| Enginee: J etroterial theory of corrosion (Wet 4 Sh ‘ Cory OF ( metals are CXPOSed to air, moisty i ; jyemical process. In this proce * : Soll ete. then they undergoes corrosion through - 85 8 50 : al surface. Corrosion always occurs a Parate anode and cathode areas are form on the gelease electron, The liberated electron te place. The overall theory is known Pym as Wel {HC0F yydsosen Liberation: js ype of corrosion evolution of hydrogen occurs in acidic medium (absence of oxygen). e's considering the metal Fe, anodic reaction is dissolution of iron as ferrous ions with qieration of electrons. At Anode Fe ——> Fe™ +.2¢" (Oxidation) ‘The electrons released flow through the metal from anode to cathode, whereas H* ions of acidic soution are eliminated as hydrogen gas, ‘At Cathode 2H" + 2c’ 5 Hy (Reduction) The overall reaction is . Fe + 2H*___,. Fo* + Ha ¢ SS SS tre ee oH +26 —=H; (Reduction) 2c" (Oxidation) i 2 {deal Intemational F- Publication wonw.iscacoinEngineering Chemistry |"! | yess of Ow ¥ fit Kk rusting of ifon takes place in a n q eutral _ gmsericonyzen & saucous NaC, 1p i MUCOUS solution of electrolytes (presence of ‘on the surface whereas the Metal surface ytes. (pr Metal parts act as develops cracks, anodic areas are the At anode cathodes, The released electrons flow a At cathode 2021.04, sr fro ™ anode to cathode through iron metal. If oxygen is in excess, ferrous hydrog, ; ; \ydroxide is easily oxi i i 4Fe (OH): +0420 — 4 Foon ‘remiytosts The yellow product form rust of Iron (Pes0s, 31,0) TSO, FSO ee Fee Se (xition) Different form of Wet corrosion Crevice Corrosion UC Cevice corrosion occurs between two joining surface which may be metal-metal or metal- tonmetal crevice. It is localized corrosion of metal or alloy surface. In crevice corrosion, the fining surface area has low concentration of oxygen as compare to other area. The portion with lower concentration of oxygen become anode and portion with higher concentration of oxygen tecomes cathode. Mechanism of corrosion is similar to absorption of oxygen step -of ¢ectrochemical theory of corrosion. {deal Intemational F- Publication 2 ‘www isca.coinlyon Engineering Chemistry | \ ed piting Corrosion { In pitting corrosion, a pit is formed when the protective coating on the metal surface brea micro pit (anode) formed on the metal surface. Once the pit is form the process of corrosion become very fast due to different amount of oxygen in contact with metal surface. ‘The portion it) with lower concentration of oxygen become anode and portion with higher concentration of oxygen becomes cathode. cathote 40: 110426 =e 2011 Redsiow, metal hem Anode Fe Fel Be (Onion) Fei FeO), yea a olor Water-line corrosion, 2 ‘When water is stored in the steel tank, then corrosion starts, along the line beneath the level of Water meniscus. As we know that beneath the water level concentration of oxygen is very low therefore metal part below the water level acts as anode and metal part above the water level have higher concentration of oxygen therefore this region act as cathode, The reaction involve ‘are as follows: {deal International F:- Publication www.iscacoiin 34Engineering Chemistry | VOL-1 Cathode 50:1 Ta JK cattote Anode Fe me Fei 4 2¢ (Oxidation) ‘Anode 20H = bey | exces oss x corre Corrosion Prevention ne Metal Coatins In order to protect base metal form corrosion metal coating process has been adopted. The coating of metal can be achieved by following processes, Anodie metal coating (Galvanization): Metal coating which is anodic to base metal, known as anodic metal coating, In order to protect 4 metal from corrosion, any metal (anodic in nature) which is higher in the galvanic series like Znis coated on the surface of mietal (base metal/ cathodic in nature). Zn —* Zn®* +2 Anodic coating with Zn Iron Sheet (Cathodic) ron is protected) The best example of anodic metal coating is Galvanization, Galvanization is a process in which coating of base metal (to be protected) takes place by dipping the base metal (cathodic in nature) into the molten zinc (anodic in nature). Cathodic metal coating (Tinning) eal International F- Publication 35 ‘www isca.cojinEngineering Chemistry | VOL-1 Metal coating which is cathodic to base metal, known as cathodic metal coating. In order to ject a metal from corrosion, any metal (cathodic in nature) which is lower in the galvanic Fries like Sn, Cu, Ni etc, are coated on the surface-of metal (base metal/ anodic in nature). z= Sn — Sn* + 2e° |-—— Cathodic coating with Sn Base metal (Anodic In nature) The best example of cathodic metal coating is Tinning. Tinning is a process in which coating of base metal (to be protected) takes place by dipping the base metal (anodic in nature) into the molten Tin (cathodic in nature). Scarification anodic protection: In this protection method, the metallic structure to be protected (base metal) is connected by a wire to a more anodic metal so that all the corrosion occurs at that anodic metal and metallic structure (cathode) is protected. The more active metal so employed is called sacrificial anode. The corroded sacrificial anode is replaced by a fresh one, when consumed completely. Metals commonly employed