Module-3: Corrosion and Electrode Systems
Module-3: Corrosion and Electrode Systems
Module-3: Corrosion and Electrode Systems
MODULE-3
3.1 Introduction
A wide variety of metals/alloys are used for the construction of bridges, buildings, large
houses and industries. These are having natural tendency to get tarnished or deteriorated by the
Corrosion is a process which involves the interaction with ambient oxygen can cause the
formation of oxide layers via diffusion controlled growth. These may passivate the material against
further oxidation.
In wet environment, aqueous corrosion can occur due to electrochemical processes which depend
upon metal ion transport and reaction. The following factors are influence corrosion rate
Corrosion may occur either in dry environment or in a wet environment (aqueous medium).
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Dr. M. Vinuth M.Sc., PGDHRM, Ph.D.
(a) Dry corrosion: It involves the direct interaction of metals with dry gases like O2, SO2, Cl2,
E.g.: The attack of metals by O2 to form an oxide layer over the surface
(Mg + ½ O2 MgO)
(b) Wet corrosion: It involves electrochemical attack on metals in aqueous environment. This
type of corrosion occurs when the metal comes in contact with a conducting liquid or when
two dissimilar metals are dipped partly in a solution. E.g.: Rusting of iron.
(a) Formation of galvanic cells: Anodic and cathodic areas are formed due to the formation of
(b) Anodic reaction: At the anodic area, Oxidation of metal takes place at the anodic region.
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Dr. M. Vinuth M.Sc., PGDHRM, Ph.D.
(c) Cathodic reaction: The electrons travel through the metal from the anodic region to
cathodic region. There are three possible ways in which reduction can takes place.
1. If the medium is aerated and neutral, oxygen is reduced in presence of water to form OH -
ions.
2. If the medium/solution is deaerated and almost neutral, water is reduced to H2 and OH-
3. If the medium is deaerated and acidic, the H+ ions are reduced to H2.
2H+ + 2e- H2
The metal ions which are formed at the anode that combines with the OH- ions to form the metal
𝟑
𝟐𝐅𝐞 (𝐎𝐇)𝟐 + 𝐎 + 𝐇𝟐 𝐎 → 𝐅𝐞𝟐 𝐎𝟑 . 𝟑𝐇𝟐 𝐎 (𝐑𝐮𝐬𝐭; 𝐛𝐫𝐨𝐰𝐧 𝐜𝐨𝐥𝐨𝐮𝐫)
𝟐 𝟐
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Dr. M. Vinuth M.Sc., PGDHRM, Ph.D.
This type of corrosion occurs when two dissimilar metals are in contact with each other and
are exposed to a corrosive environment. The two metals differ in their electrode potentials. The
metal with lower electrode potential acts as anode and the other metal with higher electrode
The anodic metal undergoes oxidation and gets corroded. A reduction reaction occurs at
the cathodic metal. The cathodic metal does not undergo corrosion.
Cell reactions:
Higher the potential difference between the anodic and cathodic metals, higher is the rate of
corrosion.
E.g.: When iron is in contact with zinc, iron acts as cathode and zinc acts as anode because zinc
has lower electrode potential compared to iron. Therefore, zinc undergoes corrosion.
Zn metal Fe Metal
Anode Cathode
On the other hand, when iron is in contact with Cu, iron acts as anode because iron has lower
Fe Anode Cu metal
Anode Cathode
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Dr. M. Vinuth M.Sc., PGDHRM, Ph.D.
To generalize, when two metals are in contact with each other results in a formation of
galvanic cells and current produced. The metal acting as anode undergoes corrosion and the metal
concentration. The part which is exposed to higher oxygen concentration acts as cathode and the
Consequently, the poorly oxygenated region undergoes corrosion. The reactions may be
represented as follows:
Cell reactions:
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Dr. M. Vinuth M.Sc., PGDHRM, Ph.D.
2) When a dirt particle sits on a metal bar, the part under the dirt undergoes corrosion.
Typical examples of differential aeration corrosion are the water line corrosion and pitting
corrosion
These type of corrosion occurs when dust particles gets deposited on a metal surface. The
portion covered by the dust will be less aerated compared to the exposed surface. So the covered
portion becomes anodic with respect to the exposed surface. In the presence of electrolytes,
impurities and moisture corrosion starts beneath the dust resulting in a pit. Once the pit is formed,
the corrosion progress rapidly due to the formation of small anodic area and large cathodic area.
3.5 Metal coatings: The process of deposition of protective metal over the surface of a base metal
Metal coating are two types’ anodic metal coatings and cathodic metal coatings
Anodic metal coatings: These are the coatings which are anodic to the base metals. For example
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Dr. M. Vinuth M.Sc., PGDHRM, Ph.D.
Example: Galvanization: the process of coating a base metal surface (Fe) with zinc metal. This
1. The metal surface is washed with organic solvents (CCl4, toluene) to remove organic
matter on the surface (Degreasing).
2. Rust and other deposits are removed by washing with dilute sulphuric acid.(Pickling
process).
4. Finally article is then dipped in a bath of molten zinc. Temperature should be maintained
at 425-430 ◦C and covered with a flux of ammonium chloride to prevent the oxidation of
molten zinc.
