CRS 301T Main Exam Nov 2011

Tshwane University of Technology

November 2011 MAIN EXAMINATION

SUBJECT: Corrosion

SUBJECT CODE: CRS301T

PAPER NO.: Paper 1
PAPER DESCRIPTION: Close Book
TOTAL MARKS:
180
DURATION: 3 HOURS

FULL MARKS: 180

SPECIAL REQUIREMENTS:
None
Non-programmable pocket calculators
Scientific calculators
Drawing instruments
Other

( )

INSTRUCTIONS TO CANDIDATES: ANSWER ALL QUESTIONS

NUMBER OF PAGES: 7 (Including this page and Appendix)

QUALIFICATION:
N DIP: Metallurgical Engineering
EXAMINER: Dr. DJ Delport

MODERATOR: Dr. N Naude

CRS 301T Main Exam Nov 2011

Question 1
Define the following terminologies;
1.1
1.2
1.3
1.4
1.5
1.6

Corrosion
Inhibitors
Passivation
Hot-Dip Galvanizing
Pack Cementation
Sessile organisms

(2)
(4)
(4)
(4)
(4)
(2)
[
20]

Question 2
2.1

The electrode kinetics of the corrosion reaction of zinc being dissolved by hydrochloric
acid. The reaction can be represented by an electrochemical potential E (volts) vs. log
current density plot, as shown in the Figure (Principles of Materials science and
Engineering 3ed). Explain the different points on the Polarization graph.
(10)

CRS 301T Main Exam Nov 2011

2.2

Name three main uses of the Pourbaix Diagram?

(3)

2.3

Name five methods of preventing stress corrosion.

(5)

2.4

The Figure (Chemistry the central science 3ed) below illustrates uniform corrosion of
iron in contact with water. Write the cathode, anode and balance the reaction for this
corrosion.
(6)

2.5

The Figure (Chemistry the central science 3ed) below illustrates cathodic protection of
iron in contact with zinc. Complete the outstanding information in the Figure.
(12)

2.6

Name the four different mechanisms how inhibitors react in a corrosive environment.
(4)

CRS 301T Main Exam Nov 2011

2.7

A Plant installation manual states that you should not connect a brass pipe directly to a
galvanized steel pipe because electrochemical reactions between the two metals will
cause corrosion. The manual recommends you use, instead, an insulated fitting to
connect them. What spontaneous redox reaction(s) might cause the corrosion? Justify
your answer with standard emf calculated values.
(8)

2.8

A Fe reactor is plated with Co to protect against corrosion. Does the cobalt protect the
iron by cathodic protection? Explain
(4)

2.9

Name the different types where environment inhibitors can be used effectively.
(6)

2.10

Draw a standard hydrogen electrode (SHE) and name the main components of such an
electrode.
(6)
[64]

Question 3
3.1

Can copper oxide be a good protective oxide layer? Proof your answer by calculating
the ratio of the oxide volume to metal volume (Philling-Bedworth) for the oxidation of
copper (500g) to copper oxide, Al2O3. (Density Cu = 8.94 g/cm3 and CuO =
6.31g/cm3. MCu= 63.55g/mol and MCuO = 79.55g/mol)
(10)
Explain your answer.
(2)

3.2

A cable supplier made use of an electroplating process that utilized 2200 A of current
by chemical dissolving (corroding) a copper anode of 45 % pure and electroplating a
copper cathode (99.9 % pure). If it is assumed that there are no side reactions, how
long will it take to corrode 0.25 kg of copper from the anode?
(6)

3.3

The underground water supply pipe of a metallurgical recovery plant made use of 4.4
kg (total mass of all the anodes), sacrificial anodes (Mg).
a)
Name the type of corrosion protection.
(2)
b)
If 50% the anodes are corroded away in 100 days, what is the average current
produced by the anode in this period?
(8)
c)
Draw such an underground protective system.
(8)

3.4

The water that is been used for cooling down the environment in a metallurgical plant
is pump to a cooling tower. The water has the following analysis:
pH = 7.1, TDS = 680 mg/L, Ca = 250 mg. L -1 as CaCO3 and Alkalinity = 44 mg. L -1
as CaCO3.
The incoming water to the cooling tower is at 82C and the outlet water at 25C.
Calculate the LSI at both temperatures and explain your answer.
(12)
4

CRS 301T Main Exam Nov 2011

[48]
Question 4
4.1

a)
A visual experiment is set up (Figure bellow) to explain the interplay of local
anodes and cathodes on different steel surfaces exposed to a corrosive environment. A
beaker containing water, 3% NaCl, Phenolphthalein and Ferroxyl was used with the
nail in it. Half of the steel nail was plated with zinc. Give the reactions of both the
Anodic and Cathodic reaction areas with a short explanation what happens; also make
use of the standard reduction potentials values (Corrosion Engineering principles and
practice by Pierre R Roberge).
(8)
b)
What type of corrosion is demonstrated by this experiment?
(2)

4.2

Can Polymers undergo corrosion? Explain.

4.4

The principle of corrosion can also be used to purify metals and it is widely used in the
electrometallurgy industry.
a) Describe how electrometallurgy could be employed to purify crude cobalt metal by
composition of the electrodes and electrolyte.
(4)
c) Write out all the electrode reactions.
(4)

4.5

When facing corrosion problems at your workplace, the main questions generally
asked by most people facing this problem are?
(5)

(4)

CRS 301T Main Exam Nov 2011

4.6

Identify the following types of corrosion illustrated in the sketches below (Corrosion
Engineering principles and practice by Pierre R Roberge).
(14)

APPENDIX

4.7

Steel in concrete is used widely and the steel enhanced the physical properties while
the concrete protects the steel from corrosion.
a)
How do concrete protect steel from corrosion
(2)
b)
Name three types of corrosion in reinforced concrete
(3)

4.8

Base on the standard reduction potentials which of the following metals could provide
cathodic protection to iron: Al, Cu, Ni and Zn?
(2)
TOTAL

[48]
[180]

CRS 301T Main Exam Nov 2011

APPENDIX
Data/Formula:
F = 96500 As mol-1 MCu = 63.5gmol-1

MFe =55.85 gmol-1 MMg=24.31g.mol-1

Formula List:

Standard reduction potentials table

-0.277V

Co2+ + 2e- Co