Engineering Chemistry and Environmental Studies UNIT VI

6. Corrosion
1) Define Corrosion?
Corrosion:
The slow and gradual disintegration of metal due to environment is called corrosion.
Eg:

Rusting of Iron
Tarnishing of silver and gold and ornaments.

2) Explain the factors influencing the rate of corrosion?

Factors influencing the rate of corrosion:
The following factors influence the rate of corrosion of metal.
1. Position of metal in the Electro Chemical Series:
The rate of corrosion is directly proportional to the reactivity.
The reactivity decreases from top to bottom in electro chemical series.
Hence, rate of corrosion also decreases in the same sequence.
Na, K, Mg metals are more reactive and easily undergo corrosion.
Au, Ag, P+ metals are less reactive and rate of corrosion is less.
2. Purity of metal:
Impure metal undergoes corrosion is less.
Corrosion increase with the amount of impurities in the metal.
So, pure metal is more resistant to corrosion than an impure metal.
3. Physical state of metal:
Grain size and stress influence the rate of corrosion.
The smaller the grain size of metal greater will be its corrosion.
The stressed areas undergo corrosion easily.
4. Nature of corrosion products:

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Corrosion

Engineering Chemistry and Environmental Studies UNIT VI

If the corrosion product is soluble in the corroding medium or evolved as a gas, then corrosion
proceeds at a faster rate.
On the other hand if the corrosion product is insoluble or acts as protective coating, reduces the
further corrosion.
Eg: Al surface is oxidized and the oxide layer acts as protective coating for the inner metal.
5 Impurities in the atmosphere:
The presence of corrosive gases like CO2, H2S, SO2, HCl, H2SO4 etc increases the rate of
corrosion.
6. Humidity of Air:
The corrosion of a metal becomes faster in humid atmosphere.
This is because the CO2, O2 and vapors furnish water to the electrolyte which is essential for
setting up of electrochemical cell.
7. Effect of pH :
The rate of corrosion is more in acid media i.e., pH < 7 than in alkali (or) neutral media.
8. Temperature:
Corrosion is a chemical process.
The rate of chemical reaction increases with temperature.
Hence, as temperature increases, the rate of corrosion increases.
3) Explain the Electrochemical theory of corrosion?
Electrochemical theory of corrosion:
This theory was introduced by Whitney.
According to this theory
(a) Corrosion is an electrochemical reaction.
(b) When tow dissimilar metals are kept in contact with each other in liquid medium or moist
air, a galvanic cell is formed.
(c) The metal which acts as anode undergoes corrosion and the other metal which acts as
cathode does not undergo corrosion.
(d) The metal which undergoes corrosion in these conditions depends upon the position of
the metal in the electrochemical series.
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Lecturer in Chemistry

Corrosion

Engineering Chemistry and Environmental Studies UNIT VI

(e) The metal ions formed at anode and non metal ions formed at cathode, diffuse towards
each other through the conducting medium and form the corresponding product.
At anode:
M
Mn+ + ne- (oxidation)
1
O
At Cathode: H2O + 2 2 + 2e2 OH- (reduction)
(Or)

O2 + 4e2O-2
+n
M + n OH M (OH)n
M+n + O-2
M2On

4) Explain the Formation of different types of corrosion cells ?

Formation of different types of corrosion cells:
Three types of galvanic cells are formed during the electrochemical corrosion.
They are:

1. Composition Cell
2. Concentration Cell
3. Stress cell.

5) Explain the Composition cell ?

Composition cell:
A cell is formed between two dissimilar metals in contact with each other in the presence of an
electrolyte is called composition cell (or) galvanic cell.
These two dissimilar metals acts as electrodes.
The metal which is more reactive acts as anode and undergoes corrosion.
The metal which is less reactive acts as cathode and does not undergo corrosion.
Eg: When Zinc and Copper which are in contact with an electrolyte electrically connected the Zn
metal acts as anode and Cu metal acts as Cathode.
In this cell Zinc undergoes corrosion.
Diagram pending.
6) Explain the Concentration Cell ?
Concentration Cell:
A galvanic cell formed due to difference in the concentration of electrolyte or gas around the
metal surface is called concentration cell.
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Lecturer in Chemistry

Corrosion

Engineering Chemistry and Environmental Studies UNIT VI

This type of corrosion occurs if a metal is exposed to an electrolyte of different concentrations.

In this cell less exposed part acts as anode and undergoes corrosion and more exposed part acts
as cathode.
Eg: If Zinc metal is partially immersed in a solution of neutral NaCl solution, the immersed part
in the solution has lower concentration of O2 and acts as anode and undergoes corrosion.
The above part of water line (non immersed) acts as cathode.
At anode:
At cathode:

Zn+2 + 2e- (oxidation)

Zn
H2O +

1
O
2 2 + 2e

Zn+2 + 2 OH-

2 OH- (reduction)
Zn (OH)2

Figure
7) Explain the Stress cell ?
Stress cell:
A cell formed between stressed and unstressed parts of metal is called stress cell.
The stressed area in a metal acts as anode and unstressed area acts as cathode.
The stressed part undergoes corrosion.
Eg:
1) In bend pipes the curved parts are stressed and acts as anode and un curved parts acts
as cathode.
The anode part undergoes corrosion.
Figure
Eg:
2) In a nail, the head and tail parts being stressed parts acts as anode and undergo
corrosion.
Figure
8) What is Rusting of iron ?
Rusting of iron:
The slow and gradual disintegration of iron due to atmosphere conditions is called rusting of iron
(or) corrosion of iron is called rusting.
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Lecturer in Chemistry

Corrosion

Engineering Chemistry and Environmental Studies UNIT VI

A piece of iron reacts with O2 and water vapor and gets a red, brown deposit on it.
This deposit is called rust.
Rust can be represented as Fe2O3.xH2O where (x = 0 3)

9) What are the Conditions for rusting of iron ?

