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17 views65 pages

Compiled Corrosion Documents

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firefireone.mail
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Module 3: Corrosion

Definition:

Corrosion is defined as the destruction or decomposition of metals and alloys by their surrounding

environment through chemical or electrochemical changes.

Note:

- Usually, metals undergo corrosion by oxidation (loss of electrons).

Types of Corrosion

1. Dry (or Direct) Chemical Corrosion:

- Caused by direct chemical attacks of dry gases like O2, Cl2, or SO2 present in the environment.

- Occurs through chemical reactions on the metal surface without the presence of moisture.

Example:

- Direct attack of metal by air (oxygen) to form oxide layers on the metal surface.

2. Electrochemical Corrosion:

- Occurs when a metal is placed in an aqueous medium (water) in the presence of moist air.

- Involves electrochemical reactions leading to corrosion.

Example:

- Rusting of iron.

Illustration (Electrochemical Corrosion):

- Example: Iron rod in aqueous conditions.

- The corrosion process includes oxidation at anode sites and reduction at cathode sites.
Differential or Galvanic Corrosion

Key Concept:

- When two dissimilar metals are in contact with each other, a potential difference is set up between the me

- The metal higher in the galvanic series acts as the anode and undergoes corrosion due to its lower electro

- The metal lower in the galvanic series acts as the cathode and is protected from corrosion due to its highe

Process Explanation:

1. Anodic Reaction:

At the anode, the metal (higher in the galvanic series) undergoes oxidation.

Reaction: Fe -> Fe2+ + 2e- (Oxidation)

2. Cathodic Reaction:

At the cathode, reduction occurs, and the cathodic metal is protected.

Reaction: Cu2+ + 2e- -> Cu (Reduction)

Example:

- Setup: Iron (Fe) and Copper (Cu) in a neutral, aerated solution of NaCl.

* Anode: Iron (Fe)

- Oxidation occurs, releasing Fe2+ ions into the solution.

* Cathode: Copper (Cu)

- Reduction occurs, depositing Cu from Cu2+ ions in the solution.

Summary:

- The flow of electrons from the anode to the cathode results in the corrosion of the anode.

- Diagram Description: The setup illustrates the flow of electrons from Fe (anode) to Cu (cathode) in

the electrolyte.
Differential or Galvanic Corrosion: Examples

Key Explanation:

- Experimental Setup:

* Two dissimilar metals, Iron (Fe) and Copper (Cu), are placed in a neutral, aerated solution of sodium chl

* Fe (Anode): Acts as the anode due to its low electrode potential and undergoes corrosion.

* Cu (Cathode): Acts as the cathode due to its high electrode potential and remains free from corrosion.

1. Reaction at the Anode:

Fe -> Fe2+ + 2e- (Oxidation)

2. Reaction at the Cathode:

Cu2+ + 2e- -> Cu (Reduction)

Observation:

This type of corrosion is common when two dissimilar metals are in electrical contact within a

conductive electrolyte.

Additional Example:

- Setup:

* A piece of iron metal is combined with zinc and exposed to a corrosive environment.

* Zinc (Zn): Acts as the anode and undergoes corrosion.

* Iron (Fe): Acts as the cathode and remains free from corrosion.

Anodic Reaction: Zn -> Zn2+ + 2e-

Cathodic Reaction: Fe2+ + 2e- -> Fe

Electrons flow from zinc to iron, as illustrated in the diagram.


Diagram Description:

1. Iron and Zinc:

- Zinc serves as the anode, releasing electrons, while iron serves as the cathode, re

- A conductive electrolyte ensures the flow of ions between the two metals.

2. Iron and Copper:

- Similar reactions occur, with iron acting as the anode and copper as the cathode.
Corrosion in Mild Steel Water Tanks and Ships

Key Concept:

- This type of corrosion is explained by the differential aeration theory, where:

* Less aerated areas (lower oxygen concentration) act as the anode and undergo corrosion.

* More aerated areas (higher oxygen concentration) act as the cathode and are protected.

Process Explanation:

1. Anodic Reaction:

Reaction: Fe -> Fe2+ + 2e- (Oxidation)

2. Cathodic Reaction:

Reaction: 1/2O2 + H2O + 2e- -> 2OH- (Reduction)

Examples of Corrosion:

1. Mild Steel Water Tanks:

- The less aerated portion (bottom or submerged parts) acts as the anode and corro

- The more aerated portion (near the surface) acts as the cathode and is protected.

- Commonly observed in water tanks used for storage.

2. Ships:

- The portion of the ship submerged in water is less aerated and acts as the anode,

- The portion of the ship above the water surface is more aerated and acts as the ca

Diagram Description:

- Anode: Represents the submerged part of the tank or ship with lower oxygen conce

- Cathode: Represents the part above the water level with higher oxygen concentratio

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