APPLED CHEMISTRY FOR ME (BCHEM 102/202)

MODULE 2

CORROSION SCIENCE AND ENGINEERING

Corrosion:

Introduction:

Corrosion is defined as “the destruction or deterioration of metals or alloys by the surrounding

environment through chemical or electrochemical reactions”.

Corrosion returns the free metal to its oxidized state or combined state in chemical compounds that are
similar or even identical to the minerals from which the metals are extracted.

In simple corrosion and metal extraction can be regarded as

Corrosion can be fast or slow depending on metal and environment.

e.g.: (i) Rusting of iron – a reddish brown scale formation on iron and steel objects

(ii) Green scales formed on copper vessels due to formation of basic cupric carbonate [CuCO3
+ Cu (OH) 3]

Corrosion may occur either in dry environment or in aqueous medium.

Why do metal undergoes corrosion:

Pure metals are relatively under higher energy state compared to their corresponding ore.

They have natural tendency to revert back to their combined state.

Therefore, when metals are put to use in different forms, they combined with the components of
environment and get converted into their compounds.

Corrosion damage:

 Poor appearanc

1
DEP. OF CHEMISTRY/ EWCE
APPLED CHEMISTRY FOR ME (BCHEM 102/202)

 Maintenance and operating cost is more

 Plant shut down
 Contamination of product
 Loss of valuable product due to leakage
Dry corrosion (Chemical corrosion): It occurs by direct attack of atmospheric gases such as oxygen,
hydrogen sulphide, halogens and sulphur dioxide on the metal forming oxide layer (chemical reaction).
It occurs in the absence of moisture.

Rate of dry corrosion depends on metal, environmental agent and corrosion product formed.

Wet corrosion (Electrochemical corrosion): Wet corrosion occurs in presence of an aqueous solution
of electrolyte and atmospheric oxygen by setting up of tiny galvanic cells on the metal surface.

Electrochemical Theory of Corrosion:

According to this theory, when a metal such as iron, is exposed to atmospheric air, the following
electrochemical changes occur gradually.

Formation of galvanic cells: Anodic and cathodic areas are formed resulting in minute galvanic cells.

Anodic reactions: At the anodic area, oxidation takes place resulting in the corrosion of iron.

Fe Fe2+ + 2e-

Cathodic reactions: The electrons flow from anodic to cathodic areas and cause reduction. There are
three possible ways in which the reduction can take place.

 If the solution is aerated and almost neutral, oxygen is reduced in presence of water to form
OH- ions according to the equation.

 If the solution is deaerated and almost neutral, water is reduced to H 2 and OH-.

2
DEP. OF CHEMISTRY/ EWCE
APPLED CHEMISTRY FOR ME (BCHEM102/202)

 If the solution is deaerated and almost acidic, the H+ ions are reduced to H2

The metal ions (formed at the anode) combine with the OH- ions to form the metal hydroxide and
finally the hydrated metal oxide (rust).

Types of corrosion:

Differential metal corrosion (galvanic corrosion):

When dissimilar metals (different potentials) like iron and copper are electrically connected and are
exposed to a neutral environment in the presence of oxygen, the metal of lower reduction potential in
the electrochemical series undergoes spontaneous oxidation and corrosion.

DEP. OF CHEMISTRY/ EWCE 3

APPLED CHEMISTRY FOR ME (BCHEM102/202)

The mechanism of differential metal corrosion is illustrated in the below figure. In this iron is contact
with copper and is immersed in a corrosive environment. Iron metal, being lower reduction potential
in the electrochemical series acts as anode area and gets corroded. But copper metal having higher
reduction potential behaves as cathodic area of the dissimilar metals. The tendency of a metal to
corrode in a galvanic cell is determined by its position in the galvanic series of metals. As a result of
this, corrosion current is pushed from the anodic area to the cathodic area by the driving force which
is due to the potential difference between the two

DEP. OF CHEMISTRY/ EWCE 4

APPLED CHEMISTRY FOR ME (BCHEM102/202)

(Note: difference between the electrode potentials of the two metal, the greater the difference the higher
the driving electric force)

Differential aeration corrosion:

We find a situation where a metal is exposed to different oxygen environment. The mechanism of
corrosion of such metals can be explained by differential aeration corrosion.

