EMM 3122

Engineering Materials

Chap. 9: Corrosion and protection

Mechanical and Manufacturing Engineering Department

Engineering Faculty
University Putra Malaysia (UPM)
©
 THE COST OF CORROSION
❑ Corrosion:

-- The destructive electrochemical attack of a material.

-- Ex: Al Capone's
ship, Sapona,
off the coast
of Bimini.

Chapter 17 - 2
Factors affect the corrosion of metals
❑ Four factors:

• The temp. and concentration of the reactants and

products of a chemical attacks.

• The state of mechanical stress in the metal.

• The presence of erosion in the metal.

• Energy state of the metal.

Chapter 17 -
 ELECTROCHEMICAL CORROSION
Ex: consider the corrosion of zinc in an acid solution
• Two reactions are necessary:
-- oxidation reaction:
-- reduction reaction:
H+
Oxidation reaction
Zn Zn2+ H+
Adapted from Fig. 17.1,
Callister & Rethwisch 8e.

H+ Acid (Fig. 17.1 is from M.G.

Zin flow of e- 2 - Fontana, Corrosion
in the metal H+ + solution Engineering, 3rd ed.,
c e H
H+ McGraw-Hill Book Company,
1986.)
H2(gas)
H+
reduction reaction

• Other reduction reactions in solutions with dissolved oxygen:

-- acidic solution -- neutral or basic solution

Chapter 17 - 4
 STANDARD HYDROGEN ELECTRODE
• Two outcomes:
-- Corrosion --
Electrodeposition
e- e- e- e-
H2(gas H+ 2e -
ne - 2e - ne -
) H+
Mn H+ Platinu Mn

Platinu
metal,
metal,

+
ions +
ions
H+
m

m
M
M

H2(gas)
25ºC 25ºC
1M n 1M + 1M n 1M +
M + sol’n H sol’n M + sol’n H sol’n
-- Metal is the anode (-) -- Metal is the cathode (+)
(relative to Pt) (relative to Pt)
Adapted from Fig. 17.2,
Standard Electrode Potential Callister & Rethwisch 8e.

Chapter 17 - 5
 STANDARD EMF SERIES
• EMF series o
• Metal with
metal Vmetal smaller
o
metal
Au +1.420 V V Cd-Nicorrodes.
• Ex: cell
more cathodic

Cu +0.340 o o
Pb - 0.126 VCd < V Ni ∴ Cd
corrodes
Sn - 0.136 - +
Ni - 0.250
o
Co - 0.277 ΔV =
Cd - 0.403 0.153V
Fe - 0.440
more anodic

Cr - 0.744 Cd 25ºC Ni
Zn - 0.763
Al - 1.662
1.0 M 1.0 M
Mg - 2.363
C 2+ Ni 2
Na - 2.714
d
Data based on Table 17.1, Adapted from Fig. +
solution 17.2,solution
K - 2.924 Callister 8e. Callister & Rethwisch 8e.

Chapter 17 - 6
CORROSION IN A GRAPEFRUIT
Cu (cathode) Zn
+ -
(anode)
H+
H+ Z 2+
n
reduction reactions 2e - oxidation reaction
H+
H+
Acid H+
H+ H+

Chapter 17 - 7
 GALVANIC SERIES
• Ranking of the reactivity of metals/alloys in seawater
Platinum
more cathodic

Gold
Graphite
(inert

Titanium
Silver
)

316 Stainless Steel (passive) Based on Table 17.2, Callister &

Nickel (passive) Rethwisch 8e. (Source of Table
17.2 is M.G. Fontana, Corrosion
Copper Engineering, 3rd ed.,
Nickel (active) McGraw-Hill Book Company,
1986.)
Tin
more anodic

Lead
316 Stainless Steel (active)
(active

Iron/Steel
Aluminum Alloys
Cadmium
)

Zinc
Magnesium
Chapter 17 - 8
 FORMS OF CORROSION
• Stress corrosion
Corrosion at crack tips
• Uniform Attack when a tensile stress • Erosion-corrosion
Oxidation & reduction is present. Combined chemical attack and
reactions occur uniformly mechanical wear (e.g., pipe
over surfaces. elbows).
• Selective Leaching • Pitting
Preferred corrosion of Forms Downward propagation
one element/constituent of small pits and holes.
o
[e.g., Zn from brass (Cu-Zn)]. Fig. 17.17, Callister &
corrosion
f Rethwisch 8e. (Fig. 17.17
• Intergranular from M.G. Fontana,
Corrosion Engineering,
Corrosion along 3rd ed., McGraw-Hill Book
Company, 1986.)
grain boundaries,
often where precip. • Galvanic • Crevice Narrow and
particles form. Dissimilar metals are confined spaces.
g.b. physically joined in the Rivet holes
prec presence of an
.
electrolyte. The
attacked Fig. 17.15, Callister & Rethwisch 8e. (Fig. 17.15
zone
more anodic metal is courtesy LaQue Center for Corrosion
Technology, Inc.)
Fig. 17.18, Callister &
s corrodes. Chapter 17 - 9
Rethwisch 8e.
 CORROSION PREVENTION (i)
• Materials Selection
-- Use metals that are relatively unreactive in the
corrosion environment -- e.g., Ni in basic solutions
-- Use metals that passivate
Metal
- These metals form a thin, oxide
Metal (e.g., Al,
adhering oxide layer that stainless
slows corrosion. steel)

• Lower the temperature (reduces rates of oxidation and

reduction)
• Apply physical barriers -- e.g., films and coatings

Chapter 17 - 10
 CORROSION PREVENTION (ii)
• Add inhibitors (substances added to solution that decrease
its reactivity)
-- Slow oxidation/reduction reactions by removing reactants
(e.g., remove O2 gas by reacting it w/an inhibitor).
-- Slow oxidation reaction by attaching species to
the surface.

• Cathodic (or sacrificial) protection

-- Attach a more anodic material to the one to be protected.
Galvanized Steel Using a sacrificial anode
Adapted Zn 2+ Cu Adapted
from Fig. e- from Fig.
17.23, zin zin steel wireMg 2+
Mg 17.22(a),
Callister &
Rethwisch c 2 - 2 -c pip anode Callister &
Rethwisch
8e. e steee e Eart 8e.
l h
e.g., zinc-coated nail e.g., Mg Anode Chapter 17 - 11
 SUMMARY
• Metallic corrosion involves electrochemical reactions
-- electrons are given up by metals in an oxidation reaction
-- these electrons are consumed in a reduction reaction
• Metals and alloys are ranked according to their
corrosiveness in standard emf and galvanic series.
• Temperature and solution composition affect corrosion
rates.
• Forms of corrosion are classified according to mechanism
• Corrosion may be prevented or controlled by:
-- materials selection
-- reducing the temperature
-- applying physical barriers
-- adding inhibitors
-- cathodic protection

Chapter 17 - 12
TERIMA KASIH

Chapter 17 -