Conditions for rusting of iron:
1.
2.
3.
4.
5.

Impure state of metal.

Moisture
O2 and CO2 present in atmosphere.
pH of electrolyte.
Temperature.

10) Explain the Mechanism of Rusting of iron ?

Mechanism of Rusting of iron:
The surface of iron metal due to mechanical strain (or) impurities lead to form a number of
galvanic cells.
The unstrained part of iron acts as cathode.
At anodic part, the iron atoms undergo oxidation by losing electrons.
At anode:

Fe+3 + 3e- (oxidation)

Fe

The electrons move to cathode part on the surface and taken by O2 and H2O of the atmosphere to
form OH- ions.
At cathode:

H2O +

1
O
2 2 + 2e

2OH- (reduction)

The Fe+3 ions and OH- ions combine to form ferric hydroxide
Fe+3 + 3 OH-

Fe (OH)3

The ferric hydroxide lose water gradually and convert into brownish rust.
2 Fe (OH)3

Fe2O3. H2O + (3 - X)H2O

Where X = 0 to 3.

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Lecturer in Chemistry

Corrosion

Engineering Chemistry and Environmental Studies UNIT VI

11) What are the Methods of prevention of corrosion (or) corrosion control methods ?
Methods of prevention of corrosion (or) corrosion control methods:
The following methods are used to control the corrosion
1) Coating methods.
2) Cathodic protection.

12) Explain the Coating Methods to prevention of corrosion ?

Coating Methods:
A coating surface isolates the underlying metal from the corrosion environment and hence
prevents the corrosion.
There are three types of protective coatings.
a) Metallic coatings
b) Inorganic coatings
c) Organic coatings.
a) Metallic coatings:
Metallic coatings are further divided into two types. They are
1) Anodic coating.
2) Cathodic coating.
1) Anodic coating:
In this type of coating, the base metal is coated an anodic metal and it protects the
base metal and it protects the base metal sacrificially.
Eg: Zinc coating on Iron ( Galvanization).
2) Cathodic Coating:
In this method of coating, the base metal is coated with a noble (or) less reactive
metal.
Eg: Coating of Tin or Iron.
a) Inorganic coating:
There are three types of inorganic coatings.
1) Phosphate coating:
In this method, the base metal is dipped in the solution of phosphoric acid and
phosphate of Zn and Fe (or) Mn and Fe.
It is useful for Fe, Zinc, etc.
2) Chromate coating:
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Lecturer in Chemistry

Corrosion

Engineering Chemistry and Environmental Studies UNIT VI

In this method base metal is dipped in a bath of acidic potassium chromate and then
neutral chromate solution.
It is useful for metals like Zn, Al, Mg, Cd etc.
3) Oxided coating:
In this method a chemical reaction is carried between the base metal with Alkaline
oxidizing solution.
They serve as base primer coatings for oils, greases and waxes.
Organic coating:
In this method the base metal is coated with organic compounds such as plastics, paints, enamels
and varnishes for the protection corrosion.
They adhere to the surface of metal and are very much effective against atmospheric corrosion.
13) Explain Cathodic protection method to prevent corrosion ?
Cathodic protection:
In this method, the metal to be protected from corrosion is made cathode by connecting it with
another active metal (or) by impressed current.
This can be done by the following two methods
a) Sacrificial anode process
b) Impressed voltage process
a) Sacrificial anode process:
In this method the metal to be protected from corrosion is made cathode by connecting it with
another more active metal.
This is more active metal acts as anode and undergoes corrosion.
This active metal is known as Sacrificial anode.
This method is called sacrificial anode process.
This metal is used in the protection of buried pipe lines, water tanks, marine structures etc.
Eg:
1) Underground iron pipelines are protected from corrosion by connecting them with a
more active metal like magnesium.
Magnesium acts as sacrificial anode and undergoes corrosion.
The iron pipes become the cathode.

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Lecturer in Chemistry

Corrosion

Engineering Chemistry and Environmental Studies UNIT VI

Figure
Eg:

2) Galvanization:

The coating of Zinc or Iron is called galvanization.

In this method Zn coating acts as sacrificial anode and corrodes to protect iron.
2) Impressed voltage process:
In this method an impressed current is applied to nullify the corrosion current and converting the
corroding metal from anode to cathode.
The impressed current is derived from a battery using graphite as andoe.
In this method, for the prevention of corrosion, electrons are supplied from an external cells so
that the metal becomes cathode and protects from corrosion.
This method is particularly useful for large structures for long term operations.
This method is used to water tanks, condensers, transmission line towers etc.
Figure

Prepared by V Naga Surendra Reddy

Lecturer in Chemistry

Corrosion