Corrosion

What is Corrosion???

Prepared
By
Dr. Biswajit Saha
 Corrosion

Corrosion Can be defined as the gradual destruction of metals by

the chemical or electrochemical reaction with the environment.

 Weakening of the material

 Loss of metallic properties such as malleability, ductility,
electrical conductivity etc

Example of corrosion
 Rusting of iron when it is exposed to atmospheric conditions.
The rusting is due to the formation of Fe2O3.xH2O on the
surface.
 Formation of green layer of basic copper carbonate of
[CuCO3+Cu(OH)2] on the surface of Cu, when exposed to
moist air containing CO2.
 Causes of Corrosion
Most of the metals occur in nature in the combined form such as
Oxides, sulphites, carbonates etc

Metallic Ore Extraction of metal Pure metal

(Lower energy, stable state) (Higher energy)

Why the Study of corrosion is important???

Corrosion deterioration of machines and equipments. Reduces
efficiency
The product obtained may be contaminated and may be leads to
several problem including health hazards
Corrosion- may contaminate stored food, dairy products , etc
Corrosion products cause pollution
Engineering design is incomplete without knowledge of corrosion
Types of corrosion
Chemical Corrosion or Dry Corrosion
Electrochemical Corrosion Or Wet Corrosion
Chemical Corrosion or Dry Corrosion

Direct chemical action of atmospheric gases such as O2, halogens,

H2S, CO2, SO2, N2, H2 or liquid metals on metal surface in the
absence of moisture.

There are 3 types of chemical corrosion

Oxidative corrosion ( Direct action of oxygen)

Liquid metal corrosion (action of liquid metal at high temperature)
Corrosion by other gases (H2S, CO2, SO2, N2, H2 )
Oxidative corrosion ( Direct action of oxygen)

Mechanism
It is brought about by the direct action of O2 present in the
atmosphere on metals at low or medium temperature in the absence
of moisture to form metallic oxides.
2M + nO2 2Mn+ + 2nO2- M2On
Alkali and alkaline earth metals are rapidly oxidized even at low
temperature.
At high temperature almost all metals except (Ag, Au, Pt, Pd) are
attacked.
Nature of Oxide formed in Oxidation Corrosion
A thin layer of oxide formed at the surface of metal can be

• Stable oxide: The oxide films on Al, Cr, Cu, Pb, Sn etc are
stable and adhere to the surface. Such film forms a
protective coating over the metal and prevents further
oxidation or correction.
• Unstable oxide: the oxide film formed on the surface of
metal decomposed back into metal and oxygen. Hence in
such cases corrosion is not possible. The oxides of Ag, Au
and Pt.
• Volatile oxide: the metal oxide film formed it gets
volatilized and metal surface again gets exposed for further
attack leading to continuous and rapid corrosion.
Mo + 3 O2 2MoO3
When the oxide film is sufficiently porous so that the diffusion of
cation M+ and anion O- takes place smoothly then oxidation
corrosion takes place continuously.

Pilling-Bedworth Rule describe the porous and non-porous nature

of metallic oxide which is formed during corrosion

According to this rule specific ratio calculated follows

Volume of metal oxide
Specific volume ration =
Volume of metal

If the specific volume ratio is smaller, then oxidation corrosion will

takes place. Because the oxide films will be sufficiently porous for
diffusion of M+ and O2-
If the specific volume ratio is more than 1 then it will be non-porous.
Corrosion by other gases

Depending on the chemical affinity between metal and gas, form

protective and non-protective layer on metal surface. Such as CO2,
SO2, Cl2, H2S, F2 have corrosive actions on metals.

2Ag + Cl2 2AgCl

If the film is non protective it destroys the metal. Chlorine gas attacks
Sn to SnCl4 which is volatile and leaves the metal exposed for
further attack.

H2S gas attacks steel forming FeS layer which is porous in nature.
Liquid metal corrosion

This type of corrosion is found in nuclear power plants.

Sodium metal leads to corrosion of cadmium in nuclear
reactor.
Corrosion takes place either due to the dissolution of solid
metal by the liquid metal or due to the penetration of
liquid metal in to the solid metal. It is due to the action of
following liquid metal at high temperature on solid metal
or alloy.