Differential aeration corrosion occurs when one part of the iron metal is exposed to different air or oxygen
concentration from the rest of the part as shown in figure. It can be noted that a portion of the metal surface
exposed to less oxygen concentration acts as an anodic area and gets corroded, while the more oxygenated
part of the metal is protected because it behaves as a cathodic area of corrosion cell.

DEP. OF CHEMISTRY/ EWCE 5

APPLED CHEMISTRY FOR ME (BCHEM102/202)

Electrons pass from the bottom of the strip to the top of the strip. The corrosion product (rust) is formed
between the anodic and cathodic areas and not on the active electrode surface. The anodic and cathodic
reactions are

Typical examples of differential aeration corrosion are

Water line corrosion

Pitting corrosion

Water line corrosion:

It is differential aeration type of corrosion observed in water storage tanks, ships, etc. During water line
corrosion, the part of the metal below the water line is exposed only to the dissolved oxygen while the
part above the water is exposed to higher oxygen concentration of the atmosphere. Thus part of the metal
below the water acts as the anode (less oxygenated) and undergoes corrosion and the part above the water
line acts as the cathode (more oxygenated) and is unaffected. The anodic area moves gradually upwards
and entire tank corrodes with an intense corrosion (creep) just below the waterline. The size of the creep
determines the rate of corrosion.

DEP. OF CHEMISTRY/ EWCE 6

APPLED CHEMISTRY FOR ME (BCHEM102/202)

Ex: This type of corrosion is commonly observed in ships floating in sea water for long period of time.

Pitting corrosion:

Pitting corrosion occurs when small particle like dust, mud etc get deposited on clean metals surface. The
portion of metal covered by the dust or other particles is less aerated and acts as anode. The other portion
of the metal exposed to more oxygen of the environment act as cathodic region. Corrosion takes place at
the portion below dust and a small pit is formed.

Once a pit is formed, the corrosion progresses rapidly, this is because due to small anodic area and large
cathodic area.

DEP. OF CHEMISTRY/ EWCE 7

APPLED CHEMISTRY FOR ME (BCHEM102/202)

Stress corrosion:

This type of corrosion is observed at stress points (riveting, welding, bending, pressing) of metal or alloy
in a corrosion environment.

Atoms of the metal in the stressed area are in their higher energy state. Hence stressed areas have higher
oxidation potential and are more reactive than those in unstressed areas. In a corrosive environment, the
stressed area becomes anode to stress free surface .Thus the stressed area undergoes corrosion.

An example of stress corrosion is intercrystalline corrosion or caustic embrittlement in boilers.

Inter crystalline corrosion or caustic embrittlement: This type of stress corrosion occurs in mild
steelboilers at 10 to 20 atmosphere pressure due to the presence of alkaline impurities in boiler water.

Na2CO 3 + H2O 2 NaOH + CO 2

In boiler, metal at stressed points like rivets, joints, bends etc will have minute hair cracks. These cracks
are very thin, irregular and alkaline impurities passes into the cracks by capillary action. Later water
evaporates leaving behind caustic soda in the cracks. When the concentration of caustic soda reaches to
10%, an electrochemical cell is set up between the iron under stress and the iron in the main body. The
iron of main boiler body surrounded by dilute NaOH is the cathode and the iron under stress which is in
contact with concentrated alkaline impurities act as the anode & get corroded resulting in boiler failure.

DEP. OF CHEMISTRY/ EWCE 8

APPLED CHEMISTRY FOR ME (BCHEM102/202)

Corrosion control:

Corrosion can be controlled by preventing the formation of galvanic cells. The methods commonly used
to control corrosion of metals are the following.

Formation of protective coating

 Inorganic coating
 Metal coating
 Cathodic protection
Inorganic coating:

Anodizing:

Anodizing is a process of artificially converting protective passive oxide film on the surface of metals
such Al, Zn, Mg, Ti, Zr, Ta, Cr, etc by electrochemical oxidation.

