Engg.

Chemistry

MODULE-II:
Corrosion and Metal finishing
Corrosion: Introduction, Electrochemical theory of corrosion, Factors affecting the rate of
corrosion: ratio of anodic to cathodic areas, nature of metal, nature of corrosion product, nature
of medium – pH, conductivity and temperature. Types of corrosion - Differential metal and
Differential aeration - pitting and water line). Corrosion control: Anodizing – Anodizing of
aluminium, Cathodic protection - sacrificial anode and impressed current methods, Metal
coatings - Galvanization.
Metal finishing: Introduction, Technological importance. Electroplating: Introduction,
principles governing electroplating-Polarization, decomposition potential and overvoltage.
Electroplating of chromium (hard and decorative). Electroless plating: Introduction, electroless
plating of nickel & copper, distinction between electroplating and electroless plating processes.
(RBT Levels: L1 & L2)
Corrosion and Metal Finishing
Definition of corrosion:-

Corrosion can be defined as “The destruction (or) deterioration (or) loss of metals or
alloys by the surrounding environment through chemical (or) electrochemical reactions”.
Ex: - 1. Rusting of Iron: - A reddish brown scale formation on iron objects.
Fe 2+ + 2OH- Fe (OH) 2
4Fe (OH) 2 + O2 + 2H2O [Fe2O3.3H2O]
Hydrated Ferric Oxide [rust]
2. Green scales formed on copper vessels.

Corrosion may occur either in a dry environment (or) in an aqueous medium. The former
is called dry corrosion and the later is called wet corrosion.

Dry corrosion [chemical corrosion]

Dry corrosion involves the direct attack of metals by dry gases mainly through chemical
reactions.
It occurs by direct attacks of atmospheric gasses such as oxygen, hydrogen, sulphide,
halogens and Sulphur-dioxide on the metal forming oxide layer.
Ex: - the attack of dry air (or) oxygen on a metal to form an oxide layer over the surface.
Wet corrosion [Electrochemical corrosion]
Wet corrosion involves reactions in aqueous solution medium. The conducting surface of
the metal undergoes an electrochemical reaction with the moisture and oxygen present in the
atmosphere.
Ex: - Rusting of Iron.
Wet corrosion is explained on the basis of electrochemical theory.

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Electrochemical theory of corrosion:-

Electrochemical Theory taking Iron as example:-

According to electrochemical theory, when a
metal such as iron is exposed to corrosive O2
Fe2+ Fe2+ OH- OH-
environment, following changes occur. A large H2O

number of tiny galvanic cells with anodic and Anodic region

Cathodic region

cathodic regions are formed. Electrons

Iron Metal

At the anodic region oxidation reaction takes

place and the metal gets converted into its ions,
liberating electrons. Consequently, metal undergoes corrosion at the anodic region.

At the cathodic region, reduction reaction takes place. Since the metal cannot be reduced further,
metal atoms at the cathodic region are unaffected by the cathodic reaction.

At Anode:-

At anode ox ideation takes place in which the metal atoms are converted into their ions liberating
electrons.
Fe Fe2+ + 2e-

At Cathode:-
The cathodic reaction is based on nature of the environment.
a). In the absence of oxygen.[Libration of Hydrogen]

i) In acidic medium, liberation of hydrogen takes place.

2H+ + 2e- H2
ii) In neutral (or) alkaline medium, Hydroxide ions are formed with simultaneous liberation of
hydrogen.
2H2O + 2e- 2OH- + H2

b). In presence of oxygen:- [Absorption of oxygen]

i). In acidic medium, absorption of oxygen takes place.

