Corr and Prev
Corr and Prev
Corr and Prev
electrochemical Interpretation
Introduction
The surfaces of all metals (except gold) in air are covered with oxide films.
When such a metal is immersed in an aqueous solution, the oxide film
tends to dissolve. If the solution is acidic, the oxide film may dissolve
completely leaving a bare metal surface, which is said to be in the active
state. In near-neutral solutions, the solubility of the oxide will be much
lower than in acid solution and the extent of dissolution will tent to be
smaller.
M Mn+ + ne-
Atom in the metal surface ion in solution electron(s) in metal
The accumulation of negative charge on the metal due to the residual electrons
leads to an increase in the potential difference between the metal and the
solution. This potential difference is called the electrode potential which thus
becomes more negative. This change in the potential tends to retard the
dissolution of metal ions but to encourage the deposition of dissolved metal
ions from the solution on to the metal, i.e. the reverse of reaction(1).
RT
0 + ln a M n+
E r,Mn+/M = E Mn+/M
nF
Continuation ….
2H + + 2e- H2 (4)
adsorbed on metal surface in metal gas
The occurrence of reaction (4) permits the continued passage of an equivalent quantity of
metal ions into solution, leading to corrosion of the metal. Reaction (4) is also reversible
and has a reversible potential given by
P 1/2
0 RT H2
E = E - ln
r, H+/H2 H+/H2
nF a H+
Continuation ….
In neutral solutions, the concentration of hydrogen ions is too low to allow reaction
(4) to proceed at a significant rate, but electrons in the metal can react with oxygen
molecules, adsorbed on the metal surface from air dissolved in the solution, to
produce hydroxyl ions
O2 + 2H2O + 4 e- 4OH-
Adsorbed on metal surface in metal in solution (6)
P4 -
RT OH
E = E0 - ln
r, O2 / OH - O2 / OH
-
4F P O2
Electrochemistry of corrosion
For corrosion to take place, the formation of a corrosion cell is essentially
comprised of the following four components.
a) Anode
b) Cathode
c) Electrolyte
d) Metallic path.
Anode:
An anode is an electrode through which electric current flows in to a
polarized electrical device.
The misconception is that anode polarity is always positive (+). This is
often incorrectly inferred from the correct fact that in all electrochemical
device negatively charged anions moves towards the anode (or oppositely
charged cations move away from it). Anode polarity depends on the device
type and sometimes even in which mode it operates.
Cathode:
One of the two electrodes in an electrolytic cell represented as a positive
terminal of a cell. Reduction takes place at the cathode and electrons are
consumed.
Electrolyte:
It is the electrically conducting solution (e.g. salt solution) that must be present for corrosion
to occur. Note that pure water is a bad conductor of electricity. Positive electricity passes
from anode to cathode through the electrolyte as cations, e.g. Zn++ ions dissolve from a zinc
anode and thus carry positive current away from it, through the aqueous electrolyte.
Metallic Path:
The two electrodes are connected externally by a metallic conductor. In the metallic
conductor, 'conventional' current flows from (+) to (—) which is really electrons flowing
from (—) to (+). Metals provide a path for the flow of conventional current which is actually
passage of electrons in the opposite direction.
Current Flow:
Conventional current flows from anode (—) to cathode (+) as Zn++ ions
through the solution. The current is carried by these positive charged ions.
The circuit is completed by passage of electrons from the anode (—) to the
cathode (+) through the external metallic wire circuit (outer current).
Mechanism of corrosion
Temperature Corrosion
Type I
Uniform or General
Galvanic or Two-metal
Crevice
Pitting
Intergranular
Velocity-assisted
Environment-assisted cracking
UNIFORM CORROSION
Corrosion over the entire exposed surface at a uniform rate. e.g.. Atmospheric
corrosion.
Maximum metal loss by this form. Not dangerous, rate can be measured in the laboratory.