Anodizing aluminium:

 Pretreatment: The article be anodized is degreased and followed by electro polished

 Aluminum is connected to positive terminal i.e., made as anode.
 Steel or copper is made as cathode
 The anode and cathode are dipped in electrolyte solution containing 5-10% chromic acid.
 The temperature of the both is maintained at 35oc
 Voltage is applied between 0-50V.
 First ten minutes potential is increased to 0-40V.
 After 20 minutes voltage is applied from 40-50V
 A thin oxide layer (Al2O3.H2O) of 2-8 microns thickness is obtained.
 Higher thickness is obtained by addition of 10% H2SO4 at 220C and maintaining a potential of 24
V.

DEP. OF CHEMISTRY/ EWCE 9

APPLED CHEMISTRY FOR ME (BCHEM102/202)

Further the article is dipped in aqueous solution of dye at 50-600C which gives color.

Applications: Widely used in industrial, commercial and domestic materials like air craft, window frames
utensils, roofs, ceilings, computer hardware, scientific instruments etc.

Metal coatings:

Corrosion of metals can be controlled by isolating them from the environment. This can be brought about
by the covering the substrate or base metal with a layer of another metal. The process is referred to as
metal coating.

Galvanization (anodic metal coating):

Galvanization is a process of coating a base metal with more active metals which are anodic to the base
metal.

Ex: coating of more active Zn metal on base metal iron

The process of coating zinc on iron by hot dipping is called galvanizing. It is carried as follows.

 The iron sheet is subjected to pretreatment by degreasing with organic solvents.

 The sheet is passed through dilute sulphuric acid (pickling) to remove rust and other deposition
and rinsed with water.
 The sheet is treated with a mixture of aqueous solution of zinc chloride and ammonium chloride
to prevent the oxidation of zinc and dried
 The treated sheet is dried and dipped in molten zinc at 430 0 -4700C.

DEP. OF CHEMISTRY/ EWCE 10

APPLED CHEMISTRY FOR ME (BCHEM102/202)

 Excess Zinc is removed by rolling, wiping or passing blast of air.

Cathodic protection:

Cathodic protection is a method of protecting a metal or alloy from corrosion by converting it completely
into cathode and no part of it allowed acting as anode.

The corrosion of the metal takes place at the anodic region whereas at the cathodic region, the metal is
unaffected. Therefore, corrosion can be prevented by eliminating the anodic sites and converting the entire
metal into cathodic area.

Cathodic protection can be achieved by the following methods.

Sacrificial anode method:

In this method the metal to be protected is connected by a wire to more anodic metal. More anodic metal
undergoes corrosion supplying electrons to the base metal thereby making the base metal as cathode and
protecting the base metal. The more anodic metals get corroded and hence are called sacrificial anodes.
So, this is called as sacrificial anode method. After continuous use these sacrificial anodes have to be
replaced.

Base metals: - Fe, Cu and alloys like brass. Anodic metals: - Mg, Zn and Al.

DEP. OF CHEMISTRY/ EWCE 11

APPLED CHEMISTRY FOR ME (BCHEM102/202)

Ex: Sacrificial anode method is used to protect buried pipe lines, ship hull, industrial water tanks and steel
rods in R.C.C by connecting to a more anodic metal using a wire.

Corrosion testing by weight loss method:

Sample preparation:

 Polish testing samples to get mirror like surface

 Measure and determine the surface area of testing samples
 Wash the samples with acetone and flowing water respectively to remove all grease. Place samples
on filter paper to absorb and remove the surface water. Then cover the sample with filter paper
and dry it in a drying oven at 105 degree Celsius for 24 hours
 Weigh the samples and record it.
Solution preparation:

Sl. No solution volume

1 20% H2SO4 400 ml
2 2% H2SO4 400 ml
3 20% NaCl 400 ml
4 6% NaCl 400 ml

 Use nylon cord to hang testing samples. Immerse completely the samples into the various beakers
containing the solutions listed above.

