AHMAD JAN 2019048

USMAN SARFARAZ 2019531

ABDULLAH 2019015
M. IDREES 2019336

MM435-Corrosion ASSIGNMENT
INTRODUCTION:
Corrosion is one of the major problems. It is an economic and social problem, and it can be
controlled after full knowledge of corrosion on every aspect. Dezincification is the selective loss
of zinc from brass, and it is one of the types of corrosion. As brass is used on large scale in
drinking water systems in valves and tube fittings etc., and release of toxic metals due to
corrosion can cause different human health problems.
Brass is an alloy of copper and zinc. It contains different proportions of zinc which counts from
5% to 40%. A single solid solution α brass can be form by dissolving zinc up to 35% in face
centered cubic (fcc) copper matrix. And higher concentration of zinc will result in zinc rich β
second phase. This zinc-rich β second phase is determined by body-centered cubic (bcc) lattice.
Duplex α + β brasses has excellent properties. And this Duplex α + β brasses are highly used for
drinking water distribution systems due to their excellent mechanical properties. But not enough
impurity control can affect these structure systems. It is cheaper and can be manufacture easily
and have better mechanical strength than α brass. Dezincification cause porosity on the material
layer. Like dezincification of zinc-rich Beta phase occur easily due to their higher tendency
towards dezincification and it leaves porous surface of copper. So, copper structure become
weak and lead to brittle.

Dezincification can simply be determined by the appearance of material. Like when mild
dezincification happens, color of material surface changes from yellow to pink. Severe
dezincification of such material can cause weakening in brass and fracture at low forces.
PRINCIPLE
The principle of dezincification refers to the process in which zinc is removed from brass or
bronze alloys through corrosion, resulting in a weakening of the material. This process occurs
when the material is exposed to an environment with high levels of oxygen and low pH, such as
in seawater or soil. The corrosion process begins at the surface of the material and gradually
progresses inward, causing the zinc to be removed and the remaining material to become more
brittle and susceptible to failure. To prevent dezincification, materials made from brass or bronze
alloys must be treated with a protective coating or used in environments with less aggressive
corrosion conditions.
The process of dezincification begins when the zinc in the brass or bronze alloy reacts with the
corrosive environment, forming zinc oxide. The zinc oxide then reacts with the bacteria or fungi
present in the environment, forming a complex molecule called zinc hydroxycarbonate. This
molecule is highly soluble in water, and as a result, it leaches out of the brass or bronze alloy,
leaving behind a porous, spongy mass of copper.

The process of dezincification is driven by the difference in electrochemical potential between

the zinc and the copper in the alloy. When the alloy is in contact with an electrolyte, such as
water, the zinc ions are more easily oxidized and lost from the alloy. This results in a depletion
of zinc and an accumulation of copper in the remaining material.
Mechanism:
There is uncertainty in the mechanism of dezincification. Workers are in doubt related to the
mechanism of dezincification. Some say that, at first it is the entire alloy that dissolved when
brass react with corrosive environment, and later on each component is replated using the same
solvent that leached the alloy.
The dissolution and mechanism reactions are followed below as:
Zn Zn++ + 2e-

Firstly, the copper is carefully deposited. Copper is deposited as a fine copper dust which can be
dissolved in electrolyte. Then the brass is selectively removed. A highly porous surface form
when zinc is leached out from the brass. Leaching of zinc left behind porous copper mass, which
is weaken in properties.
There are three steps involved shown in above equations.
1. First step is Cu and Zn dissolution (in equation I and II)
2. In second step Zinc remains in the solution
3. In third step, copper plates back (equation III)
As we already know the more the metal is active, the more readily it will dissolve and take part
in corrosion. So, zinc being the more active metal dissolve at first and copper has less tendency
to dissolve than zinc. The E° for zinc is -0.763V and that for copper is 0.337V. The more the
value of reversible potential is negative the more the element is active. Copper being the noble
metal replaced by the zinc in solution. So porous will be redeposited on the surface. This
porosity is because of leaching of zinc from brass alloy. So, the brass is weaken and its strength
is significantly reduced. The slight increase in the load can rupture the porous brass material.
The mechanism of dezincification involves the formation of a galvanic cell, which is created
when two different metals are in contact with each other in the presence of an electrolyte. In the
case of dezincification, the brass or bronze alloy serves as the cathode, while the zinc in the alloy
serves as the anode. When the brass or bronze alloy is immersed in an electrolyte, such as water
or soil, the zinc in the alloy begins to dissolve. This occurs because the zinc has a more negative
standard electrode potential than the brass or bronze, making it more susceptible to corrosion. As
the zinc is dissolved, it leaves behind a porous structure that is prone to further corrosion and
mechanical failure.

