Module 3 Material
Module 3 Material
Module 3
Corrosion
by chemical and/or
Corrosion is the gradual destruction of materials (usually a metal)
electrochemical reaction with their environment
"Corrosion is responsible for the wastage of metal in the form of its compounds.
Failure of machinery, chemical plants etc., so life span is reduced.
Examples of corrosion,
Wet or Electrochemical Corrosion: This type of corrosion is due to the electro chemical
attack of metal surfaces by the atmospheric air and moisture.
Example: Rusting of Iron, corrosion of metals like Zn, Mn,Cu etc.
ELECTROCHEMICAL THEORY
i)The formation of anodic and cathodic areas (galvanic cells) in contact with cach other on
the same metal surface due to the presence of two metals in conducting medium, impurities
and stress in metals.
Corrosion occurs at anodic areas only and formation of corrosion product takes place
somewhere between anodic and cathodic areas.
This involves flow of electron-current between the anodic and cathodic arcas.
Cathodic reaction consumes electrons with either by (a) evolution of hydrogen or (b)
absorption of oxygen, depending on the nature of the corrosive environment. Possible ways
are,
Yellow rust
(b) If the supply of oxygen is limited, the corrosion product is black anhydrous magnetite,
Fe:O4
3Fe (OH): +0; Fe;O4.3 H;0
Black rust
wate
H,0
Rust
fe,0,H,0 cathodic
site
anodic
site
fels Fe
Types of Corrosion:
(1)Differential metal corrosion (Galvanic corrosion)
(2) Differential Aeration corrosio
1. Differential metal Corrosion/Galvanic corrosion/Bimetallic corrosion.
When two dissimilar metals are in contact with each other a potential difference is set
up resulting in a galvanic current which leads to galvanic corrosion. The two metals with
different reduction potentials have the tendencies to undergo oxidation. The one with lower
electrode potential or the more active metal acts as anode and the one with higher electrode
potential acts as cathode. The anodic metal undergoes corrosion and the cathodic metal is
generally un attacked. A metal placed above in an electrochemical series is said to be anodic
to the metal placed below it. Thus, iron is anodic to Cu, Ni & Sn. On the other hand, iron is
cathodic to Zn and Mg. The rate of galvanic corrosion depends on the potential difference
between the metals.
Eg: Iron corrodes severely in presence of copper (pot difference +0.7v),than in the
presence of tin (pot diff +0.3v).
Electrolyte
Anode reaction: solution
Cathodie reaction:
MM+2e 0,t2H,0t4e40H
Low-potential High-potential
metal metal
Reactions:
Anode corrosion
product
Differential acration corrosion
OH lon
Cahode
1. Applied coatings.
a. Metal coatings
b. organic coatings
2. Surface conversion coatings
a. Anodizing.
b. Chromating
c. Phosphating
3. Cathodic protection.
a
Sacrificial anode protection.
b. Impressed current cathodic protection.
4. Anodic protection
5. Corrosion inhibitors
Substrate
Solution.
Anodic Coating: Anodic coatings are produced by coating a base metal with more active
metals which are anodic to the base metal.
E.g.: Iron is coated with anodic and active metals like
Zn, Mg, and Al.
One advantage of anodic coating is that,
even if the coating is rupturcd, the base mctal
does not undergo corrosion. The exposed
surface of the metal is cathodic with respect to the
coating metal. Therefore, anodic coating is also known as
sacrificial coating.
Galvanisation is a process of coating a base metal surface with Zinc metal.
Galvanisation is carried out by hot dipping method.
Surface Preparation
Cooling and
Drying Zinc Inspection
Flux bath
Rinsing solution
Plckling
Degreasing Rinsing
Galvanization is used to protect roofing sheets, water pipes, barbed wire, buckets etc.
Galvanised articles are not used for preparing and storing foodstuffs, since Zinc dissolves in
dilute acids producing toxic Zinc compounds.
2)Inorganic Coating:
Inorganic coatings are generally chemical conversion coatings. A surface layer of the
metal is converted into a compound, by chemical or electrochemical reactions, which forms a
barrier between the underlying metal surface and the corrosion environment.
Anodized coating or Anodising:
Anodized coating is generally produced on nonferrous metals like Al, Zn, Mg and their
alloys by anodic oxidation process.
In anodization of aluminium, by passing direct current
through the electrolytic cell containing
clean, polished aluminium as anode, immersed in an acid bath like
chromic acid & sulphuric
acid. Inert elcctrodes like lead are generally used as cathode. The
anodic oxide film formed
on Al in bath as aluminium oxide, which is porous and
provides goodadherence for paints.