DEP. OF CHEMISTRY/ EWCE 12

APPLED CHEMISTRY FOR ME (BCHEM102/202)

 Remove samples after exactly 5, 10, 15, 20, 25 and 30 days and wash them with tap water.
Removing corrosion product:

 Wash samples with 12% HCl

 Wash samples from step above by acetone and deionized water respectively. Place samples on
filter paper to absorb surface water. Then cover the sample with filter paper and dry it in an oven
for 3 hours
 Weigh and record the weight loss of the testing sample after drying

Corrosion penetration rate (CPR):

The corrosion penetration rate (CPR) is defined in three ways:

The speed at which any metal in a specific environment deteriorates due to a chemical reaction in the
metal when it is exposed to a corrosive environment.

The amount of corrosion loss per year in thickness.

The speed at which corrosion spreads to the inner portions of a material.

The speed or rate of deterioration depends on the environmental conditions and the type and condition of
the metal under study.

Corrosion penetration rate may also be known as corrosion rate. 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).

The density of the metal.

The total surface area initially present.

The time taken for the metal to corrode.

The CPR is calculated as follows:

CPR = (k x W) / (D x A x T) OR Corrosion penetration rate = K (ai/nD)

DEP. OF CHEMISTRY/ EWCE 13

APPLED CHEMISTRY FOR ME (BCHEM102/202)

where k = a constant

W = total weight lost

T = time taken for the loss of metal

A = the surface area of the exposed metal

D = the metal density in g/cm³

i= current density

n= valency change

The CPR is conveniently expressed in terms of either mils (1/1000 inch) per year (mpy) or millimeters per
year (m/yr).

CPR in mpy CPR mm/yr

K 534 87.6

W (wt loss) mg mg

ρ or D g/cc g/cc

A inch2 cm2

T or t Hrs Hrs

The corrosion penetration rate is best expressed in terms of thickness or weight loss where the surface of
the metal corrodes uniformly across an area.

DEP. OF CHEMISTRY/ EWCE 14

APPLED CHEMISTRY FOR ME (BCHEM102/202)

This method involves the exposure of a weighed piece of test metal or alloy to a specific environment for
a specific time. This is followed by a thorough cleaning to remove the corrosion products and then
determining the weight of the lost metal due to corrosion.

The rate may vary if the rate expressed by the formula above is used to compare corrosion rates for a
period of time longer than one year with rates calculated over short periods. This is because the short time
periods are prone to fluctuating environmental changes from season to season and also from day to day.

Numerical problems on CPR:

1. A piece of corroded metal alloy plate was found in a submersed ocean vessel, it was estimated that
the original is plate was 800 cm2 and that approximately 7.6 Kg had corroded a way during the
submersion, assuming a corrosion penetration rate of 4 mm/yr for this alloyin seawater, estimate
the time of submersion in years, the density of alloy is 4.5 g/cm3.
Solution:

CPR = (k x W) / (D x A x T)T = (k

x W) / (D x A x CPR)

W = weight loss = 7.6 Kg = 7.6 x 106 mgD = density of alloy = 4.5 g/cm3.

A = Exposed specimen area = 800 cm2

CPR =4 mm/Yr

CPR Value given in the unit of mm/Yr so the value of K = 87.6

T = (87.6 x7.6 x 106 mg) / 4.5 g/cm3 x 800 cm2 x 4 mm/Yr

= 46233 3 hrs / (365X24)

T = 5.27 year

DEP. OF CHEMISTRY/ EWCE 15

APPLED CHEMISTRY FOR ME (BCHEM102/202)

2. A sheet of carbon steel one-meter-wide by three meters long has lost 40gto corrosion over the past
six months. Convert that mass loss to a penetration rate of the steel in mmunits and mpy units.
What would be the corrosion rate? (Carbon steel density=7.8g/cc)
To calculate CPR in mm/yr

Given CPR mm/yr

K = 87.6

W = 40g = 40X1000 mg

ρ or D = 7.8g/cc = 7.8 g/cc

A = 1mx3m = 3m2 = 3x100X100 cm2

T = 6 months = 6x30X24 hrs

CPR = (k x W) / (D x A X T)

