Lecture 1
Introduction
Ove rview of c our se
Importanc e of studying mate ria ls degra dation
some e xa mples of ca tas trophic fa ilure
MSE 480/580:
R AJEEV G UPTA
INTRODUCTIONS
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COURSE INFORMATION
Course Website: [Link]
Course Credit Hours: 3
Meeting Time
Monday & Wednesday 11:45 am–1:00 pm
In person: 02240 MRC 313
Prerequisites
MSE 370 and MSE 380
5 minutes break
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Moodle
Lecture notes will be posted on Moodle
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COURSE OVERVIEW
Catalog Description
Covers principles and prevention of the degradation of materials. The topics will include dissolution of
polymer and ceramic materials, electrochemical corrosion, oxidation of metals and polymers, degradation
of polymers, friction and wear, degradation of electrical device components, bio-deterioration of materials,
and failure analysis. The general practice in failure analysis will be applied to a variety of case studies to
illustrate important failure mechanisms..
Course Structure
Course will be synchronous with two lectures every week. Both PowerPoint slides and a whiteboard
will be used in lectures. PowerPoint slides will be uploaded on the Moodle at end of every week. A
weekly plan with the scheduled topics is provided in the end of the “course schedule”. All the students
are required to attend the class. Students should accept ~ 8 assignments in total.
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LEARNING OUTCOMES
Upon completion of this course, students will be able to:
1. Type of degradation and understanding methods to quantify
degradation of materials
2. Thermodynamics and kinetics of materials degradation
3. Effect of composition and microstructure on material degradation
4. Understand basic concepts of failure failure analysis
ABET LEARNING OUTCOMES
Outcome 5: Be able to demonstrate knowledge of thermodynamics and
kinetics relevant to MSE.
Outcome 6: Be able to identify the structure-property-processing-performance
relationships for metallic, ceramic, polymeric and electronic materials.
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COURSE MATERIALS
Required Textbook
Introduction to Corrosion Science (E.
McCafferty), Required
Optional Materials
Principles and Prevention of Corrosion (D.
Jones), Recommended
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COURSE SCHEDULE
Please Note: Course
schedule is subject to
change.
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SYLLABUS MODIFICATION STATEMENT
Our syllabus represents a flexible agreement. It outlines the topics we will cover and the order we will cover
them in. Dates for assignments represent the earliest possible time they would be due. The pace of the class
depends on student mastery and interests. Thus, minor changes in the syllabus can occur if we need to slow
down or speed up the pace of instruction.
Changes to syllabus information will be communicated to students in the class. Lecture slides will have most
updated information. Revised syllabus will be uploaded on the Moodle.
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Grade Components
MSE 480
Component Weight Details
Homework 15% Expect ~ 8 homework assignments
Lecture summary 5% Summary of each topic or lectures by end of the week
Exams 50% Two mid semester exams (25% each)
Final comprehensive exam 30%
MSE 580
Weight Details
Component
Homework 10% Expect ~ 8 homework assignments
Project 5% Informaiton will be provided in the class
Lecture summary 5% Summary of each topic or lectures by end of the week
Exams 50% Two mid semester exams (25% each)
Final comprehensive exam 30%
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How do I calculate grades?
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Academic Integrity:
NCSU’s policy on what constitutes academic integrity in a course can be found
at: [Link]
For homework assignments in this course authorized aid includes discussing the interpretation
of the problem statement, sharing ideas or approaches for solving the problem, and explaining
concepts involved in the problem.
Policy on Late Assignments:
Homework assignments will be due at the beginning of the class period on the due date, unless
late submission due to a schedule conflict has be preauthorized by the instructor. Students will
COURSE
loose 10% each POLICIES
day the assignment is late.
Late Assignments
● Late assignments will be accepted with 10% points taken off for every day submitted late.
● Assignments submitted later than two weeks passed the original due date will NOT be
accepted.
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Health and Well-Being Resources
These are difficult times, and academic and personal stress is a natural result. Everyone is
encouraged to take care of themselves and their peers. If you need additional support, there are
many resources on campus to help you:
• Counseling Center ([Link]
• Health Center ([Link]
• If the personal behavior of a classmate concerns or worries you, either for the classmate’s
wellbeing or yours, we encourage you to report this behavior to the NC State CARES team:
([Link]
• If you or someone you know are experiencing food, housing or financial insecurity, please see
the Pack Essentials Program ([Link]
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Some important points
• Ask questions, participate in discussion
•Fun and stress-free learning
•Be respectful to each other
•Please meet all the deadlines
• Sound scientific understanding
•Your wellbeing, health and safety is most
important
•your feedback is very important
• I am open to suggestions and discussion
Do not use cell phone in class
please.