The strength and corrosion resistance of the anodised film can be
increased by sealing.
The pores are finally sealed by dipping in hot water to produce
Al;03.H:0, which acts as a
non-porous protective layer preventing corrosion.
Anode reaction: 2Al + 3H;0 ’ Al,0; + 6H+ +6e
Cathode reaction: 6H+ + 6e-’ 3H2
Anodizing of aluminium produces a hard, compact, and strongly adherent oxide film that
significantly improves corrosion resistance. The appcarance and characteristics of the oxide
film can be a function of the type of anodizing treatment. The
appearance can also be
impacted by a wide range of dyes.
Aandos thode
Electro
A’o,
Advantages:
1. Anodised aluminium products have a protective layer; they have harder and
durability
than normal aluminium.
2. The anodized surface show good adhesion to paint and gives a
coloured appearance.
3. The thick outer coating produced, along with the proper sealing, increases the
corrosion
resistivity of the surface as it prevents further oxidation.
Common applications for anodized finishes:
Structures and architectural categories of all types.
Appliances.
Commercial and residential building products.
" Food preparation equipment.
Furniture.
3. Cathodic Protection
Ooject
Sacrlcial
anode
protected
ProteCtve urert
Electrode Systems:
Reference electrode:
Calomel electrode:
It is a metal-insoluble salt clectrode, where metal in contact with its insoluble salt and the
solution contains the anion of the salt.
H HC
H
The potential values depend on the concentration of the solution used in the construction of
the electrode:
Advantages:
1)It is simple to construct.
Disadvantages:
It cannot be used above S0°c, because Hg:Cl; breaks down yielding unstable readings and it
is toxic.
Uses:1)It is used as a secondary reference electrode in the measurement of single electrode
potential
Definition:
Principle:
When two solutions of different hydrogen ion concentrations, i.e., different pH values
are separated by a thin glass membrane, there develops a potential difference between the two
surfaces of the glass membrane. The potential developed is proportional to the difference in
the pH values of the two solutions. If the pH of the one solution is kept constant, the potential
becomes proportional only to the pH of the other solution. This is the basis of the glass
electrode.
Construction:
-Vacuun tube
Platinum wire
GHass.
clectrode
KO Nd
solutn
He
EG- Es+ERertEAssy
difference in response of the inner
EAsy is the asymmetric potential which arises due to the
activity. ERefr is the potential of
and outer surface of the glass bulb to changes in H ion
internal reference clectrode. Substituting for Eb we get,
EG- L-0.0591 pH +ERertEAy
is simplified to,
Since, L, ERef, and EAssy are constants, the equation
EG- EG°-0.0591 pH Where, Ec'= L+ ERertEAssy is a constant.
Advantages:
range 0-9, with special type of glass
1. This electrode can be used to determine PH in the
even up to 12 can be calculated.
Therefore, from thermodynamic consideration it has been shown that E, and E; are related to
the hydrogen ion activities, Ci and C; in the outer and inner solution respectively.
By Nernst equation,
Es=E° +0.0591 Log Ci- [E° +0.0591 log C:)
Es= 0.0591Log Ci -0.0591 log C:
4. It is simple to
operate, hence extensively used in various
laboratories.
Limitations
1. The glass membrane though it is very thin, it offers high
resistance. Thereforc, ordinary
potentiometers cannot be used; hence it is necessary to use electronic
potentiometers.
2. This electrode cannot be used to determine the pH above 12
because it will become
sensitive to Naand includes alkaline
erTors.
Determination of pH using Glass Electrode:
The given glass electrode is dipped in the
unknown solution containing hydrogen ions,
constitutes a half cell. It is coupled with reference electrode (ex:
saturated calomel electrode)
through a salt bridge, where calomel electrode forms an
outer reference electrode.
The above cell may be
represented as:
Hg/ Hg-Clz (paste) /Sat. KCI/ analyte solution l glass
membrane /0.1M HCL/AgCV Ag
In the above cell, the glass
electrode behaves as cathode and calomel clectrode as
anode.
The cell potential may be determined
using electronic potentiometer.
The EG is obtained by repeating the
experiment the using solution of known pH.
The pH value of the experimental solution can be
calculated by substituting the values
of Ecell, Ecalomel and EG in the following relation:
Electro analytical methods are the techniques that involves the analysis of the sample
containcd in clcctrochemical ccll, by measuring the potential or current.
