School of Mechanical and Chemical Engineering

TUTORIAL SOLUTIONS

MECH4428
Degradation of Materials
Chapter 2: Corrosion of Metals
Practice Question Sheet 1 - Solutions

1. Group Discussion: It is said that corrosion is a natural phenomenon. Explain the context
and implications of this statement. Can corrosion be used to our benefit? Give an example
if you think so.
Corrosion is a “natural” phenomenon, in the context that a metal is put back into a
“combined” state, very much like how we have found them in the nature (the minerals).
For most metals we found them in various mineral forms and we refine (reduce) them
into metallic form. In this context, corrosion is only to reverse what we have done.
A natural phenomenon can always be put into good use, so can corrosion. Etched glass
(with artistic designs of patterns, for example) is produced by chemically corroding the
glass surface away in selected areas to form a pattern (Figure 1). Printed circuit boards
are made by corroding away the unwanted parts leaving behind the circuit design (Fig. 2).
Anodised aluminium has a man-made protective surface oxide payer (corrosion product)
for corrosion and wear protection. …. Can you think of another example?

Fig. 1. Etched glass is another example of
good use of the phenomenon of corrosion,
this time on glass.
Fig. 2. A printed circuit board, produced by
etching (corroding) away the unwanted
parts of a continuous copper foil, leaving
behind the connecting “wires” behind, a
method invented by Paul Eisler in in 1943.
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TUTORIAL SOLUTIONS

Fig. 3. Anodisation of Al encourages the formation of extra thick and hard surface oxide for
better wear and corrosion resistance, and the ability for colouring as a bonus.

Fig. 4. Small printed circuit heat exchangers. Each exchanger is effectively a stack of panels
with many small groves chemically etched into their two sides to provide passages for heat
exchange fluids or air. They are produced by “chemical machining”, which is effectively a
corrosion process.

2. For design engineers and corrosion engineers it is important to determine the corrosion
rate. One way of determining corrosion rate is to measure the weight loss of a sample
coupon over a period of time submerged in a corroding medium.
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(a) Group Discussion: Design an immersion test for a carbon steel in seawater:
describe sample specification and preparation; describe test procedure and
conditions, describe what to measure and how to obtain the data.
(b) Individual Work: Derive an expression of the rate of corrosion in mmpy using
data from such a measurement. (Identify every variable in your equations).

(a):
(b): For such type of questions, the important thing is not to start writing the equations
immediately. The important thing is to see the “road map” of the solution: i.e., the logic links
necessary to bring us from where we start to the end answer:
1. We measure the weight loss, W, in grams
2. That is over a period, t, in days
3. This must be over a certain surface area: sample surface area, two sides
maybe: A, in mm2
4. The weight lost need to be converted to volume, so we need density, ρ
If we have volume loss per time per area, then that is mm/s, our corrosion rate. Right?
Now try to put the math together. Make sure you convert all the units correctly.
365000𝑊𝑊
[my answer is: 𝐶𝐶𝐶𝐶 = 𝜌𝜌𝜌𝜌𝜌𝜌
. Same as yours?]

If having difficulty, please refer to lecture ppt presentation, or see me.

3 It is important to recognise galvanic corrosion when it happens. Consider the following

cases:
(a) It is noticed that a magnesium drain plug in the steel oil pan of an automobile is
visibly corroded on the inside (oil side). Is this a case of galvanic corrosion?
The oil is not an electrolyte, so this is not likely a galvanic corrosion.
(b) Equal areas of copper and Monel sheet bolted together (Monel nuts and bolts) are
immersed in seawater for one year. Inspection shows some general corrosion of
the copper and no visible attack of the Monel. Is this a typical case of galvanic
corrosion?
Check the galvanic series to see how different or similar these two metals are. You may also
need to find out what Monel alloy is, for it may not appear in the galvanic series table.
Monel is a group of Ni alloys, with Cu as the primary alloying element. The most common is
Monel 400 (also known as Alloy 400, N04400).
The two alloys show modest potential difference in the galvanic series, with Cu being more
anodic. This is possibly a galvanic corrosion.
(c) A 10 m2 carbon steel plate contaminated by a small drop (10 mm2) tin on its
surface is immersed in seawater. Will this produce galvanic corrosion? What
about if it is a lead plate?
Think about the area ratio effect for galvanic corrosion.
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The steel plate is the anode. It is most likely that some corrosion will occur in the steel plate
in the immediate area around the tin drop. No galvanic corrosion is expected to the rest of the
plate.
If the plate is Pb, little galvanic effect is expected, because Pb and Sn have very similar
potentials, with Sn being more anodic (so Sn will corrode and self disappear)

(d) A graphite fibre reinforced aluminium composite shows delamination of the fibre
from the matrix after exposure to a salt spray.
Very likely. Graphite fibre is a good electrical conductor, and is much more inert than
aluminium. Salt spray provides an electrolytic environment. These provide an ideal situation
for galvanic corrosion.

4 During animal testing of alloys for surgical implants, most procedures recommend that
only one type of metal be tested in each animal to avoid galvanic corrosion even though
the specimens are physically separated. Is this a reasonable criterion?
No contact, and body fluid is not a good electrolyte. The possibility of galvanic corrosion is
practically nil, and the recommendation is not necessary from an engineering viewpoint.
However, tradition, culture and lack of engineering knowledge in the medical profession may
not accept a contradictory recommendation.