CHM578/674 2020

Experiment 3: Corrosion Rate (Weight Loss Method) (20 marks)

Name : Yuslyn Shazmyra binti Mohamad Yussoff ID: 2019252694

Group : AS2224M2

(Refer Lab manual Exp. 3 CHM674 prior to answering the following Post-Lab Questions)

Objectives
a) To study the corrosion of steel in two different acid solutions.
b) To study the corrosion resistant efficiency of steel alloy (ie: stainless steel).

Background:
Steel will corrode when exposed to acid solutions. Electrochemical reactions involved for
steel in two different acids are as follows:

Anodic reaction:
Fe → Fe2+ + 2e Eo = -0.44 V
Cathodic Reaction:
NO3- + 4H+ + 3e ↔ NO + 2H2O Eo = +0.96 V
SO42- + 4H+ + 2e ↔ SO2 + 2H2O Eo = +0.17 V

The simplest, and longest-established method of estimating corrosion losses in plant and
equipment is weight loss analysis. A weighed sample (coupon) of the metal or alloy under
consideration is introduced into the process, and later removed after a reasonable time interval.
The coupon is then cleaned of all corrosion product and is reweighed. The weight loss is
converted to a corrosion rate (CR) as follows:

Density: steel = 7.86 g/cm3 , Stainless Steel = 7.0 g/cm3 , Exposed Area : 2 x 2 x 2 = 8 cm2,
K–factor (corrosion rate in mm/yr) = 8.76 x 104

Procedure:

All metal specimens (steel and stainless steel) must be in the same size. All the metal specimens
were polished with emery paper to remove all dusts and impurities and then rinsed with alcohol.
12 vials or containers were labeled as S1(a)- (c), S2(a) – (c), SS1(a) – (c) and SS2(a) – (c).
All the metal specimens were weighed prior to immersion in acidic solution using a 4-decimal
analytical balance. Each of the specimen was put into the right labelled container containing
the right acidic solution as in the report table. All samples were taken out after 1 hour; and
dried before re-weighing.

The corrosion resistance efficiency of stainless steel is calculated using the following equation:

Corrosion Protection/Resistance Efficiency (η%) = CR steel - CR stainless steel x 100

CR steel

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Results (4 marks)

1. Immersion of Steel in 1M H2SO4 for 1 hour

Metal specimen Weight before immersion (g) Weight after immersion (g) Weight loss (g)
S1(a) 3.0570 3.0250 0.0320
S1(b) 3.0621 3.0301 0.0320
S1(c) 3.0562 3.0254 0.0308
Observation: All solutions turned to cloudy with a lot of bubbles formed on the steel surface.

0.0320 + 0.0320 + 0.0308

Average weight loss (WL): = 0.0316 g
3

2. Immersion of Steel in 1M HNO3 for 1 hour

Metal specimen Weight before immersion (g) Weight after immersion (g) Weight loss (g)
S 2(a) 3.0560 2.8592 0.1968
S 2(b) 3.0630 2.8707 0.1923
S 2(c) 3.0521 2.8668 0.1853
Observation : All solutions turned to green-black solution, a lot of bubbles evolved.

0.1968 + 0.1923 + 0.1853

Average weight loss (WL): = 0.1915 g
3

3. Immersion of Stainless Steel in 1M H2SO4 for 1 hour

Metal specimen Weight before immersion (g) Weight after immersion (g) Weight loss (g)
SS 1(a) 3.0156 3.0155 0.0001
SS 1(b) 3.0293 3.0290 0.0003
SS 1(c) 3.0179 3.0170 0.0009
Observation: No changes in the solution and on the surface of specimen.

0.0001 + 0.0003 + 0.0009

Average weight loss (WL): = 0.0004 g
3

4. Immersion of Stainless Steel in 1M HNO3 for 1 hour

Metal specimen Weight before immersion (g) Weight after immersion (g) Weight loss (g)
SS 2(a) 2.9980 2.9978 0.0002
SS 2(b) 3.0188 3.0178 0.0010
SS 2(c) 3.0298 3.0290 0.0008
Observation: No changes in the solution and on the surface of specimen.