4H+ + O2 + 4e- 2H2O
ii). In neutral (or) alkaline medium, hydroxide ions are formed.
2H2O + O2 +4e- 4OH-
2+
Then Iron ions (Fe ) form anode combine with hydroxyl ions from cathode to form iron
hydroxide on the surface, b/w the anode and cathode areas.
Fe2+ + 2OH- Fe (OH) 2

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Iron hydroxide further reacts with oxygen and water forming hydrated iron oxide which is the
corrosion product [Rust].
4Fe (OH) 2 + O2 + 2H2O 2[Fe2O3.3H2O]
Rust
Types of Corrosion:-

Differential Metal Corrosion:-

Differential metal corrosion occurs when two dissimilar metals are in contact with each
another and exposed to a corrosive conducting medium, the metal with lower electrode potential
acts as anode undergoes oxidation and gets corroded. and the other metal with higher electrode
potential acts as cathode. Undergo reduction & protected from corrosion. This type of corrosion
is known as galvanic corrosion (or) differential metal corrosion.
The rate of corrosion depends mainly on the difference in potential b/w two metals.
Higher the difference faster is the rate of corrosion.
The reactions may be represented as,
At anode: - M Mn+ + e-
At cathode:- reduction reaction takes place, depending upon the nature of the environment.
2H+ + 2e- H2 (or)

2H2O + O2 +4e- 4OH-

Ex:-i). When iron is in contact with copper [0.34V], iron [-0.44V] becomes anodic and
undergoes corrosion whereas copper becomes cathodic and remains unaffected.

Fe Metal Cu Metal Zn metal Fe Metal

Anode Cathode Anode Cathode

ii). Tin coating copper vessel.

iii). Steel pipe connected to copper plumbing.
iv). Bolt and nut made of different metals.

Differential Aeration Corrosion:-

When a metal is exposed to different concentrations of air (or) oxygen, part of the metal
exposed to lower concentration of oxygen becomes anodic and undergoes corrosion. Whereas,
other part of the metal exposed to higher concentration of oxygen becomes cathodic and remains
unaffected. This kind of corrosion is called as differential aeration corrosion.
Ex:- Iron rod partially immersed in Nacl solution, part of the metal immersed in solution is
exposed to lower concentration of oxygen becomes anodic and undergoes corrosion. Whereas part

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of the metal outside Nacl solution, is exposed to more oxygen becomes cathodic and remains
unaffected.

The anodic and cathodic reactions are Iron

More O2,
At Anode:- Fe Fe2+ + 2e- (Cathode)

At Cathode:- 2H2O + O2 +4e- 4OH-

Fe2+ + 2OH- Fe (OH) 2 Less O2, (Anode)

Nacl solution

Other Examples:-
1. Part of the nail inside the wall undergoes corrosion.
2. When a dust particle sits on a metal bar, the part under the dust undergoes corrosion.
3. Partially filled iron tank undergoes corrosion inside water.

Typical examples of differential aeration corrosion are the Water-line corrosion & Pitting
corrosion.

a). Water-line Corrosion:-

It is observed in steel (or) Iron water tanks partially filled with water.

When a steel tank is partially filled with water for a long time, the inner portion of the
tank below the water line is exposed only to dissolve oxygen, whereas the portion above the
water line is exposed to more oxygen. Thus the portion below the water line acts as anode and
undergoes corrosion. The upper portion acts as cathode and is unaffected.

A distinct brown line is formed just

More oxygen,
below the water line due to the deposition of (Cathode) Rust
rust.

The cell reactions are Less Oxygen

(Anode)
Water
At Anode: - M Mn+ +ne-
At Cathode: - 2H2O + O2 +4e- 4OH-
Finally, the ions combine to form corrosion product.

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Ex: - Ships which remain partially immersed in sea water for a long time undergo water line
corrosion.

b). Pitting Corrosion:-

This type of corrosion is observed when dust particles (or) oil drops deposited over the
metal surface.
Pitting corrosion is due to
i). Metal surface is not homogeneous. ii). External environment is not homogeneous.
iii). Crystallography directions are not equal in the reactivity.
iv). Environments are not uniform with respect to concentration.
Pitting corrosion results when the portion of the metal covered by dust which is less
aerated becomes anodic and undergoes corrosion and form pit. The remaining area of the metal
which is exposed to higher concentration of oxygen becomes cathodic and remains unaffected.
Once a small pit is formed the rate of corrosion increases because formation of small
anodic area [pit] to corrode faster because accepting
electrons from the cathodic area increases.
The cell reactions are
At Anode: - Fe Fe2+ + 2e-
1
At Cathode: -2O2 + H2O + 2e- 2OH-
Net reaction: - Fe2+ + 2OH- Fe (OH) 2

Factors affecting the rate of corrosion:-

Several factors affect the rate of corrosion of metals. These are broadly classified as
primary factors which are due to the metal and secondary factors which are due to the
environment.

