MECH ENG 7061 - Corrosion: Principles & Prevention
North Terrace Campus - Semester 2 - 2014
General Course Information
Course Code MECH ENG 7061 Course Corrosion: Principles & Prevention Coordinating Unit School of Mechanical Engineering Term Semester 2 Level Postgraduate Coursework Location/s North Terrace Campus Units 3 Contact Up to 4 hours per week Course Description This course presents the concepts behind corrosion and corrosion prevention. The different forms of corrosion are introduced, along with how to recognise them. Methods for assessing the extent of corrosion are described including the theory on the reaction chemistry. Finally, ways of designing against corrosion and slowing its progress are discussed. Topics covered include: Fundamentals of corrosion: free energy of oxidation, oxidation and reduction reactions. Pourbaix diagrams, corrosion kinetics, polarisation curves, passivation. Design against corrosion. Investigating corrosion failures. Atmospheric and general corrosion, bimetallic corrosion. Differential aeration corrosion; pitting, corrosion, MIC. Environmentally assisted cracking, erosion. Case studies into corrosion failures, identifying mechanisms and evaluating mitigation strategies.
Course Coordinator: Dr Erwin Gamboa
The full timetable of all activities for this course can be accessed from Course Planner.
Course Learning Outcomes
On completion of the course, students should be able to:
1 recognise the different forms of corrosion; 2 identify likely forms of corrosion that a system could be susceptible to; 3 estimate product lifetime in corrosive environments; 4 design against corrosion; 5 design protection systems against corrosion of infrastructure, plant, equipment and machinery; 6 ability to apply knowledge of basic science and engineering fundamentals; 7 ability to communicate effectively, not only with engineers but also with the community at large; 8 in-depth technical competence in at least one engineering discipline; 9 ability to undertake problem identification, formulation and solution; 10 ability to utilise a systems approach to design and operational performance; 11 ability to function effectively as an individual and in multi-disciplinary and multi-cultural teams, with the capacity to be a leader or manager as well as an effective team member; 12 understanding of the professional and ethical responsibilities and commitment to them; 13 expectation of the need to undertake lifelong learning, and the capacity to do so.
University Graduate Attributes
This course will provide students with an opportunity to develop the Graduate Attribute(s) specified below:
University Graduate Attribute Course Learning Outcome(s) Knowledge and understanding of the content and techniques of a chosen discipline at advanced levels that are internationally recognised. 1-6, 8-10 The ability to locate, analyse, evaluate and synthesise information from a wide variety of sources in a planned and timely manner. 1-6, 8-10 An ability to apply effective, creative and innovative solutions, both independently and cooperatively, to current and future problems. 1-12 Skills of a high order in interpersonal understanding, teamwork and communication. 7,11 A proficiency in the appropriate use of contemporary technologies. 1-6, 8-10 A commitment to continuous learning and the capacity to maintain intellectual curiosity throughout life. 13 A commitment to the highest standards of professional endeavour and the ability to take a leadership role in the community. 1-12 An awareness of ethical, social and cultural issues within a global context and their importance in the exercise of professional skills and responsibilities. 11,12
Lecture notes provided are a brief guide, students are expected to do further reading out of recommended resources.
Corrosion for Science and Engineering (Trethewey and Chamberlain), 2nd Edition, Pearson Education 1998
Corrosion Engineering (Roberge), McGraw Hill 2008
Corrosion Engineering (Fontana), 3rd Edition, McGraw Hill 1986
Uhlig’s Corrosion Handbook (Revie), 2nd Edition, John Wiley 2000
Further material will be available through MyUni under the “Course Material” section for this subject.
Learning & Teaching Activities
Learning & Teaching Modes
The assignments take the form of open-ended industry problems, which tests students’ ability to bring information (from class and from their research) to bear on the given problem. As with all things in life, there is no single right answer to the assignments. Answers that demonstrate a well reasoned approach to solving the problem, taking account of all of the parameters that impact on the solution, attract full marks. This tests not only the students’ ability to provide a technically correct answer, but also one that is succinct and readily understandable by others. The assignments are marked, with the mark contributing to the final grade for the subject. Feedback is provided on each student’s work along with a general solution to the assignment being discussed in class and posted on MyUni.
The assignments allow the students to demonstrate their deep understanding of the subject matter applied to a case study of their choice. The assignment is a formative assessment, based on the ability of the students to draw on what they have researched and learned and apply it.
The examination is a summative assessment and is intended to assess the student’s knowledge and understanding of the course material and how it fits into the global engineering context.
The information below is provided as a guide to assist students in engaging appropriately with the course requirements.
It is recommended that students spend some time prior to each class revising the appropriate background knowledge in chemistry, as this course will build upon material covered in that area.
Despite the apparently simple theory of corrosion, its application to industry practice is very complex and “non-textbook”, so students are expected to spend further time in doing the recommended reading.