CPR = 87.6 X 40 X 1000mg / (7.8g/cc x 3x100x100 cm2 x 6x30x24 hrs)

= 3.466 X10-3 mm/yr

CPR = 0.003466mm/yr

To calculate CPR in mpm/yr

Given CPR in

K = 534

W = 40g = 40 x 1000 mg

ρ or D = 7.8g/cc = 7.8 g/cc

DEP. OF CHEMISTRY/ EWCE 16

APPLED CHEMISTRY FOR ME (BCHEM102/202)

A = 1mx3m =3m2 = 3 x1550 inch2t

= 6 months = 6 x 30 x 24 hrs

(1 sq mt= 1550 sq inch)

CPR = (k x W) / (D x A x T)

CPR=534 X 40 X 1000mg / (7.8g/cc x 3 x1550 inch2 x 6x30x24hrs)

CPR = 0.1363m

Metal finishing:

“Metal finishing defined as the modification of the surface properties of metal by deposition of
layer ofanother metal or a polymer or by the formation of an oxide film”.

The principles of metal finishing are used in the Electroplating of metals, alloys and composites.
Manufacture of electronic components such as printed circuit boards, capacitors and plating of metal
over cheap materials like plastics and other insulators.

Important electrochemical metal finishing techniques are

Electroplating of metals, alloys and composites

Electroless plating of metals, alloys and composites

Technological Importance of metal finishing:

 Metal finishing is carried out to give a decorative surface and

 To impart the following desirable characteristics to metals, alloys or composites. These include
(i) to offer corrosion resistance
(ii) to impart abrasion and wear resistance
(iii) to impart thermal resistance and resistance to impact

DEP. OF CHEMISTRY/ EWCE 17

 APPLED CHEMISTRY FOR ME (BCHEM102/202)

(iv) to provide electrical and thermal conduction

(v) to offer the surface a thermal or optical reflectivity
(vi) In the manufacture the electrical and electronic components such as printed circuit boards
(PCB), capacitors and contacts.
(vii) to manufacture the metal articles entirely by electroplating
(viii) to reproduce finely engraved dies or similar finely divided articles such as gramophone records
and In electrochemical machining, polishing and etching.

Electroplating:

Electroplating or Electro deposition is a process by which a thin and uniform metal is deposited on
metal or alloy by passing a current through an electrolytic solution containing the metal ions to be
deposited.

Factors affecting nature of Electro deposit:

The nature of electro deposit is affected by several factors.

1. Current Density: It is the current per unit area of the electrode surface. When current density is low
metal is deposited slowly providing adequate time for the metal nuclei to growand with little scope for
the creation of fresh nuclei. Thus the deposits produced are gross grained.
When current density is increased, the rate of electro deposition increases but crystal size decreases.
Thedeposit produced in that range will be fine grained and uniform. When the current density is high
the rate of deposition is high, but deposition is loose, rough and brittle. Therefore an optimum current
density is used to obtain a fine and smooth deposits.

2. Plating Bath:The plating bath contains a solution of the metal salt. Other electrolytes, complexing agents
& various organicadditives are added to improve the nature of deposit.
3. Metal ions: The metal ion concentration is usually 1-3 mol/dm3. Higher concentrations increase the
masstransfer leading to poor deposit.
4. Other electrolytes: Other electrolytes are added to increase the conductivity of the plating bath. They
do not participate in the electrode reactions but increase the conductivity of the plating and control the

DEP. OF CHEMISTRY/ EWCE 18

 APPLED CHEMISTRY FOR ME (BCHEM102/202)

change in pH.
5. Complexing agent: The metal ion is converted into complex ion by the addition of a suitable
complexingagent to get a fine and more adherent deposit.
Ex: Cyanides, Hydroxides and Sulphamates.

6. Organic additives: These modify the structure, morphology and properties of electrodeposits. These
includes
Brighteners: brighteners are added to produce microscopically fine deposits on the surface.

Ex: Aromatic sulphones/sulphonates and molecules containing CN, NCS or CO groups.

