QUESTION 5 a) Meaning of material corrosion Corrosion is the gradual destruction of material, usually metals, by chemical reaction with its

environment. In the most common use of the word, this means electrochemical oxidation of metals in reaction with an oxidant such as oxygen. Rusting, the formation of iron oxides is a well-known example of electrochemical corrosion. This type of damage typically produces oxide(s) or salt(s) of the original metal. Corrosion can also occur in materials other than metals, such as ceramics or polymers, although in this context, the term degradation is more common. Corrosion degrades the useful properties of materials and structures including strength, appearance and permeability to liquids and gases.

b) I) intergranular corrosion

Intergranular corrosion (IGC), also known as intergranular attack (IGA), is a form of corrosion where the boundaries of crystallites of the material are more susceptible to corrosion than their insides. (Cf. transgranular corrosion.)

This situation can happen in otherwise corrosion-resistant alloys, when the grain boundaries are depleted, known as grain boundary depletion, of the corrosion-inhibiting elements such as chromium by some mechanism.

In nickel alloys and austenitic stainless steels, where chromium is added for corrosion resistance, the mechanism involved is precipitation of chromium carbide at the grain boundaries; resulting in the formation of chromium-depleted zones adjacent to the grain boundaries (this process is called sensitization).

Around 12% chromium is minimally required to ensure passivation, mechanism by which an ultra-thin invisible film, known as passive film, forms on the surface of stainless steels. This passive film protects the metal from corrosive environments.

The self-healing property of the passive film makes the steel stainless. Selective leaching often involves grain boundary depletion mechanisms.

II) Crevice corrosion

Crevice corrosion refers to corrosion occurring in confined spaces to which the access of the working fluid from the environment is limited. These spaces are generally called crevices. Examples of crevices are gaps and contact areas between parts, under gaskets or seals, inside cracks and seams, spaces filled with deposits and under sludge piles.

C) FOUR (4) factors that control the rate of metal corrosion I. II. III. IV. position in chemistry series touch merger of two different metals from deep position in the electrochemical series the presence of foreign elements in metal structure cracks

D) I) Two (2) physical and mechanical properties for each metal Physical ALUMINIUM Very light metal good conductor of electricity COPPER good conductor of electricity very high thermal conductivities

Mechanical ALUMINIUM soft and weak corrosion-resistant COPPER simple attribute machine increased strength at high temperatures

II) Two (2) application for each metal ALUMINIUM For construction of cast components for cookware, aircraft Packaging (cans, foil) Power generation and transmission - generators, transformers, motors, bus bars and cables provide and deliver electricity safely and efficiently to homes and businesses. COPPER make wire and turbine blades