Primary Factors:-

1. Nature of Metal:-

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• The position of the metal in the galvanic series decides the rate of corrosion and extent
of corrosion.
• The metals with lower e-de potential values are more reactive and more susceptible for
corrosion than the metal with higher e-de potential values. Ex:- Zn, Mg,etc….
• The rate of the corrosion depends upon the difference in the position of the metals in the
galvanic series, higher the difference, faster is the corrosion at anode.
Ex: - Li corrodes faster than Mg, Zn corrodes faster than Fe, Cu corrodes faster than Ag.

2.Nature of the Corrosion Product:-

The product of the corrosion is usually the oxides of the metals. The nature of
oxide layer determines the corrosion rate.
• If the corrosion product formed is insoluble, stable, uniform, non-porous and non-volatile,
it acts as a protective film and prevents further corrosion of metal because it acts as barrier
b/w the fresh metal surface and the corrosive environment.
Ex: - Meals like Al, Ti, Pt and Cr the oxide film formed acts as protective film hence the
corrosion is controlled.
• If the corrosion product formed is soluble, unstable, non-uniform, porous and volatile in
nature continues the corrosion process because it acts as non-protective film.
Ex: - In case of metals like Fe, Zn and Mg the oxide film formed acts as non-protective
film and corrosion is continued till the metal is completely destroyed.

3. Anodic and Cathodic Areas: -The rate of corrosion is highly influenced by the relative area
of anode and cathode.
• If the metal has small anodic area and large cathodic area, more intense and faster is the
corrosion.
• If the metal has, large anodic area and small cathodic area, decrease the rate of corrosion.
Small anodic area

Ex: -A broken coating of tin on iron surface, a small

exposed part of iron acts as anode and rest of large Tin-metal
tin coated area act as cathode. Because of small anodic [][[[cathode]
area to cathodic area the rate of corrosion is high. Fe-metal
[anode]

Secondary Factors:-

1.PH:-

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Acidic media are generally more corrosive than alkaline (or) neutral media. The P H of the
solutions decides the type of cathodic reaction.
• The rate of corrosion increases with decreases in PH
Ex: -iron does not undergo corrosion at PH greater than 10, this is due to the formation of
protective coating of hydrous oxides of iron. If PH is less than 3, corrosion occurs fastly
• The rate of corrosion decreases with increase in PH
Ex: - Zn suffers from corrosion even in the presence of mild acidic medium, whereas
corrosion is minimum at PH=11.

2.Temperature: - The rate of chemical reaction increases with increase in temperature.

• The rate of corrosion increases with increase in temperature.
• Increase in temperature increases the ionic conductivity of the medium increases, decreases
hydrogen voltage hence increases the rate of corrosion.
• A Corrosion resistant passive metal becomes active at high temperature and increase the
rate of corrosion with increasing temperature.
Ex: - Caustic embrittlement in high pressure boilers.
3.Conductance:-
• The rate of corrosion is directly proportional to the conductance medium.
• The rate of corrosion increases in the presence of conducting species in the atmosphere
because corrosion is in electrochemical phenomenon.[
Ex: -i). The corrosion of metal structures is faster within the clay and mineralized soils
than in dry sandy soils.
ii). The rate of corrosion is more in ocean water and less in river water.
Note:- higher the conductivity of the medium, faster the ion can migrate between the anodic
and Cathodic regions of the cell.

Corrosion Control Methods:-

Corrosion can be controlled by preventing the formation of galvanic cells on the surface
of metals.
The methods to control corrosion can be classified as,
1. Design & Selection of materials.
2. Protective coatings. i). Inorganic coatings. ii). Metal coatings.
3. Cathodic Protection.
1. Protecting Coating:-

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Corrosion is prevented by the application of protective coating on the surface of

metal, there by the metal surface is isolated from the corrosive environment. Important
types of protective coating are,
a. Metal coating. b. Inorganic coating.
a.Metal coating:-
“The process of coating base metal with a layer of protective metal is known as metal
coating”.
There are two types of metal coating,
1. Anodic coating. 2. Cathodic coating.