5. The excess zinc on the surface is removed by passing through a pair of hot rollers that
wipe the excess zinc coating and produces a thin film coating.
Application: Galvanization of iron is carried out to produce roofing sheets, fencing wire, buckets,
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Dr. M. Vinuth M.Sc., PGDHRM, Ph.D.
Note: 1. Even if the Zn coating falls off at some places, the base metal (Fe) does not get
corroded at those places. This is because the base metal acts as cathode. In corrosion
2. Galvanized articles are not used for preparing and storing food because zinc
These are generally chemical conversions coatings. A surface layer of the metal is
In practice, there are two types of inorganic coating techniques (a) Anodizing (b)
Phosphating
Anodizing: Anodizing is process in which a protective passive oxide film is produced chemically
or electrochemically on certain metals (Al, Zn, Mg, Cr etc) in oxidizing acid bath.
oxidation in an electrolytic cell. Metals such as Al, Ti, Mg, V and Zr are anodized in the presence
of electrolyte like chromic acid, sulphuric acid, oxalic acid or boric acid, by electrochemical
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Dr. M. Vinuth M.Sc., PGDHRM, Ph.D.
1. The Al article to be anodized is first treated (washed) with organic solvents and polished to get
3. Both the electrodes are dipped in the 5-10 % chromic acid electrolytic solution (any acid
electrolyte /solution). The electrolysis is carried out by passing D.C voltage of 40 V at 35-40
˚C.
4. A thin oxide layer of aluminium (Al2O3) of 5-20 mm thickness is formed on the anode. This
5. The strength of oxide layer formed is increased by dipping in boiling water. This treatment
changes the porous surface into a sealed surface by forming monohydrate of aluminium oxide
(Al2O3.H2O)
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Dr. M. Vinuth M.Sc., PGDHRM, Ph.D.
Applications
1. Anodized aluminium is used in manufacture of pressure cookers, aircrafts & window frames.
It is a method of protecting a metal or alloy from corrosion by converting it completely into cathode
Sacrificial anode method: In this method, the protected metal structure is converted into a cathode
by connecting it to a more active metal. This active metal acts as auxillary anode. Usually Zn, Mg
and Al are the common used as auxillary anodes. Moreover, these metals are active in nature which
acts as an anode and undergoes preferential corrosion by protecting the metal structure. Since the
anodic metals are sacrifices themselves for the protection of metal structure. Therefore this method
is called as Sacrificial anode method. Exhausted sacrificial anodes are replaced by new one, if it is
required.
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Dr. M. Vinuth M.Sc., PGDHRM, Ph.D.
Applications
2. Mg bars are fixed to the sides of ocean-going ships to act as sacrificial anodes.
The speed at which any metal in a specific environment deteriorates due to a chemical
Or
Several pieces of data must be collected to calculate the corrosion penetration rate for any given
metal:
The weight lost (the decrease in weight of the metal during the period of reference).
𝐊×𝐖
CPR= 𝛒 × 𝐀 × 𝐭
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Dr. M. Vinuth M.Sc., PGDHRM, Ph.D.
The CPR is conveniently expressed in terms of either mils per year (mpy) or millimeters per
year (mm/yr)
1. A sheet of carbon steel one meter wide by three meter long has lost 40 g to corrosion over the
past six months. Convert that mass loss to a penetration rate of the steel in mm units and mpy.
What would be the corrosion rate? (Carbon steel density = 7.8 g/cc)
𝐊𝐖
𝐂𝐏𝐑 =
𝛒𝐀𝐭
87.6 × 40 × 1000 mg
CPR = g
7.8 cc × 3 × 100 × 100 cm2 × 6 × 30 × 24 hrs
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Dr. M. Vinuth M.Sc., PGDHRM, Ph.D.
534 × 40 × 1000 mg
CPR = g
7.8 cc × 3 × 1550 inch2 × 6 × 30 × 24 hrs
the original area was 10 inch2 that approximately 2.6 kg had corroded away during the
submersion. Assuming a corrosion penetration rate of 200 mpy for this alloy in sea water.
𝐊𝐖
𝐂𝐏𝐑 =
𝛒𝐀𝐭
KW
t=
ρ × A × CPR
534 × 2.6 × 106 mg
t= g
7.9 × 10 inch2 × 200 mpy
cc
t = 87873.41 hrs
87873.41
𝑡= = 𝟏𝟎. 𝟎𝟑 𝒚𝒓𝒔
365 × 24
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Dr. M. Vinuth M.Sc., PGDHRM, Ph.D.
3.10 Electrode is a device consists of metal and its own ionic solution. Following are some
To overcome all these difficulties, secondary reference electrodes are used to measure the
electrode potential of unknown electrodes
These are the electrodes, selects only specific ions ignoring other ions. In this electrode, a
glass membrane is in contact with a solution, with which it can exchange ions.
E.g.: Glass electrode (exchanges H+ ions with solutions), various metal ion selective electrodes
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Dr. M. Vinuth M.Sc., PGDHRM, Ph.D.