Levelers: Levelers helps to produce an evenly deposited surface by getting adsorbed at regions where
rapiddeposition takes place.

Ex: Sodium allyl sulphonates for Ni deposition. Many brighteners also act as levelers.

Structure Modifiers (Stress relievers): Structure modifiers modify the structure of the deposit in such a
way as to alter the deposit properties. Electrodeposits are associated with internal stress and give way
impact if the stress level is too high; this result in the micro cracking of the deposits.

Ex: Saccharin is used as stress reliever

Wetting agents: During electroplating H2 gas is evolved at the cathode. Wetting agents are added to
release the H2 gas bubbles from the surface. They also improve the levelling and uniformity of the deposit
and reduce its brittleness. In the absence of wetting agents, the gas bubbles get entrapped within the plated
metal and try to escape after the plating. This makes the substrate metal brittle.

Ex: Sodium lauryl sulphate is a good wetting agent.

pH: At low pH, evolution of H2 gas occurs at the cathode resulting in a burnt deposit. At higher pH,
electrode surface gets coated with insoluble hydroxides. Therefore a pH range of 4 to 8 is used. P H is
maintained by adding a suitable buffer to the plating process.

Ex: Borate buffer for Ni plating & Citrate buffer for Gold plating.

DEP. OF CHEMISTRY/ EWCE 19

APPLED CHEMISTRY FOR ME (BCHEM102/202)

Temperature: High temperatures lead to H2 gas evolution at the cathode, corrosion of equipment and
sometimes decomposition of the organic additives. At moderate temperatures, surface diffusion is more
than H2 gas evolution and a good deposit is obtained. Hence plating of metals is generally carried out
between 35 to 60 OC.

Throwing power: Throwing power of a plating bath has been used as a measure of the uniformity in the
distribution of the deposit on different parts of an article. It is defined as “the degree of uniformityof metal
distribution or evenness of deposit thickness obtained on a cathode of irregular shape”

Electroplating of Chromium:

Chromium is also one of the widely used metals for electroplating. In the field of electroplating two
types of chromium are employe

Decorative chromium

Hard chromium

Decorative chromium:

A thin deposit of chromium (0.25- 0.75µm) is applied over nickel undercoat. It confers a pleasing look
and non tarnishing nature to the plated article

Plating bath: chromic acid (CrO3) and H2SO4 in 100:1 proportion should contain trivalent chromium
and oxalic acid

Operating temperature: 45-60oCCurrent density: 145-430A/ft2 Current efficiency: 8-12%

Anode: Insoluble anodes-Pb-Sb or Pb-Sn coated with PbO2 or stainless steel

Cathode: Object to be plated- Pretreated

Application: Decorative and corrosion resistant finish

DEP. OF CHEMISTRY/ EWCE 20

APPLED CHEMISTRY FOR ME (BCHEM102/202)

The amount of Cr3+ ions should be restricted in order to obtain good deposit. Insoluble anodes like Pb-Sb
or Pb-Sn alloys covered with a layer PbO2 which oxidize Cr3+ to hexavalent Cr are used thus controlling
the Cr3+ion concentration.

Hard chromium:

Hard chromium plating involves deposition of a thick coating of chromium directly over the substrate.
The usual thickness of chromium is 2.5- 300 µm

Plating bath: chromic acid (CrO3) and H2SO4 in 100:1 proportion should contain trivalent chromium

Operating temperature: 45-60oCCurrent density: 290-580A/ft2

Current efficiency:17-21%

Anode: Insoluble anodes-Pb-Sb or Pb-Sn coated with PbO2 or stainless steel

Cathode: Object to be plated- Pretreated

Chromium anodes are not used in Cr plating because

This is because of the wide difference b/n anode and cathode efficiency

The anode efficiency is nearly 100% but cathode efficiency is at best around 20%

This means the metal going into solution is five times of the metal getting deposited, resulting in
building up of excessive chromic acid concentration.

This leads to imbalance of bath composition with respect to Cr(III) and Cr(VI) ratio, both of which are
important factors in deciding the nature of the deposit.