1.Anodic coating;-
“The coating metal is anodic to base metal is called anodic coating”.
Ex: - Galvanization.

Galvanization:-

“The process of coating zinc on the base metal [Fe, Steel] surface by hot dipping is known
as galvanization”.
The galvanization process is carried out as follows

➢ The metal surface is washed with organic solvent[CCl4, Toulene,Benzene] to remove

organic matters.
➢ The metal surface is treated with dil.H2SO4 to remove rust and other deposits.
➢ Then it is well washed with water & it is air dried by passing with hot air.
➢ The metal is treated with a mixture of zinc chloride and ammonium chloride solution
which prevents the oxidation of the coated metal.
➢ Then the metal is dipped in molten Zinc at 4500c
➢ Excess of zinc on surface is removed by passing a pair of hot rollers, which removes
excess of zinc and produced thin coating

Iron Sheet Rollers Drier

Galvan
ized
Sheet

Organic Dil.H2SO4 ZnCl2 +NH4Cl Molten Zn Excess Zn

solvent flux [450°𝐶]

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Application: - Galvanized materials are used in fencing wire, buckets, bolts, nuts, nails, screw
etc.

Note:- Galvanized sheets cannot be used for preparing (or) storing food because zinc dissolves in
acidic medium and forms toxic compounds.

b. Inorganic coating:-

These coatings are produced at the surface of the metal by chemical (or) electrochemical
reactions.

Ex: - Anodizing and Phosphating.

Anodizing:-

Anodizing coatings are generally produced on non-ferrous metals like Al, Zn, Mg and
their alloys by anodic oxidation processes in which the base metal is made as anode.

Anodizing of Aluminum:-

When aluminum metal is made anodic in an electrolytic bath with H2SO4 (or) chromic
acid as the electrolyte, a thin layer of Al2O3 is formed on the surface. This process is called
Anodizing (or) Anodic oxidation of Aluminum.

The porous coating is obtained by anodic oxidation; it is carried out by making it anode
in an electrolytic bath containing a suitable acid like chromic acid (or) H2SO4 at 350-400c. A
plate of lead (or) stainless steel is made the cathode. When current of moderate density is passed,
the O 2 liberated at the anode combines with it to form oxide which takes the form of thick film
Al2O3 deposits on the surface of the object.

Over all reaction:- 2Al + 3H2O Al2O3 + 3H2

The coating is slightly porous and it is sealed by

dipping in hotwater. Al2O3 gets hydrated to Al2O3.H2O
which occupies more volume and
hence protects the metal from corrosion.

Application:- Metals such as Al, Mg, Ti etc are Temp-35-

anodized to control corrosion. 450C

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Cathodic Protection:-

Cathodic protection is the technique of offering protection to a specimen against

corrosion by providing electrons from an external source.

There are two important methods of cathodic protection.

1. Sacrificial Anode Method.

2. Impressed Current /Voltage Method.

1. Sacrificial Anode Method:-

Sacrificial anode method involves the use of a metal which is anodic to the
specimen.

In this method the metallic structure to be protected is connected to a more anodic metal
using a metallic wire. More active metal gets corroded, while the parent metallic structure is
protected from corrosion.

Ex: - when steel metal to be protected, it may be connected to a block of Mg of Zn , in

such case, steel acts as cathode and is unaffected. Mg or Zn act as anode and undergo sacrificial
corrosion. When the sacrificial anode gets exhausted, it is replaced with new ones.

The commonly used sacrificial anodes are Mg, Al, Zn, and their alloys.

Ex: - 1. Protection of ship’s hull by fixing Zinc plates.

2. Protection of an underground pipeline with a magnesium anode.

Electrical Conductor

Steel Pipe [Cathode]

Mg Block
[Anode]

Impressed Current Method:-

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In Impressed current method the electrons are supplied from a source of direct
current [Battery].

In Impressed current method, the metal to be protected is connected to the negative

terminal of an eternal D.C. power supply. The positive terminal is connected to an inert electrode
such as graphite. Under these conditions, the metal acts as cathode and hence does not undergo
corrosion. The inert electrode acts as anode, but it does not undergo corrosion because it is inert.
Battery
Advantages:-
1. Requires low installation cost and minimum
maintenance cost after installation.
2. It is used for protecting water storage tanks
and oil pipe lines.

