QUESTION AND ANSWER OF CORROSION 5. What is Pilling bedworth rule?

PART - A The ratio of the volume of the metal oxide formed to the
1. Define corrosion
volume of metal is known as Pilling – Bedworth rule. According to
Corrosion is defined as the gradual destruction of a metal or this, If the volume of the oxide layer formed is less than the
alloy by the chemical or electrochemical reaction with its volume of the metal, the oxide layer is porous and non protective.
environment. Examples: Na, Mg, Ca
If the volume of the oxide layer formed is greater than the
2. Why do metals undergo corrosion?
volume of the metal, the oxide layer is non porous and protective.
Most of the metals (except noble metals) naturally exist in Examples: Pb, Sn
combined form. During metallurgy metals are extracted from the
ores by reduction. In pure metallic state these are unstable and
6. What is H2 embrittlement?
considered to be in the excited state. So these metals have a
When metals comes in contact with H2S at ordinary temperature
tendency to attain stable state, which is known as corrosion. causes evolution of atomic hydrogen .This atomic hydrogen
diffuses into the metal and collects in the voids, where it
3. What are the types of corrosion? recombines into molecular hydrogen developing very high
Based on the environment, corrosion is classified into pressure, which causes cracks and blisters in the metal. This is
(i) Dry (or) chemical corrosion (ii) Wet (or) Electrochemical known as hydrogen embrittlement.
corrosion.
7. Comment on liquid-metal corrosion.
4. What are the consequences of corrosion? Liquid-metal corrosion is due to the chemical action of flowing
 The efficiency of machine will be lost due to the loss of liquid metal at high temperature on solid metal or alloy. The
useful properties of metals. corrosion reaction involves,
 Products get contaminated due to corrosion i. either dissolution of solid metal in liquid metal
 Increase in maintenance and production cost. [or]
 Preventive maintenance like metallic (or) Organic coating ii. internal penetration of the liquid metal in to the
is required. solid metal. This causes weakening of the solid
 Toxic products are released metal.
Example: Devices used for nuclear power plant.