GALVANIC CORROSION
When two dissimilar metals are joined together and exposed, the more active of the two
metals corrode faster and the nobler metal is protected. This excess corrosion is due to the
galvanic current generated at the junction.
Prevention of galvanic corrosion:
Cavitation Damage :
Cavitation is a special case of Erosion-corrosion. In high velocity
systems, local pressure reductions create water vapour bubbles which
get attached to the metal surface and burst at increased pressure,
causing metal damage
Environment Assisted Cracking:
When a metal is subjected to a tensile stress and a corrosive medium, it may experience
Environment Assisted Cracking. Three types:
1) Stress Corrosion Cracking
2) Hydrogen Embrittlement
3) Liquid Metal Embrittlement
Temperature corrosion:
Generally corrosion rates increase with increases in temperature. This is due to
several interrelated factors:
1. Higher temperatures tend to promote the corrosion reaction kinetics. Therefore
except in cases where oxygen is free to escape, higher temperatures boost the
corrosion rate.
2. Corrosive by products will have a higher diffusion rate at higher temperatures
and thus will be delivered to the corroding surface more efficiently.
(a) High Temperature corrosion
(b) Low temperature corrosion
High temperature corrosion
High temperature corrosion is a form of corrosion that does not
require the presence of a liquid electrolyte. Sometimes, this type of
damage is called "dry corrosion" or "scaling".
High temperature metals requires neither moisture nor dissolved
electrolytes (salts, acids) to proceed.
1. Reduction of metal thickness leading to loss of mechanical strength and structural failure or
breakdown.
2. Hazards or injuries to people arising from structural failure or breakdown (e.g. bridges,
cars, aircraft).
3. Loss of time in availability of profile-making industrial equipment.
4. Reduced value of goods due to deterioration of appearance.
5. Contamination of fluids in vessels and pipes (e.g. beer goes cloudy when small quantities
of heavy metals are released by corrosion).
6. Perforation of vessels and pipes allowing escape of their contents and possible harm to the
surroundings.
7. Loss of technically important surface properties of a metallic component.
8. Mechanical damage to valves, pumps, etc, or blockage of pipes by solid corrosion products.
10) Buried gas or water supply pipes can suffer severe corrosion which is not
detected until an actual leakage occurs, by which time considerable damage may be
done.
11) In electronic equipment it is very important that there should be no raised resistance at
low current connections.
12) The lower edge of this aircraft skin panel has suffered corrosion due to leakage and
spillage from a wash basin in the toilet.
13) Sea water is a highly corrosive electrolyte towards mild steel. This ship has suffered
severe damage in the areas which are most buffeted by waves, where the protective coating
of paint has been largely removed by mechanical action
Prevention of
corrosion
There are many methods of protecting metals against corrosion.
They are
1) Barrier protection
2) Sacrificial protection
3) Cathodic protection.
Barrier protection :
Here, a thin barrier is developed between the surface of iron and
atmosphere by one of the following methods:
a) Painting of the surface
b) Coating the surface with a thin film of oil or grease
c) Developing a thin layer of some non –corrosive metal like nickel,
chromium copper etc., by electroplating.
Sacrificial protection:
In this case, the surface of iron is covered with a more electropositive metal like
zinc or aluminum. Since this metal loses electrons more readily than iron, rusting
is prevented. As long as metal is present, iron does not get rusted. This type of
protection is called ‘sacrificial production’.
Cathodic protection (Electrical protection):
This method is especially used for underground iron pipes. Here, the iron
pipe or tank is connected to a more electropositive metal like magnesium or
aluminum. The more electropositive metal acts like anode (supplies electrons) and
iron acts like cathode (receives electrons). Thus, iron is protected by turning it as a
cathode. Hence, the method is called ‘cathodic protection’ .
Conditioning the Metal
By retarding either the anodic or cathodic reactions the rate of corrosion can
be reduced. This can be achieved in several ways:
This can be sub-divided in to two main groups:
(a) Coating the metal
(b) Alloying the metal