Protected Metal

Inert Anode
Metal Finishing

The term metal finishing covers a wide range processes carried out to modify the surface
properties of a metal by deposition of a layer of another metal (or) polymer (or) by the formation
of an oxide film.

Definition:-

Metal finishing is the process of deposition of a layer of the metal on the surface of
substrate.

Technological Importance of Metal Finishing:-

Metal Finishing is carried out to obtain technologically important surface properties,

these properties are

• A decorative appearance.
• An improved corrosion resistance.
• An improved heat resistance.
• An improved surface hardness.
• To provide good electrical and thermal conducting surface.

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• To increase good thermal resistance.

• To increases good optical reflectivity.

Important Techniques of Metal Finishing:-

1. Electroplating.
2. Electrolessplating.
3. Metal Cladding
4. Metal Spraying

Electroplating:-

“Electroplating is a process of electrolytic deposition of a metal on the surface of another

metal by electrolysis”.
(OR)
Electroplating is the deposition of a metal by electrolysis over the surface of a substrate.
The substrate may be a metal, a polymer, a composite.

Theory of Electroplating:-

Electroplating is achieved by passing an electric current through an electrolytic solution

con

taining metal ions and electrodes.

The process of electroplating is made of four important

parts.
DC power

1. Electroplating bath solution:- it contains a suitable ne- Supply

ne-

salt solution of the metal being plated. It also contains

Anode Cathode
other additives.
2. Anode:- it is positive elect rode in the electrolysis, Electroplated

where metal ions are created. It may be inert electrode, Metal layer

it should be electrically conducting.

3. Cathode: - it is negative electrode in the electrolysis,
where metal ions gets deposited and it is an article to Electrolyte

be plated.
4. DC-Power supply: - the +ve terminal of the power

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supply is connected to the anode and the –ve terminal is connected to the cathode. The
electricity that passes from the anode to the cathode.

Reactions at Anode & Cathode during Electroplating:-

At Anode oxidation takes place M Mn+ + ne- Ex:-Cu Cu2+ + 2e-

When anode used is an insoluble [inert] material, Evolution of oxygen takes place
1
H2O 𝑂2 + 2𝐻 + + 2𝑒 −
2

At Cathode, Reduction occurs; the metal gets deposited on the cathode surface.

𝑀 → 𝑀𝑛+ + 𝑛𝑒 − Ex: - Cu2+ + 2e- Cu

Principles of Metal Finishing:-

The fundamental principles governing metal finishing are

a. Polarization
b. Decomposition potential
c. Overvoltage.

Polarization:-

Polarization is an electrode phenomenon.

It is defined as “a process in which there is the variation of electrode potential due to

slow supply of ions from the bulk of the solution to the surface of electrode”.

The electrode potential is given by Nernst’s equation

0.05691
E = Eo + log [Mn+]
𝑛

Explanation: - Consider an Electrolytic cell under operation. When current is being passed,
positive ions are produced at the anode and are consumed at the cathode. If the diffusion of ions
in the electrolyte is slow [due to variation in current density, temperature or PH] there will be an
accumulation of positive ions in the vicinity of anode instead of cathode takes place. As a result
there will be a decrease of ions in the vicinity of cathode takes place. Under these conditions, the
anode and cathode are said to be polarized.

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Polarization depends on

• Nature of Electrode
• Electrolyte concentration and its conductivity.
• Products formed at electrodes.
• Temperature.
• Rate of stirring of the electrolyte.

Decomposition Potential:-

Decomposition potential is defined as “The minimum external potential required for the
continuous electrolysis of an electrolyte”.

The decomposition potential is determined by using an electrolytic cell as shown in fig.

The cell consists of two Pt- e-des immersed in the electrolyte. The voltage is varied by
moving the contact maker D along the wire AB and the current passing through the cell is
measured using an ammeter.

If dilute solution of acid (or) base taken in the cell, at low voltages no reaction is found to
occur and when the voltage is slightly higher than 1.7v, a sudden evolution of H2 and O2 at the
electrode is noted. This is accompanied by increase in the current. Thus the applied voltage of
1.7v is the decomposition potential for dilute acids and bases.

