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Definition
Gradual attack on a metal
Chemical or electrochemical reaction by its
surroundings
Metal is converted into its oxide, salt or
some other compound that is,
deterioration and loss of material due to
chemical attack
Contd.
6.
General types
1.
2.
3.
4.
Direct corrosion
Electrochemical corrosion
Galvanic corrosion
high-temperature oxidation
Specific types
1. uniform corrosion
2. Pitting corrosion
3. Intergranular corrosion
4. Atmospheric corrosion
5. Stress corrosion
6. Corrosion fatigue
7. Erosion corrosion
Contd.
8.
Direct corrosion
Control
By adding some inhibiting chemicals in the
corrosive solution
They act as barriers between the metal
involved and the environment
Electrochemical corrosion
Takes place at or near room temperature
Takes place due to reaction of metals with
water or with aqueous solutions of salts,
acids or bases
Involves transfer of electrons
Flow of electricity from certain areas of the
metal surfaces to other parts through a
medium which conducts electricity
Contd.
Potential
Contd.
Cathode is that portion at which current
returns to the metal from the environment
Reduction takes place at cathode and
the metal is not affected at cathode
Highly pure single phase metals corrode
at a slower rate than impure metals and
alloys containing many phases
Electrochemical Series
Metals are arranged in the order of their
standard electrode potentials
The ability of metals to resist corrosion is
to some extent dependent upon their
position in the electrochemical series
Galvanic Series
The various standard electrode potentials
listed in the electrochemical series were
measured under certain chemical conditions
at a particular concentration and temperature
The electrodes were completely clean and
free from oxide films
Therefore, not always possible to predict
which will be anode and which will be cathode
Contd.
For practical purposes, electric potentials of
many materials are obtained in a single
environment, viz., sea water
These when arranged in the decreasing order
of oxidation potential is called galvanic series
Pair of metals from this series connected
together in sea water, the metal which is
higher in the series would be anode
Farther they are apart, greater the corrosion
tendency
Galvanic series
Contd.
3. Change in concentration of
alloying components in different
points of the metal (that may occur
as a result of the original casting
technique or as a consequence of the
precipitation of very fine particles)
4. Presence of more than one phase
in the metal as in the case of
multiphase metals
External factors
Associated with metals as well as corrosive
environments
1. Residual and applied stress in the metal
particularly after mechanical working
2. Presence of dust, dirt, soot and other
foreign bodies on the metal surface
External factors
3. Presence of protective oxide films on metal
External factors
5. Local changes in the concentration of an
cells
(i) Electrochemical cells (ii) galvanic cells
Electrochemical cells electrolysis takes place;
anode is +ve and cathode is ve
Electrical
chemical
Galvanic cells Chemical
electrical
Anode is ve (oxidation); cathode is +ve
(reduction)
(-)
(+)
Anode
cathode
Galvanic cell
Daniel cell
Zn
+
current
oxidation
e-
ZnSO4
Cu
Reduction
CuSO4
Zn Zn2++2e-
Cu2++2e-
Cu
Concentration polarization
As reaction proceeds near electrodes, ionic
Overvoltage
This
Presence of films
Protective films are formed on the
electrodes both at the cathode and the
anode as a result of the combined effect
of the electrode reactions and the action
of the environment
Resistance between cathode and anode
increases and the rate of diffusion
decreases
Galvanic cells
Metal of high electrode potential is placed
in water and is electrically connected to
another metal of much lower electrode
potential
A current will flow through the wire
connecting the electrodes called
galvanic cells
Electrochemical corrosion involves a
transfer of electrons
Summary of electrode
reactions in galvanic cells
Mn++ne- (metal
Anode: M
dissolves)
H+ + OH Cathode: H2O
2H+ + 2eH2
H2O + O2 + 2e2OH
Oxygen absorption at the cathode uses
more electrons; hence rate of corrosion
increases
Mechanism of
electrochemical corrosion
Involves transfer of electrons
Electrons must flow between
anodic and cathodic areas
Anodic reaction: always dissolution
of metals and formation of ions
Cathodic reaction: may involve two
different processes depending on
the nature of corrosive
environment evolution of
hydrogen gas, absorption of oxygen
Acid waste
H
2
Fe2+
H+
Steel tank
H+
Fe2+
Small Cu scrap
Oxygen absorption
mechanism
Corrosion
Drop of water
crack
cathode
rust
Film or scale
rust
Fe2+
Fe2+
e-
Steel plate
e-
Anode at crack
Contd.
In course of time, oxide layer will form on
the surface of the steel plate and drops of
water may collect over a small crack in the
oxide film present on the surface of the
steel (figure)
Water acts as the electrolyte, crack as the
anode and the scale protected steel as
cathode
Contd.