B. Course Syllabi for Materials Engineering

1. Course Name: Mat E 444 Corrosion and Failure Analysis

2. Catalog Description: Mat E 444. Corrosion and Failure Analysis. (2-3) Cr. 3. Part I: Corrosion and corrosion control of metallic systems: corrosion fundamentals; classification of different types of metallic corrosion; corrosion properties of various engineering alloys; corrosion control. Part II: Failure analysis: characteristics of common types of metallic failures, case studies of failures (e.g., corrosion, fatigue, creep, etc.), designing to reduce failure risk.

3. Prerequisites: Mat E 211, 318.

4. Textbook/Materials: Denny A. Jones, Principles and Prevention of Corrosion, 2nd Edition, Prentice Hall, NJ, 1996.

5. Course Learning Objectives:
The specific objectives are to train students to:

• Competently identify the various forms of corrosion and potential corrosion problems.
• Have a knowledge of the causes of corrosion and the methods by which it can be controlled.
• Select appropriate materials for corrosive applications and to communicate effectively with other corrosion professionals.
• dentify failure types by observation of the fracture surface
• Reduce possible failure through a proper combination of part design and material selection.

Students will be able to:

• Identify the various forms of corrosion and select alloys for different corrosive conditions.
• Select optimum methods for corrosion control.
• Source and use engineering corrosion tables to obtain predicted corrosion rates or behavior.
• Identify failures common to metals. Know the causes for each type of failure and how to design a part to minimize specific failure types.
• Communicate clearly and effectively both orally and in writing.
• Work effectively as part of a team.

6. Topics Covered:
Part I:

• Electrochemistry of Corrosion
• Thermodynamic and kinetic aspects of electrochemistry; polarization; EMF and galvanic series; Pourbaix diagrams; corrosion rate and current flow; passivity.
• Types of Metallic Corrosion
• General, galvanic, localized, intergranular, and stray current corrosion; dealloying; erosion corrosion; fretting; stress corrosion cracking; hydrogen damage; high temperature corrosion; case studies.
• Corrosion Properties of Various Metals and Alloys
• Carbon and low alloy steels; stainless steels; copper and its alloys; aluminum and its alloys; titanium and its alloys; magnesium; and zinc.
• Methods of Corrosion Control.
• esign; inhibitors; cathodic and anodic protection; coatings; case studies.

Part II:

• Characteristics and Causes of Common Failure Types.
• Fundamental mechanisms of failure; micro and macrostructure of failures.
• Case Studies and Remedies of Typical Failures.
• Failures due to unsatisfactory processing, excursions in service conditions, overload, fatigue, and creep.

7. Class Schedule: Class MW 9-10, Lab/Tutorial T 8-11

8. Professional Component: Mat E 444 contributes 3 credits toward Engineering Ttopics and to the professional component of this program through the discussion of case studies which include economic, sustainability, ethical and manufacturability issues.

9. Relationship of Course to Program Learning Outcomes and Program Educational Objectives: Objectives: A, C, E Outcomes: a, b, e-g, k-o, r (significant)

10. Prepared by: B. Gleeson, 8/10/99, rev. 5/24/00 KPC