Different electroanalytical methods are,
1) Potentiometry
2) Conductometry
POTENTIOMETRY:
Potentiometry is an electroanalytical technique which the concentration of ionic solution
can be determined by measuring emfbetween the two electrodes dipped in the solution.
PRINCIPLE:
The potential difference between the two electrodes is the basis of the potentiometry. The
addition of a titrant leads to a change in the ionic concentration, causing changes in the
potential difference.
Which is given by Nernst equation,
E- E° +0.0591 log (M"*)
n
i.e., the potential of an electrode depends on concentration of ion to which it is
reversible.
INSTRUMENTATION:
Patertiometer
Indicator
Saturatad elactrode
calumel
electrode
Analyte
solutlon
Magnetic stirter
Applications:
1) Estimation of FAS potentiometrically using standard K2Cr;0, solution
Redox titrations can be carried out potentiometrically. In potentiometric titration of Mohr's
salt solution with potassium dichromate solution, the standard calomel electrode is used as
reference clectrode and platinum electrode is used as indicator electrode. When, acidified
Fe'solution is titratcd slowly against K;Cr:0; from the burcette, the following reaction takes
place.
6Fe+Cr, o 6Fe*+2C'*
Before the cquivalence point, the potential is determined by the Fe? /Fe redox system. After
the cquivalence point the potential is determined by the Cr20, /C system. At the
equivalence point, the potential is average potential of both the systems. Thus, there is an
abrupt incrcase in potential of the solution near the end point.
Procedure:
Pipette out 10cm offerrous ammonium sulphate (FAS) solution into a 100 ml beaker.
Add one test tube full of dilute sulphuric acid. Immerse, the platinum calomel electrode
assembly in to the solution. Mcasure the potential by adding K,Cr0; solution from the burette
in increments of 0.5 cm². Stir the mixture for few seconds, and measure the potential of the
solution after each addition.
Plot a graph of AE / AV against volume of K;Cr:O, 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 litre of the solution
Report: Mass of FAS present in one dm of solution =
mVem-3
K;Cr:0, in cm'
CONDUCTOMERTIC TITRATION:
The electrical conductance (C) of a solution is a measure of the ability of a solution to
conduct electricity. It is expressed in Ohm -,mho's or Siemen (S) in SI units.
According to Ohm's law, current (I) flowing in a conductor is directly proportional to
cmf (E) and inversely proportional to resistance (R).
|=R
Therefore, the reciprocal of resistance is conductance. The
resistance of a homogencous
material of uniformcross section with an arca of 'a'sqg.cm and
length " cm is given by,
R= PI /A
Proportionality constant P is the spccific resistance.
The reciprocal of specific resistance is spccific conductance.
Specific conductance:( K)
Specific conductance is the conductance ofa solution present
betwcen 2 parallcl
clectrodes of arca lcm² which are kept lcm apart.
K= 1/R* Va Va =cell constant
When I =1, a=lcm², K =C
The unit of K in SI units is Sm!
The specific conductance of an electrolytic solution at any
temperature depends on
ions present and hence varies with ionic concentration. On
dilution, specific conductance
decreases as no of ions per ml also decrease.
Principle:
Electrolytic conductivity is a measure of the ability of a solution to carry electric current.
Electrolyte solutions conduct current by the migrations of ions under the influence of an
electric field. To measure the conductance of a solution, conductivity cell is placed.
INSTRUMENTATION:
A simple arrangement of consists of conductivity cell or conductance cell dipped in the
analyte solution taken in a beaker.
Conductivity cell consists of 2 platinum clectrodes, clectroplated with platinum black and a
conductance measuring device. The 2 electrodes have unit area of cross section and are
placed unit distance apart. The system responds readily to changes in concentration of
analyte.
NaOH + HCI NaCl + H,0
HCI
conductvity
meter
end point
The titrant is added from a burette and the solution is stirred. The conductance is measured
after the addition of the titrant in the increments of 0.5ml or one ml.
Applications:
Used to determine the solubility of sparingly soluble salts.
Determination of degree of dissociation.
Conductometric titrations.
Conductometric titrations:
In this method, the variation of electrical conductance of a solution during the course of a
titration is followed.
The principle of conductometric titrations is that ions ofa particular 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 conductance
against titre values.
ADVANTAGES:
Volume of NaoH(m).
Limitations:
Can be employed only when there is appreciable change in conductance during titration.
Redox titrations cannot be carried out.
Note: for observations and calculations refer lab manual(only acetic acid).
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