as sacrificial anode are Mg, Zn, Al and their alloys which possess low reduction potential (more reactive) and occupies higher end in electrochemical series. The underground water pipelines and water tanks are also’ protected by sacrificial anode method. Cathode Inpr al protecti a cathosic prote! ent from external source is applied in opposite direction to hn this method sed |, an impressed curre i Neutralize the ei current, and convert the corroding metal from anode to cathode. Thus Tea! Intemational 36 ‘www isea.Engineering Chemistry | VOL. anodic corroding metal becomes cathodic and Protected from corrosion. The impressed nt is deriving fom the extemal DC source. The negative terminal of DC source is fonnected with metal to Protected whereas the positive terminal of DC is connected to the je, Here anode may be graphite, stainless steel scrap iron etc. The impressed current protection method is used for water tanks, water & oil Pipe lines, transmission line towers etc. Electroplating: In electroplating, electro-deposition of metal (anode) by means electrolysis over surface of metals and alloys (cathode or base metal). The two electrodes are dipped in the electrolyte solution which contains the metal ions to be deposited on the base metal. When a direct current is passed from an external source, the coating metal ions migrate towards cathode and get deposited over the surface of base metal in the form of a thin layer. In electroplating metal like Au, Ag, Zn, Sn, Cr, Ni etc. can be placed on the surface of base metal (Cathode). aL r | | object to be plated aa i ead (Oxidation) Redoe ie Electrolyte Corrosion inhibitors: Inhibitors are the chemical substances (organic or inorganic) which effectively reduce the corrosion, The corrosion When added to the corrosive environment “ x 2 in either by anodic or by cathodic reactions. inhibitors reduce the rate of corrosion of metal {deal Intemational F- Publication eT www.isca.coinEngineering Chemistry | VOL 1 odic areas or blocks ‘and molybdates are jodie areas and and form a Anodic inhibitors (Passivation inhibitors): It reduces the corrosion at ant the anodic reaction. The anodic inhibitors like metal phosphates, chromates, an oxygen rich material which reacts with the newly produce metal ions in an form sparingly soluble compound. Then they are absorbed on metal surface protective film over the anodic area and protect the metal from further corrosion. Cathodie inhibitors: It reduces the corrosion at cathodic areas or blocks the cathodic reaction. In this case chemical reaction inhibit the corrosion at the cathodic area of metal by decreasing the diffusion of H™ ion to the cathode and removal of oxygen from corrosive environment: Inacidic medium, the corrosion process involves the following cathodic reaction. 2Ht + 2e~ > Ha (8) The eathodie poison like arsenic, bismuth, antimony can be reducing by slow down the rate of diffusion of H" ions or reduce the rate of hydrogen reduction. In ncutral solution, cathodic reaction can be written as, 1 H,0 + 502 +2e” = 20H" In above reaction the hydroxide (OH) ions are formed in presence of oxygen. In this case corrosion can be controlled by using oxygen scavengers like Na,SOs, hydrazine eliminating oxygen from the corroding environment and the metal like Ca, Mg, Zn precipitate oxygen (through cathodic precipitate) as metal oxide which form a protective layer over the metal. Exercise QI. What do you mean by corrosion of metal? Q2. Which gases in the atmosphere accelerate the rusting of iron? Q3. Why zinc coating on iron is called sacrificial anode? Q4. What do you mean by wet corrosion? factors affecting corrosion? an be controlled by perfect designing. {eat International - Publication pwitencain ad QS. What are the Q6. Explain how corrosion ¢Engineering Chemistry | VY" 7. Explain galvanization and tinning process. 8. Explain types of corrosion observed in metals. Q9. Explain dry theory of corrosion, Q10. What is the role of sacrificial anode in corrosion control? QUI. What do you mean by corrosion inhibitors? QI2. What is the principle of waterline corrosion? Q13. Explain the mechanism of oxidation corrosion. Q14. Explain the pitting and crevice corrosion. QI5. What is cathodic metal coating? Explain with suitable example. QI6, Write a note on anodic metal coating. QI7. What are protective coatings? How they are classified. Q18. How the temperature and pH affect the rate of corrosion? Q19. Describe the process of electroplating with suitable diagram. Q20. Explain cathodic, anodic protection and also explain the sacrificial cathodic and impressed current prevention. Q21. Explain the corrosion of iron by dilute mineral acids. Q22. What happen when zinc rod is half immersed in saline water? Q23. Explain electrochemical corrosion by Hz evolution and O, absorption mechanism. Q24, Explain the term cathodic protection. Indicate how metal coating can effectively prevent corrosion. Q25. Rusting of iron is faster in saline water than in ordinary water Give reason. Q26. What are corrosion inhibitors? Explain with example how anodic and cathodic inhibitors provide protection against corrosion. {deal International E- Publication 39 ‘www.isca.co.in