0.0002 + 0.0010 + 0.0008

Average weight loss (WL): = 0.0007 g
3

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Post- Laboratory Questions (16 marks) :

1. Calculate the corrosion rate of steel and stainless steel in both acids for 1 hour.

Exposed Area : 8 cm2

𝐂𝐨𝐫𝐫𝐨𝐬𝐢𝐨𝐧 𝐑𝐚𝐭𝐞 (𝐂𝐑)

𝐖𝐞𝐢𝐠𝐡𝐭 𝐥𝐨𝐬𝐬 (𝐠) × 𝐊

= 𝐠
𝐀𝐥𝐥𝐨𝐲 𝐃𝐞𝐧𝐬𝐢𝐭𝐲 ( 𝟑 ) × 𝐄𝐱𝐩𝐨𝐬𝐞𝐝 𝐀𝐫𝐞𝐚 (𝐀) × 𝐄𝐱𝐩𝐨𝐬𝐮𝐫𝐞 𝐓𝐢𝐦𝐞 (𝐡𝐫)
𝐜𝐦

Corrosion rate (mm/yr) of steel in 1M H2SO4:

(0.0316 g) × (8.76 × 104 )

Corrosion Rate (CR) =
(7.86 g/cm3 ) × (8 cm2 ) × (1 hr)

44.02 cm 10 mm 24 hr 365 days

= × × ×
hr 1 cm 1 day 1 yr

3.856 × 106 mm
=
yr

Corrosion rate (mm/yr) of steel in 1M HNO3:

(0.1915 g) × (8.76 × 104 )

Corrosion Rate (CR) =
(7.86 g/cm3 ) × (8 cm2 ) × (1 hr)

266.78 cm 10 mm 24 hr 365 days

= × × ×
hr 1 cm 1 day 1 yr

23.37 × 106 mm
=
yr

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Corrosion rate (mm/yr) of stainless steel in 1M H2SO4:

(0.0004 g) × (8.76 × 104 )

Corrosion Rate (CR) =
(7.0 g/cm3 ) × (8 cm2 ) × (1 hr)

0.6257 cm 10 mm 24 hr 365 days

= × × ×
hr 1 cm 1 day 1 yr

5.481 × 104 mm
=
yr

Corrosion rate (mm/yr) of stainless steel in 1M HNO3:

(0.0007 g) × (8.76 × 104 )

Corrosion Rate (CR) =
(7.0 g/cm3 ) × (8 cm2 ) × (1 hr)

1.095 cm 10 mm 24 hr 365 days

= × × ×
hr 1 cm 1 day 1 yr

9.592 × 104 mm
=
yr

2. Why corrosion rate of steel is higher in nitric acid than in sulfuric acid?

It is because of strong oxidizing property in nitric acid. When the surface of the carbon

steel exposed to nitric acid, the primary displacement of H+ ions from the solution is

followed by HNO3 reduction rather than hydrogen evolution since the acid reduction

leads to a marked decrease in free energy. As the corrosion rate in acidic solution are

attributed to the presence of water, air, and H+ which accelerated the corrosion

process. Its show the rate of a chemical reaction and dissolution increases, with

increasing concentration of the corrosion media and exposure time, then affected the

corrosion of steels. Hence, the carbon steels in nitric acid environment indicates higher

corrosion rate when compared to sulfuric acid.

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3. Why corrosion rate of stainless steel is lower than of steel?

Due to the interaction between stainless steel alloying elements and the environment.

Stainless steel that reacts with oxygen (from water and air) will form a stable film that

prevents additional corrosion by acting as a barrier that limits oxygen and water access

to the underlying metal surface. It is sufficiently reactive to protect itself from further

attack by forming a passive corrosion product layer. As the film forms so readily and

tightly, stainless steel remains stainless shows the corrosion rate is at very low levels.

4. Calculate the corrosion resistance efficiency of the alloy (ie: stainless steel) in nitric
acid.

Answer:

CR steel − CR stainless steel

Corrosion Resistance Efficiency (η%) = × 100 %
CR steel

(23.37 × 106 ) − (9.592 × 104 )

= × 100 %
(23.37 × 106 )

= 99.59 %