  2. Forms of Corrosion (Handout supplemental materials): uniform corrosion, galvanic corrosion, pitting corrosion, crevice corrosion, inter-granular corrosion, stress corrosion, hydrogen damages.
  3. Thermodynamics of Corrosion (Chapter 2): electrode potential, the Nernst equation, EMF and galvanic series; Pourbaix diagrams.
  4. Kinetics of Corrosion (Chapter 3): polarization, Tafel equation, mixed potential theory, concentration polarization; passivity.
  5. Corrosion Testing and Measurement (Chapter 5): coupon exposure test, accelerated corrosion test, linear polarization, Tafel extrapolation, and electrochemical impedance spectroscopy.
  6. Atmospheric Corrosion & High Temperature Corrosion (Chapter 12): corrosion in various atmospheres; oxidation reactions and oxide films, thermodynamics and kinetics of oxidation, high temperature corrosion by water vapor, hydrogen, carbon dioxide, sulfur-containing gases, etc.
  7. Corrosion Prevention and Protection (Chapters 13 & 14): cathodic protection, anodic protection, corrosion inhibitors, coatings, equipment design for corrosion prevention
  8. Other Corrosion Environment and Materials Selection (Chapter 11 & 15): selection of corrosion resistant materials for use in acids, alkalies, atmosphere, soils, seawater, freshwater, etc.

Class Time: Mondays, Wednesdays, Fridays 4:00 - 4:50 p.m. in CAMP 175

*Numbers in [] refer to evaluation methods used to assess student performance. Numbers in () refer to the program outcomes of the Chemical Engineering Department.