The corrosion of materials is often a life limiting process that affects almost all materials. It is expensive, both in terms of the potential tremendous economic costs that can arise from unexpected failures, environmental damage and so forth, but also the high cost of maintenance and repair associated with the life extension of plant equipment and service.

Material scientists and engineers often have to conduct many expensive and time-consuming corrosion experiments to fully qualify a material or design more corrosion resistant ones. Corrosion is a kinetic process that is driven by the underlying thermodynamics of a system that is a material in a given environment. Thermodynamic investigation of corrosion under various environments is extremely important for efficient design and production of high-quality materials, for advanced processing of corrosion-resistant coatings, for optimal performance of commercial materials in industrial, environmental, medical and military applications and for environmental protections and safety assessments.

View our webinar: The Application of CALPHAD Based Tools to Corrosion Modeling

Different types of corrosion can be considered using Thermo-Calc Software’s tools.

  • Aqueous Corrosion
  • High temperature gas corrosion
  • Metal dusting
  • Internal oxidation
  • Degradation of coatings through inter-diffusion
  • Molten salt corrosion

Some examples of use:


  • A specialised module for Pourbaix diagrams is available that can be used in conjunction with alloy and aqueous databases to predict Pourbaix diagrams for multicomponent alloys.
  • The general Thermo-Calc calculation routines can be used to predict the amounts and compositions of phases for metal-aqueous, metal-gas and metal-molten salt systems.


  • Simulating degradation of protective NiAl coatings for Ni-based superalloys
  • Predicting oxide growth on Fe surface with diffusion through the oxide as the rate limiting step
  • Internal oxidation