A plot of current v/s voltage shows gradual increase of current with increase in applied
voltage in the beginning and large increase in current above ED and the decomposition voltage is
determined by extrapolation of the curve as shown in the above figure.

Over Voltage:-

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Over voltage is defined as “the excess voltage that as to be applied above the
theoretical potential for continuous electrolysis”.
η= Experimental decomposition potential-Theoretical decomposition potential

Ex: - the theoretical potential of oxygen at platinum electrode is 1.23v but the actual
decomposition potential of oxygen is 1.68v. The excess 0.45v is the overvoltage of oxygen on
platinum e-de surface.

Factors affecting Over Voltage:-

a. Nature of electrode
b. Current density
c. Temperature.
d. Impurities

Plating Process:-
The plating process is carried out by pretreating (or) surface preparation of the object
followed by electrolysis.
Pretreatment (or) Surface preparation:-
It is very much necessary to clean the surface of the base metal before electroplating in
order to get a good deposit.
Surface cleaning involves following steps.
1. Removal of organic substances: - Solvent and Alkali cleaning.
2. Removal of inorganic substances: - mechanical and Pickling.
3. Rinsing with water.

1. Solvent Cleaning:-
It is used to remove oils, greases, etc.. from the surface. For cleaning organic solvents
such as Benzene, Toluene, Carbon tetra chloride etc.. are used.
Ex: - Trichloroethylene was previously used for removing paints and resins.
2. Alkali Cleaning:-
Residual oil & grease from the surface is removed by treatment with alkaline
solutions. [NaOH, Na2CO3, etc..].
3. Mechanical cleaning:-
Mechanical cleaning involves removal of the oxide layer (or) rust and other
inorganic deposits on the metal surface. The simple methods involve the hand cleaning
with sand paper, bristle brush, polishing tools etc…

4. Pickling (or) Acid cleaning:-

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It is used to remove oxides, rust and other contaminants from the metal surface
by immersing in an acid such as dilute Hcl (or) H2SO4.

5. Rinsing with water:-

The object is finally rinsed with deionized water preferably in hot conditions and
dried before it is subjected to electroplating.

Electroplating of Chromium:-

The surface of the object is cleaned thoroughly; organic substances are

removed by solvent cleaning and alkali cleaning. Inorganic substances are removed by
mechanical cleaning and picking. Finally the surface is washed with deionized water. Then
chroming plating is done under the following conditions.
In the field of electroplating two types of chromium are employed: decorative &
hard.

Decorative chromium
Plating conditions Hard chromium plating
plating
1. Plating bath composition Chromic acid (H2CrO4) + Chromic acid (H2CrO4) +
H2SO4 H2SO4
in the weight ratio 100 : 1 in the weight ratio 100 : 1
2. Operating temperature 45-55oC 45-55oC
3. Current density 145 – 430 A/ft2 290 – 580 A/ft2
4. Current efficiency 10 – 15 % 17 – 21 %
5. Anode Insoluble anode: Pb-Sb or Pb- Insoluble anode: Pb-Sb or Pb-
Sn alloy coated with PbO2. Sn alloy coated with PbO2.
6. Cathode Object to be plated Object to be plated
7. Anodic reaction Liberation of oxygen: Liberation of oxygen:
H2O 1/2 O2 + 2H+ + 2e- H2O 1/2 O2 + 2H+ + 2e-
8. Cathodic reaction Cr3+ + 3e- Cr Cr3+ + 3e- Cr
In chromic acid, chromium is present in 6+ oxidation state. It is first reduced to 3+ satate
by a complex anodic reaction in the presence of sulphuric acid. The Cr3+ then gets reduced to Cr
on the surface of the substrate.

For a good deposit, the Cr3+ concentration must be low. The PbO2 oxidizes a part of Cr3+
to Cr6+ thus reducing the concentration of Cr3+.

2Cr3+ + 3O2 2CrO3 + 6e-

Chromium anodes are not used in Cr-plating, because

• If chromium dissolves at anode, there will be a high concentration of Cr3+ in solution; in

such case a black deposit is obtained.

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• In acidic solutions, chromium may undergo passivation.