Principle: If a thin walled glass bulb containing an acid is immersed in another solution
containing H+ ions as shown in fig. A potential was developed across the glass membrane.
Boundary potential (Eb); It is a potential developed across the glass membrane when
concentration of the solution inside and outside the glass membrane are different.
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Dr. M. Vinuth M.Sc., PGDHRM, Ph.D.
L is a constant which depends on the pH of the solution taken in the bulb and the glass
electrode assembly.
Since C2 = [H+] of the solution and -log [H+] = pH, equation (3) is written as
Eb = L ― 0.0591 pH (4)
Construction: The glass electrode consists of a long glass tube with a thin walled bulb at the
bottom as shown in fig. The composition of the glass used in glass electrode is SiO2, Na2O,
Al2O3 etc., and it allows only H+ ions. The bulb consists of 0.1 N HCl (Assume concentration
is C1) and Ag/AgCl electrode it serves as internal reference electrode as shown in fig. If the
glass electrode is dipped into any solution containing H+ ions then glass electrode develops
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Dr. M. Vinuth M.Sc., PGDHRM, Ph.D.
If C1 = C2, equation (1), Eb = 0. Moreover, it has been observed that under this condition, a small
potential is developed. This is called asymmetric potential and denoted by Eassy.
3.10.4 Determination of pH
To determine the pH of given solution, glass electrode is dipped in a solution whose
pH Meter
Glass
Calomel Electrode
Electrode
Solution of
Unknown pH
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Dr. M. Vinuth M.Sc., PGDHRM, Ph.D.
Construction: It consists of glass tube. The bottom of the glass tube is filled with pure mercury
(Hg) on which a calomel paste (Hg + Hg2Cl2) is placed. The remaining part of the glass tube
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Dr. M. Vinuth M.Sc., PGDHRM, Ph.D.
It also contains side tube serves as salt bridge and a platinum wire is dipped into the mercury
so that it serves as electrical contact.
The electrode potential of the calomel electrode is mainly depending on the concentration of KCl
used; Electrode potential is calculated using Nernst equation,
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Dr. M. Vinuth M.Sc., PGDHRM, Ph.D.
For,
Electrode Concentration (KCl) Ecalomel (V)
Normal 1N 0.281
Advantages
1. It is simple to construct.
2. The cell potential is stable and reproducible does not vary with temperature.
Applications
Limitations
Analytical techniques are the methods utilized for the determination of compounds
techniques. This technique aids to study the physical or chemical properties of chemical substances
and mixture.
concentration, partial pressure, and activity into a measurable signal. It is composed of two parts;
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Dr. M. Vinuth M.Sc., PGDHRM, Ph.D.
(a) recognition part: - interacts with the target ions or molecules in the sample, (b) transducer part:
Introduction
solution is determined from measurement of the emf between two electrodes that are dipped
Theory
When a metal M is immersed in a solution containing its own ions Mn+, the electrode
2.303RT
Ecell = E O + log[M n+ ]
nF
E can be measured by combining the indicator electrode with a reference electrode and measuring
the standard emf of the cell, Whereas E° is the standard potential of the system. Especially for
redox titrations could be carried out potentiometrically using platinum – calomel electrode
A potentiometer connected with the electrode assembly involves the combination of the
platinum-calomel electrode immersed in the given sample (FAS) into a 100 cm3 beaker followed
by the addition of 2 test tubes of H2SO4. Measure the change in potential by adding potassium
dichromate from the burette with 0.5 cm3 increments. Stir the mixture after each addition, and
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Dr. M. Vinuth M.Sc., PGDHRM, Ph.D.
Plot a graph of ∆E / ∆V against the volume of K2Cr2O7 as shown in the figure. Find the
equivalence point from the graph. Knowing the equivalence point, calculate the normality of the
FAS solution and determine the amount of FAS per liter of the solution
Cr2 O2− + −
7 + 14 H + 6e → 2Cr
3+
+ 7H2 O
Advantages
1. This technique gives experimental results more reliable than that obtained from
3. This method is suitable for titration of week acids and bases for which indicators are
not available.
Applications
1. This method is used to find the end point of redox and acid base titrations.
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Dr. M. Vinuth M.Sc., PGDHRM, Ph.D.
current. Electrolyte solutions conduct current by the migrations of ions under the influence
of an electric field”.
conductance are replaced by ions of different conductance. Therefore, there is a sudden change in
conductance of the solution at the equivalence point. The conductance of a solution depends on
the number and mobility of ions. The equivalence point is determined graphically by plotting
Let us consider that acetic acid is titrated against NaOH. Initially the conductance is low
due to the low ionization of weak acid. However, increase in addition of NaOH to the acid to form
salt (CH3COONa). This salt formation tends to increase the conductance of the system, because
conducting power of ionized salt exceeds that of weak acid. This phenomenon gradually increases
until the equivalence point. Beyond this point, conductance rapidly increases due to the highly
conducting OH- ions. Consequently, the linear portion shown in the figure in the alkaline region
is steeper. The equivalence point is obtained by intersection of two lines i.e., one in acidic region
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Dr. M. Vinuth M.Sc., PGDHRM, Ph.D.
Other applications
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