Looking to the first group, the other group claims that a selective species from the alloy is
dissolved, which lead into porous structure of more noble metal is left.
And the third group believes that both mechanisms operate.
The figure shows the dezincified region below the metal surface. Deposits of copper are the
alterations displayed above. The accompanying graphic illustrates the data suggesting that both
systems could be in use at once.
The mechanism of dezincification is complex and involves several factors. First, the presence of
oxygen and water in the environment allows for the formation of an oxide layer on the brass
surface. This oxide layer, along with the presence of certain microorganisms, can create an acidic
environment that promotes the corrosion process.

Here are the four strips. These strips show the mechanism of dezincification with time. The brass
strip on the very left is not immersed in the solution. The electrolyte solution is of hydrochloric
acid. While the other three strip were dipped in the hydrochloric acid. The length of the time for
three immersed strips were different. The dezincification phenomena occur in the very first few
hours, and there was not seen much change after 24 hours. From left to right: there were no
exposure to hydrochloric acid, 6 hours of exposure, 24 hours of exposure, and 72 hours of
exposure. The layer produced on the strip is thin enough and cannot be remove by polishing.

EVALUATION:
The evaluation of dezincification involves assessing the extent of zinc removal and the resulting
effects on the brass. This can be done through various methods, including visual inspection,
chemical analysis, and mechanical testing. The impact of dezincification on the mechanical
properties of the brass should also be considered. This can be evaluated through tensile testing,
which measures the strength and flexibility of the brass. Dezincification can weaken the brass,
making it more prone to breakage or failure.
Other factors that may be considered in the evaluation of dezincification include the presence of
external stressors, such as temperature or pH, and the effectiveness of protective coatings or
corrosion inhibitors.
  visual inspection:
One type of evaluation of dezincification is visual inspection. When dezincification occurs the
brass may change color which can be inspect through naked eyes. In some brasses, selective
leaching of any material cause plug type dezincification. This plug type dezincification ca be
visually inspected. Selective leaching of grey iron is the indicator of rusting which can be inspect
visually. when mild dezincification happens, color of material surface changes from yellow to
pink.

 Electrochemical hysteresis method:

Electrochemical hysteresis method can be used to determine the dezincification mechanism. It
involves the pH versus Voltage diagram. The pH-potential diagram also shows the of zinc and
copper dissolution. It shows the domain where zinc is leaching and also show the domain, where
copper and zinc dissolve in solution. The diagram shows that from potential 0.00 to +0.200 V SHE,
Both copper and zinc dissolve. But copper may deposit on specimen surface with no evidence.
Both alloy dissolve with no redeposition above +0.200 V SHE. Deposition of copper will take place
if first potential is held for long time above +0.200 VSHE and then lowered by this potential.
One chemical method to evaluate dezincification is through the use of a potentiometric titration.
This involves measuring the potential difference between an electrode and a reference electrode
as a solution of known concentration is added to a sample of the zinc-containing material. The
point at which the potential difference reaches a maximum indicates the point at which
dezincification has occurred, as the zinc ions are being removed from the sample. Another
method is through the use of atomic absorption spectroscopy, which measures the concentration
of zinc ions in the sample before and after dezincification has occurred. The difference in
concentration can then be used to determine the extent of dezincification.
  Microscopic evaluation:
The microscopic evaluation of dezincification involves examining the surface of the brass or alloy using a
microscope to determine the extent of zinc loss. This is typically done using a metallographic microscope,
which allows for the observation of fine details on the surface of the material.

During the microscopic evaluation, the presence of dezincification can be identified by the presence of a
distinctive pattern of pits or cavities on the surface of the material. These pits are created as the zinc is
selectively removed from the brass or alloy, leaving behind a network of interconnected cavities.

REMEDIES:
There are several remedies for dezincification:

1. Use a dezincification-resistant brass alloy: Brass alloys with a higher zinc content
are more prone to dezincification. Using a brass alloy with a lower zinc content or a
dezincification-resistant brass alloy can help prevent dezincification.
2. Use a protective coating: Applying a protective coating such as a clear lacquer or
zinc-rich paint can help prevent the corrosion caused by dezincification.
3. Regular maintenance and cleaning: Regular cleaning and maintenance can help
prevent dezincification by removing any dirt or debris that may be causing corrosion.
4. Replace damaged components: If dezincification has already occurred, it may be
necessary to replace the damaged components to prevent further corrosion.
5. Use a corrosion inhibitor: A corrosion inhibitor can help prevent dezincification by
creating a barrier between the brass and the corrosive environment.
 6. Control the environment: Dezincification is more likely to occur in environments
with high levels of chlorine, so controlling the levels of chlorine in the environment can
help prevent dezincification.
7. Thermal heat treatment can also prevent the dezincification by breaking beta phase of
stringers into small islands.

