BGAS Grade 2 - Ch-1 Corrosion

Ch1: Corrosion
Contents:
 What is corrosion?
 Mechanism of corrosion
• Electrical Circuit
• Chemical Reactions
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Q. What is corrosion?
Degradation of a metal by chemical or electro-chemical

means
Electro-Chemical Process
1. Formation of Electrical Circuit: For corrosion
circuit to exist three things are needed;
• Anode (Positively charged area)
• Cathode (Negatively charged area)
• Electrolyte (conduct current)
2. Chemical Reaction
Example of a corrosion cell
Iron Atomic Structure:
A stable Iron atom has;

• 26 Protons (at nucleus)
• 26 Electrons (revolving in
4 orbits)
At Anode: Iron atom becomes iron ion by loosing 2 electrons:
• The current in the corrosion circuit is DC –
Direct Current
• An ion is a charged particle, and can be

positive or negative
• The Fe++ is called a positive iron ion
Cathode:
 Negatively charged area
 More electrons than needed in its passive

state. These are electrons released from the
anode.
 The electrons enter into the electrolyte to

pass back to the anode.
Electrolyte:
 Conduct current (electrons passes through the
electrolyte)
 It broken down by itself (dissociate into ions).
 Water is the most abundant and efficient electrolyte.
 Acids, alkalis and salts in solution are also very

efficient electrolytes.
Electrolyte: When electrons pass into the electrolyte, the
electrolyte gets dissociated into positive and negative ions
H2O H+ + OH-
Where, H+ : Hydrogen Ion and OH- : Hydroxyl Ion
H+ + H+ H2
The Hydrogen ions join together to form hydrogen gas which is a by-
product of this entire reaction system.
This is production of Hydrogen gas is termed as being evolved, or given off

from the cathode. Website: www.weldingandndt.com
The hydroxyl ions return to the anode
through the electrolyte carrying the
electrons.
Fe(OH)2: Iron Hydroxide Or Hydrous Iron Oxide (Rust)
Important Point:
• Corrosion occurs at the anode only, never at the
cathode, hence the term cathodic protection.
• If a structure can be made to be the cathode in

a circuit, it will not corrode.
Corrosion Triangle
Factors that increase the corrosion reaction rate
1. Temperature: Hotter the steel, faster the corrosion
2. Hygroscopic salts:
 Attract water and dissolve in it.
 If salts are present on steel surface and a coating is applied over them,
water will be drawn through the film and the resulting solution builds up a
pressure under the film. Eventually the film is forced up to form blisters
called as osmotic or hygroscopic blisters and are defined as pinhead sized
water filled blisters.
 Sulphates and chlorides are the two most common salts, chlorides
predominant in marine environments and sulphates in industrial areas
and sometimes agricultural.
Factors that increase the reaction rate
3. Aerobic conditions (presence of oxygen):
• By introducing oxygen into the cathodic reaction the

number of Hydroxyl ions doubles.
• Double the corrosion rate. Shown by :-2H2O + O2 +

4e 4OH-
Factors that increase the reaction rate
4. Bacteria:
• Sulphur reducing bacteria, better known as SRBs
• Metal eating microbes (MEMs)
5 Acids and alkalis
6 Bi-metallic contact (Also known as bi-metallic
corrosion)
Galvanic List, Electro Motive forces series or the
Electro-Chemical series:
MILL SCALE
• Appearance: Blue
• Thickness: 25µm to 100µm
• Formed during the rolling operation of steel sections like beams, angles & channels
• The oxides are compressed during the rolling operation to produce mill scale
• (Note: The oxides of iron form very quickly at temperatures in excess of 580°C.)
 FeO – Wustite
 Fe3O4 – Magnetite
 Fe2O3 – Haematite
• Mill Scale is only produced during rolling, If removed by any surface preparation
method, it can never recur.
Thank You

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Ch1: Corrosion

 Education: Mechanical Engineer

 Hobby: I like to share knowledge

2. Can attend the live sessions

3. Priority reply to your comments

You can download the PDF of this presentation

Degradation of a metal by chemical or electro-chemical

A stable Iron atom has;

• An ion is a charged particle, and can be

• The Fe++ is called a positive iron ion

 More electrons than needed in its passive

 The electrons enter into the electrolyte to

 It broken down by itself (dissociate into ions).

 Water is the most abundant and efficient electrolyte.

 Acids, alkalis and salts in solution are also very

This is production of Hydrogen gas is termed as being evolved, or given off

Fe(OH)2: Iron Hydroxide Or Hydrous Iron Oxide (Rust)

• If a structure can be made to be the cathode in

3. Aerobic conditions (presence of oxygen):

• By introducing oxygen into the cathodic reaction the

• Double the corrosion rate. Shown by :-2H2O + O2 +

5 Acids and alkalis

6 Bi-metallic contact (Also known as bi-metallic

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