The assignments should be completed with 5 hours’ work each.
Learning Activities Summary
Topic 1: Introduction to corrosion. Costs to society. History of corrosion. Electrochemical nature of corrosion. Types of cells (dissimilar electrodes, concentration, differential aeration).
Topic 2: Eight forms of corrosion (general, pitting, crevice, dealloying, intergranular corrosion, corrosion fatigue, stress corrosion cracking, hydrogen embrittlement) and other unusual forms of corrosion (polymers, liquid metal embrittlement, ceramics, microbial induced corrosion).
Topic 3: Thermodynamics of corrosion. Change in Gibb’s free energy. Standard Hydrogen Electrode. Galvanic coupling/series.
Topics 4 and 5: Pourbaix diagrams. Stability of oxides. Electrode kinetics (activation polarisation, concentration polarisation, exchange current density). Activation polarisation – forward and backward reactions. Tafel equation.
Topic 6: Galvanic coupling. Area and environment effects. Galvanic protection, cathodic protection of structures.
Topic 7: Passivity of metals. Oxide layers, potentiodynamic scans. Influence on cathodic half reaction by oxidiser concentration, velocity, temperature, corrosion current.
Topic 8: Inhibitors, corrosive concentrations vs oxidiser concentrations. Atmospheric corrosion.
Topic 9: Measuring corrosion rates. Weight loss, electrochemical methods (potentiodynamic scans, Tafel extrapolation, linear polarisation).
Topic 10: Design against corrosion. Basic requirements, design options, minimise costs. Rules and suggestions (corrosion allowance, simplify methods of construction, avoid moisture/provide drainage, avoid galvanic corrosion and their protective measures, care with joints and junctions, coatings, inhibitors and insulators).
Industry speakers will be invited to speak to the class through the semester. Advance notice will be given to the class of each visit.
Specific Course Requirements
This course will undertake at least one field trip as part of the course. The destination will be announced in advance. Further details will be announced through MyUni. The field trip is typically two hours long and is within Adelaide. Students are expected to arrange for their own transport.
The minimum requirement for attendance at the field trip is long sleeve clothing, safety glasses and steel cap toes.
The University's policy on Assessment for Coursework Programs is based on the following four principles:
- Assessment must encourage and reinforce learning.
- Assessment must enable robust and fair judgements about student performance.
- Assessment practices must be fair and equitable to students and give them the opportunity to demonstrate what they have learned.
- Assessment must maintain academic standards.
Assignments: 5% each (10% total). Assignment 1 is due at 5 PM on Monday 15th Sep 2014. Assignment 2 is due at 5 PM on Monday 27th Oct 2014.
Laboratories: 1% each (10% total). Laboratories are due at 5 PM on Monday 3th Nov 2014.
Semester long assignment: Failure investigation, 10%. Due at 5 PM on Monday 27th Oct 2014.
Exam: 70% total
Assessment Related Requirements
Attendance at laboratories is compulsory. If the total mark for laboratories is less than 30% for that section, the student will automatically fail the subject.
Assignments will be marked for clarity, proper referencing, interpretation and justification of results. Justification and explanation of thought process can be as important as the final numerical answer given.
Submissions are to be handed in to the submission box located on level 2 of Engineering South Building with a signed cover page. Submissions not having a cover page will not be marked.
It is compulsory to hand in the assignment electronically to “Turnitin”. User names and password will be supplied in class.
It is strongly recommended that an electronic submission is also submitted to the “Digital dropbox” within MyUni. This ensures that they are timestamped and that there is a backup copy submitted in case there are problems later with the paper copy.
- Electronic submission file MUST be named in the format of “s(student number) Asst 1”. If you submit a file with a different filename, it will not be marked.
- An easy way to compile the assignment is to scan handwritten calculations and diagrams, and then to insert them into the main document.
- Your submission needs to include all appendices, etc within the file. Separate files will not be marked.
Any late submission will be marked at -10% penalties per calendar day late.
Marked assignments and quizzes will be returned in the “submission return” pigeonholes in the second floor of Engineering South (beside the elevator).
Students are encouraged to contact the lecturer as soon as possible if there is a problem with handing in assignments/quizzes so as to request a different deadline.
Grades for your performance in this course will be awarded in accordance with the following scheme:
M10 (Coursework Mark Scheme) Grade Mark Description FNS Fail No Submission F 1-49 Fail P 50-64 Pass C 65-74 Credit D 75-84 Distinction HD 85-100 High Distinction CN Continuing NFE No Formal Examination RP Result Pending
Further details of the grades/results can be obtained from Examinations.
Grade Descriptors are available which provide a general guide to the standard of work that is expected at each grade level. More information at Assessment for Coursework Programs.
Final results for this course will be made available through Access Adelaide.
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