This diagram shows the different scenario of inhibitor addition to prevent dezincification.
Thermal effect also effects the dezincification of material.
This show the concentration of zinc dependence on the rate of dezincification and also on
thermal effect and inhibitor
Other elements can also be added in brass with higher zinc concentration to prevent
dezincification. Element addition make zinc more resistant to dezincification. Recent alloys
resist dezincification better the modern alloy. Because ancient alloys contain tin or impurity
element to resist dezincification. While modern brass alloys contain zinc and copper which are
more prone to dezincification and so does to failures. By addition of 0.5 to 1 wt% tin, the modern
alloy brass (containing Cu and Zn) can be made resistant to dezincification. Further the small
addition of arsenic, phosphorous or antimony in range of 0.02 to 1 wt% to brass can give
protection against dezincification.

Case History:
Dezincification in a Water Distribution System
Background:
A water distribution system serving a small community had been experiencing problems with
dezincification in its galvanized iron pipes. The pipes were originally installed in the 1950s and
had been in service for over 60 years. The water in the distribution system had a high pH and
contained high levels of chlorine and other dissolved minerals.

Symptoms:
The first symptoms of dezincification were observed in the form of reduced water flow and
pressure in the distribution system. This was followed by the appearance of discolored water and
the release of sediment and debris into the water supply. The water had a metallic taste and a foul
odor, leading to complaints from residents about the quality of the water.
Diagnosis:
Upon further investigation, it was determined that the pipes in the distribution system were
suffering from dezincification. This is a corrosion process in which the zinc coating on
galvanized iron pipes is selectively dissolved, leaving behind a thin layer of iron. This process
can be caused by the presence of high levels of chlorine and other dissolved minerals in the
water, as well as the high pH of the water.
Treatment:
The first step in addressing the dezincification problem was to lower the pH of the water by
adding a corrosion inhibitor. This helped to reduce the rate of corrosion and prevent further
deterioration of the pipes. The water distribution system was also treated with a chemical
flushing agent to remove sediment and debris from the pipes.
After these initial steps, it was determined that the most effective solution would be to replace
the affected pipes. This was a costly and time-consuming process, but it was necessary to ensure
the continued reliability and safety of the water distribution system.
Conclusion:
The dezincification problem in the water distribution system was successfully addressed through
a combination of chemical treatment and pipe replacement. Regular monitoring and maintenance
of the pipes will be necessary to prevent future dezincification and ensure the continued quality
of the water supply.

Case history 2:
A plumbing system in a residential building was experiencing problems with low water pressure
and frequent leaks. Upon investigation, it was discovered that the pipes were made of brass, and
the water in the area had a high level of dissolved zinc.
Further testing revealed that the pipes had undergone dezincification, a process in which the zinc
in the brass pipes corroded and was leached out, leaving behind a weaker and more porous
material. As a result, the pipes were prone to leaks and unable to maintain proper water pressure.
To solve the issue, the plumbing system was replaced with pipes made of a different material
that was resistant to dezincification. The new pipes were installed, and the water pressure and
leak issues were resolved.
Lessons learned:
It is important to use materials that are resistant to corrosion in plumbing systems, particularly in
areas with high levels of dissolved zinc in the water.
Regular maintenance and inspections can help identify potential issues before they become major
problems.
Dezincification can lead to serious issues with plumbing systems, including leaks and low water
pressure, and should be addressed promptly to prevent further damage.

CONCLUSION:
The main consequence of dezincification is the loss of strength and structural integrity of the
affected metal. This can lead to the failure of equipment and structures made from brass or
bronze, such as pipes, valves, and bridges. Dezincification can also reduce the lifespan of the
metal, leading to increased maintenance and replacement costs.
To prevent dezincification, it is important to use the appropriate brass or bronze alloy for the
intended application, and to properly maintain and protect the metal from corrosion. This can
include using corrosion-resistant coatings, using corrosion inhibitors, and properly storing and
handling the metal. By understanding and addressing the factors that contribute to
dezincification, we can help ensure the safe and reliable use of brass and bronze alloys.

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