8. Write the elemental reactions involved during electrochemical

corrosion.
i. In the anodic part, oxidation (or) dissolution of metal occurs
 M M2++2e- Self controlled Continuous process
ii. In the cathodic part, reduction occurs, which depends on the Follows adsorption mechanism Follows electrochemical reaction
nature of the corrosive environment
(c) If the corrosion environment is acidic, hydrogen 12. What is galvanic corrosion? Discuss
evolution occurs When two different metals are in contact with each other in
presence of an aqueous solution or moisture, galvanic corrosion
2H+ + 2e- H2 occurs.The more active metal ( more negative electrode potential)
(d) If the corrosive environment is slightly alkaline or acts as anode and less active metal ( positive electrode potential)
neutral, hydroxyl ion is formed acts as cathode.
½ O2 + 2e- + H2O 2OH- Example:
(a) Zn – Fe couple : Zn( - 0.76V) is more active and dissolves in
9. What type of corrosion takes place when a Zinc rod dipped in preference to Fe( - 0.44V)
HCl solution? (b) Fe – Cu couple: Iron (- 0.44V) is more active than Cu (
Hydrogen evolution corrosion takes place. Since Zinc displaces +0.34V) and undergoes corrosion in preference to Cu.
hydrogen easily from acids.
13. Iron corrodes faster than aluminium, even though iron is placed
10. State two conditions for wet corrosion to take place. below aluminium in the emf series. Why?
This type of corrosion occurs in moist environment. It occurs This is because aluminium forms a non-porous, very thin, tightly
(i) When the conducting liquid is in contact with metal adhering protective oxide film on its surface and this film does not
(ii) When two different metals are immersed or dipped partially in permit corrosion to occur.
the solution.
14. How can you minimize galvanic corrosion?
11. Differentiate chemical and electrochemical corrosion Galvanic corrosion can be minimized by
Chemical corrosion Electrochemical corrosion a. providing an insulating material between the two metals
Occurs only in dry condition Occurs in the presence of b. providing smaller area for cathode and larger area for
moisture or electrolyte anode
Due to direct chemical attack Due the setting up of large
of the metal by environment number of anodic and cathodic 15. Rusting of iron is quicker in saline water than in ordinary
areas water. Why?
Corrosion products accumulate Corrosion occurs at the anode, The presence of sodium chloride in water leads to increased
in the same place where while the product gathered at conductivity of water layer in contact with the iron surface, thereby
corrosion occurs cathode corrosion current increases and rusting is speeded up.
 dangerous because the formation of small anodic and large
cathodic areas results in severe corrosion of the anode region.
16. Copper equipment should not possess a small steel bolt. Give Example: Metal covered by a drop of water or aqueous NaCl, sand,
reason. dust.. The area covered by the drop acts as an anode due to less
Iron (- 0.44V has negative electrode potential) acts as anode and oxygen concentration and suffers corrosion Uncovered area acts as
while copper equipment (+ 0.34 V has positive electrode potential) cathode
acts as cathode resulting a galvanic corrosion. Since anodic area is
very small, it is completely corroded in due course of time and the 21. How does purity of a metal influence corrosion?
action of bolt is finished, i.e., the equipment loses its bolt after 100% pure metal will not undergo any corrosion,presence of
sometime. impurities will create heterogeneity resulting galvanic cells.
Effect of impurites on the rate of corrosion of Zn
17. In a structure, dissimilar metals should not be allowed to come % purity of Zn 99.999 99.99 99.95
in contact with each other. Why? Corrosion rate 1 2650 5000
When two dissimilar metals comes in contact with each other,it
leads to galvanic corrosion, metal having negative electrode 22. What are the objectives of electroplating?
potential undergoes corrosion. (i) To increase the resistance to corrosion
(ii) To improve the hardness and appearance
18. Bolt and nut made of the same metal is preferred in practice. (iii) To increase the decorative value
Why? (iv) To increase the chemical attack
Bolt and nut made of the same metal is preferred, because such a (v) To improve the surface properties
combination will not permit galvanic corrosion to take place.
23. What is the need for preliminary treatment of metal surfaces?
19. What is differential aeration (concentration cell)corrosion? Generally metal surfaces are covered with impurities like rust,
This type of corrosion occurs when a metal is exposed to different scale, oil and grease. Presence of these impurities will produce
concentrations of Oxygen. The part of metal which is more porous and discontinuous coatings.
exposed to oxygen (air) act as cathode and unaffected. The other In order to obtain uniform, smooth, cohesive and adherent coating,
part of the metal, which is less, exposed to oxygen(air) act as these impurities must be removed from the metalsurfaces to be
anode and undergoes corrosion. coated

20. What is pitting corrosion? Why is it severe? 24. What is electroless plating?
Pitting is localised attack, resulting in the formation of a hole Electroless plating is a technique of depositing a noble metal
around which the metal is relatively unaffected. Pitting corrosion is (noble metal salt solution) on a catalytically active surface of the
base metal by using a suitable reducing agent without electric electrolyte together with an anodically connected tool.
current.
The reducing agent reduces the metal ions to metal, which gets
plated over the catalytically activated surface giving a uniform
coating.

25. Bring out the reactions taking place during electroless plating
The object to be plated, is immersed in the bath containing the salt
of the metal and reducing agent. The metal ion from the solution
will be reduced to the corresponding metal and gets plated over the
surface of the object
Reactions
At cathode : M2+ + 2e - M
At anode : HCHO + 4 OH - HCOO - + 2 H2O + H2 + 2e -

Net reaction: M2+ + HCHO + 4 OH ______ HCOO - + 2 H2O + H2

26. What are the advantages of electroless plating?

i. No electricity is required
ii. Can be easily plated on insulators
iii. Complicated parts can be easily electroplated
iv. coating possess unique mechanical, chemical and
magnetic features

27. What is electrophoretic coating?

Electrophoretic deposition EPD is a method of coating a
conductive part with particles suspended in a fluid dispersion
under the influence of an electric field applied between the work
part and the counter electrode.
28. What is electrochemical machining?
Electrochemical machining is a process of a selective dissolution
of the anodically connected work piece material submerged in an