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What is material
degradation and
corrosion?
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Physical degradation?
Fracture
Fatigue
Wear
Erosion
Radiation damage
Chemical/environmental
degradation?
Environmental Assisted
degradation?
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What is Corrosion?
Corrosion is the destructive result of chemical
reactions between a metal and the environment.
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We live in metal based society and
metals corrode.
Why do metals corrode? Can we
prevent corrosion of metals?
Economics of corrosion
Why do metals corrode? Can
we prevent corrosion of
metals?
Environmental impacts
Rust has been called “the
great destroyer,” the
“pervasive menace,” and
Availability of recourses
“the evil.” “This look at
corrosion—its causes, its
consequences, and
especially the people
devoted to combating it—
is wide-ranging and
consistently engrossing”
(The New York Times).
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Economics of corrosion
• Year 1949, the cost of corrosion was estimated to be 2.5%
of GDP.
• The Global cost of corrosion in year 2013 is estimated to be
$2.5 trillion, equivalent to 3.4% of the global Gross domestic
product (GDP)
• The cost does not include individual safety, environmental
impacts, loss of reputation…
• Cost to corrosion is not uniformly distributed across the
globe
• Direct and indirect costs
Example:
Inspection of pipelines to detect corrosion
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Risk-based inspection varuses scheduled inspection
Environmental impacts
• Wastage of Resource
• Need to produce more material
• Need of specific materials to manage corrosion
• Use of heavy materials in transportation
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Availability of recourses
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1. Swimming Pool Roof Collapse
2. Aircraft Corrosion
3. Pipeline corrosion
4. Infrastructure
5. Chemical industries
[Link]
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Kaohsiung (Taiwan) gas explosion
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Material Selection
Mechanical properties
Cost
Physical
properties Material Availability
Appearance
Fabricability
Corrosion
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Mars Fontana, Corrosion Engineering
Complexity in understanding corrosion
Environment
electrolyte,
pH, chloride
content,
heavy metals,
flowrate,
stresses,
inhibitors,
temperature,
UV rays……)
System design
(surface finish, galvanic coupling, sharp
edges, stresses, drainage, …)
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Complexity in understanding corrosion: practial example
Body implant
Stainless steel implant
Heat treated
Deformation
Tensile stresses
SCC → Failure
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Some practical examples
Lamp post
Corrosion monitoring???
Test coupon
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Main forms of corrosion grouped by their
ease of reorganization
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Corrosion management
• IDENTIFICATION OF CORROSION RISKS
• CORROSION RISK ANALYSIS
• CORROSION MONITORING AND
INSPECTION
• MAINTENANCE STRATEGIES
• LIFE CYCLE COSTING
• CORROSION MITIGATION
• Coatings and inhibitors
• Design, cathodic and anodic protection
• Material selection
• New corrosion resistant materials
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Risk management process
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Chapter 4.30 Corrosion management overview: Shreir’s Corrosion, page 308
Homework
1. Examples of corrosion can be found in everyday life.
Describe one example which you have seen.
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Corrosion
Economics:
Not for exams
This is intended
to give you a
basic idea
Handbook of corrosion engineering Roberge, Pierre R, McGraw-Hill : New York, 2012, Appendix C, Corrosion
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Economics, page 1001
Life cycle costing (LCC)
• Direct Expenses
– Capital
– Operational
• Indirect cost
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LCC
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LCC
A new heat exchanger is required in conjunction with a rearrangement of existing facilities.
Because of corrosion, the expected life of a carbon steel heat exchanger is 5 years. The
installed cost is $9500.
An alternative to the heat exchanger is a unit fabricated of AISI type 316 stainless steel, with
an installed cost of $26,500 and an estimated life of 15 years, to be written off in 11 years.
The minimum acceptable interest rate is 10 percent, the tax rate is 48 percent, and the
depreciation method is straight line.
Determine which unit would be more economical based on annual costs.
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Next class
Basics of corrosion/electrochemical corrosion
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