ElectrolessPlating:-

Electrolessplating is the deposition of a metal without the use of electrical energy.

It is defined as “the process in which metal is depositing over a substrate by controlled

chemical reduction of metal ions by a suitable reducing agent without using electrical energy”.

The Electroless plating can be represented as,

Mn+ + Reducing agent M + oxidized product.

Composition of Electroless Plating bath:-

▪ Metal salts to provide Mn+ for deposition. Ex:- NiCl2, CuSo4

▪ Reducing agent to reduce metal ions into metal atoms.
Ex:- sodium hypophosphite, Formaldehyde.
• Complexing agents to form complex compounds with metal ions.
Ex: EDTA, sodium Succinate
• Accelerators to increase rate of plating.
• Stabilizer to give more stability to solution.
• Buffer to control the PH. Ex: Sodium Hydroxide + Rochelle salt.

Surface Preparation:-
Before Electroless plating the surface of the substrate should be catalytically activated as
follows.
• Acid Treatment.
• Electroplating a thin layer of the metal followed by heat treatment.
• For non-conducting surfaces such as plastics (or) printed circuit boards, the surface is
treated with Sncl2 and Palladium chloride solution alternately.
Electroless Plating of Copper:-
Before Electroless plating the plastic board is degreased and etched in acid. It is
activated by dipping in SnCl2 / HCl at 250c followed by dipping in PdCl2.

Electroless plating is done under the following conditions,

Plating bath solution Copper Sulphate

Reducing agent Formaldehyde
Complexing agent and exaltant EDTA
Buffer Sodium Hydroxide[PH=11]

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Temperature 250c
Anode Reaction 2HCHO + 4OH- 2HCOO- + 2H2O + H2 +2e-
Cathode Reaction Cu2+ +2e -
Cu
Net Reaction 2HCHO + 4OH- + Cu2+ 2HCOO- + 2H2O + H2 + Cu

Typical application of Electroless copper plating is printed circuit boards,

particularly double sided boards in which plating through holes is required.

Electroless Plating of Nickel:-

Before Electroless plating the non-metallic materials are degreased and etched in
acid. It is activated by dipping in SnCl2 / HCl at 250c followed by dipping in PdCl2.

Before Electroless plating the metallic materials are degreased and etched with acid.

Plating bath solution Nickel Chloride [or ]Nickel Sulphate

Reducing agent Sodium Hypophosphite
Complexing agent and exultant Sodium Succinate
Buffer Sodium Acetate [PH=4.5]
Temperature 930c
Anode Reaction NaH2PO2 + H2O NaH2PO3 + 2H+ + 2e-
Cathode Reaction Ni2+ +2e -
Ni
Net Reaction NaH2PO2 ++ H2O + Ni2+ NaH2PO3 + 2H+ + Ni

Distinctions b/w Electroplating and Electrolessplating:-

Property Electroplating Electrolessplating

Driving Force Electric Current Autocatalytic Redox Reaction.
Anode Separate Anode Catalytic surface of substrate
Cathode Article to be plated Catalytically active surface.

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Reducing agent Electrons Chemical reagent

Anode reactant Metal (or) H2O Chemical reagent
Applicability Only to conductors Conductors and non-conductors.
Throwing Power Low High.
Most Probable Questions:-

1. Define Corrosion? Explain Electrochemical theory by taking Iron as Example.

2. Explain Differential metal & Differential aeration Corrosion with Example.
3. Explain Differential aeration Corrosion with Typical Examples.[Water line & Pitting
Corrsion]
4. Explain the Factors affecting rate of corrosion.[All Factors].
5. Explain Galvanizing Process.
6. Explain Anodizing of Aluminum.
7. Define Cathodic Protection? Explain Sacrificial anode & Impressed Current method.

Metal finishing

1. Define Metal Finishing?Write any five Technological importance of Metal Finishng.

2. Explain the following Principles governing Electroplating Process
a. Polarization b. Decomposition Potential c. Over Voltage
3. Define Electroplating? Explain Electroplating of Chromium.
4. Define Electrolessplating? Expalin Electrolessplating of Copper.
5. Define Electrolessplating? Expalin Electrolessplating of Nickel.
6. Mention difference between Electroplating & Electrolessplating Process.

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