Applications

It is mainly used in automobile industry as decorative & protective coating.

DEP. OF CHEMISTRY/ EWCE 21

APPLED CHEMISTRY FOR ME (BCHEM102/202)

Electroless Plating:

Electroless plating is a method of depositing a metal or alloy over a substrate bycontrolled reduction
of the metal ions by a suitable reducing agents without electrical energy.

Reducing agent converts to metal ions (Mn+) to the metal (M) which get plated over the catalytically
active

In electroless plating, driving force is auto catalytic redox reaction on a pretreated active surface.
Thepretreatment is done by one of the following techniques.

Composition of Electroless plating bath:

A typical electroless plating bath consists of the following components.

 Electrolyte: Soluble electro active metal salt.

 Reducing agent (hypophosphites formaldehyde, hydrazine )
 Complexing agent (Citrate, tartrate, Succinate) – to improve the quality of the plating.
 Exaltant ( Succinate, glycinate, fluoride) – to increase the rate of plating
 Stabilizer (Pb, Ca, Th, thiourea) –to prevent the instability of the bath.
 Buffer ( to control the pH)

Advantages of Electroless Plating over Electroplating:

 Use of electrical power and electrical contacts are eliminated.

 Semi conductors and insulators like plastics can be plated.
 Electroless baths have better throwing power. Complicated parts with irregular shapes, inside
parts oftubes can be uniformly coated.
 H2 gas liberated is not trapped in holes.

DEP. OF CHEMISTRY/ EWCE 22

APPLED CHEMISTRY FOR ME (BCHEM102/202)

 Electroless coatings are harder.

 No levellers are required.
 Deposits have unique chemical, mechanical & magnetic properties.

Distinction between electroless plating and electroplating:

Particulars Electroplating Electroless plating

Driving force Electric current Redox reaction
Cathodic reaction 𝑀𝑛+ + 𝑛𝑒 − → 𝑀 𝑀𝑛+ + 𝑛𝑒 − → 𝑀
Anodic reaction 𝑀 → 𝑀𝑛+ + 𝑛𝑒 − Reducing agent oxidized
product + 𝑛𝑒 −
Site of cathodic reaction Substrate surface Substrate surface catalytically
prepared
Site of anodic reaction Separate anode Reducing agent in the
solution
Applicability Only for conductors Conductors, semiconductors
and insulators
Nature of deposit Porous Non porous

Electroless plating of Nickel:

Nickel will deposit spontaneously in presence of a suitable reducing agent on metals such as gold, silver,
platinum, palladium, rhodium, iron, cobalt and nickel. Insulators like plastics and glass are to be activated
before subjecting to electroless plating.

Electroless nickel plating is done in baths containing nickel salts. Radium hypophosphite and buffering
agents. The formulas of the plating solutions are based on two types of baths, alkaline and acid. In suitable
temperature and pH ranges nickel is deposited from these baths onto metallic surface immersed in the
solutions. The nickel coatings produces by the electroless method vary in appearance from a dull gray to
shiny lustre depending on the plating conditions. The variation of plating rate with temperature and with
the concentration of the chemical components has been studied.

DEP. OF CHEMISTRY/ EWCE 23

APPLED CHEMISTRY FOR ME (BCHEM102/202)

Pretreatment and Activation of the surface:

The plastic board is degreased and etched in acid. It is activated by dipping in SnCl2 solution containing
HCl at 25OC followed by dipping in PdCl2. Then the surface is dried to get layer of palladium.

Procedure:

Plating bath solution:

Electrolyte : a solution of NiCl2(20g/lt)

Reducing agent: sodium hypophosphate(20g/lt)

Buffer: sodium acetate(10g/lt)

Complexing agent: sodium succinate

P H: 6.5

Temperature: 25 ̊ C

Reactions:

H2PO2- +H20 H2PO3- +H2

Ni2+ +H2 Ni + 2

DEP. OF CHEMISTRY/ EWCE 24

APPLED CHEMISTRY FOR ME (BCHEM102/202)

DEP. OF CHEMISTRY/ EWCE 25