Unit 4 CORROSION AND ITS CONTROL_LC (7)
Unit 4 CORROSION AND ITS CONTROL_LC (7)
Unit 4 CORROSION AND ITS CONTROL_LC (7)
IT – A
Prepared By,
Dr Likha Chandran
CORROSION AND ITS CONTROL
The surface of almost all the metals begin to decay rapidly when exposed to atmospheric gases,
water or other reactive liquid medium.
The deterioration of a metal by chemical or electrochemical reaction by its environmental attack is known as
corrosion.
Metals undergo corrosion and convert to their oxides, hydroxides, carbonates, sulphides, etc. E.g. Iron
undergoes corrosion to form reddish brown color rust [Fe2O3. 3H2O].
Copper undergoes corrosion to form a green film of basic carbonate [CuCO3 + Cu(OH)2]
Causes of corrosion
1. The metals exist in nature in the form of their minerals or ores, in the stable combined forms as
oxides, chlorides, silicates, carbonates, sulphides etc.
E.g. Iron undergoes corrosion to form reddish brown colour rust [Fe2O3. 3H2O].
Copper undergoes corrosion to form a green film of basic carbonate [CuCO3 + Cu (OH)2]
2. During the extraction of metals, these ores are reduced to metallic state by supplying considerable
amounts of energy.
3. Hence the isolated pure metals are regarded as excited states than their corresponding
ores. So metals have natural tendency to go back to their combined state (minerals/ores).
When metal is exposed to atmospheric gases, moisture, liquids etc., and the metal surface reacts and forms
more thermodynamically stabled compounds.
Effects of corrosion
1. Wastage of metal in the form of its compounds.
2. The valuable metallic properties like conductivity, malleability, ductility etc. are lost due to corrosion.
3. Life span and efficiency of metallic parts of machinery and fabrications is reduced.
4. Life of equipment and machinery gets reduced.
5. Necessity for replacement of corroded product.
6. Probability of plant shut down due to machine failure.
7. Buildings and other historic monuments are damaged.
8. Loss of valuable metallic properties such as conductivity.
9. Ductility, malleability and luster etc.
10. Contamination of drinking water.
11. Leakage of inflammable gases can cause fire hazards.
Theories of corrosion
Chemical corrosion (Dry corrosion)
This type of Corrosion occurs mainly through the direct chemical action of atmospheric gasses like O2,
halogens, H2S, SO2, N2 or anhydrous inorganic liquid with the metal surface.
There are three types of chemical Corrosion:
(1). Oxidation corrosion
(2). Corrosion due to other gases
(3). Liquid metal corrosion
(1) Oxidation Corrosion: This is carried out by the direct action of oxygen low or high temperatures on
metals in absence of moisture. Alkali metals and Alkaline earth metals are rapidly oxidized at low
temperatures. At high temperature all metals are oxidized (except Ag, Au, and Pt).
2+
M M + 2e- (Oxidation); O2 + 2e- 2O2– (Reduction)
M Mn+ + ne-
The cathodic reaction consumes electrons with either evolution of hydrogen or absorption of oxygen
which depends on the nature of corrosive environment.
Evolution of hydrogen: This type of corrosion occurs in acidic medium.
E.g., Considering the metal Fe, anodic reaction is dissolution of iron as ferrous ions with Liberation of
electrons.
Eg: When Zn an Cu are connected and exposed to corroding environment, Zinc (higher in
electrochemical series) forms the anode; undergoes oxidation and gets corroded. Cu (lower in
electrochemical series) acts as cathode; undergoes reduction and protected as the electrons released by
Zn flow towards Cu.
Prevention:
1) Galvanic corrosion can be avoided by coupling metals close to the elec- trochemical series.
2) Fixing insulating material between two metals.
3) By using larger anodic metal and smaller cathodic metal.
Example of galvanic corrosion:
1) Steel screws in brass marine hardware,
2) steel pipe connected to copper plumbing,
3) steel propeller shaft in bronze bearing,
4) zinc coating on mild steel,
5) lead–tin solder around copper wires.
If a metal rod is dipped in an electrolyte, the portion dipped in water is poor in oxygen concentration
and works as anode which gets corroded and the portion above water acts as cath-ode which is
protected. The system will act as a concentration cell and the chemical reactions for zinc dipped in water
are given as: Zn(OH)2 appears as corrosion products .Examples: Water line corrosion, Drop corrosion.
WATERLINE CORROSION
When water is stored in the steel tank, then corrosion starts, along the line beneath the level of water meniscus.
As we know that beneath the water level concentration of oxygen is very low therefore metal part below the
water level acts as anode and metal part above the water level have higher concentration of oxygen therefore
this region act as cathode. The reaction involve are as follows:
PITTING CORROSION
In pitting corrosion, a pit is formed when the protective coating on the metal surface break, a micro pit (anode)
formed on the metal surface. Once the pit is form the process of corrosion become very fast due to different
amount of oxygen in contact with metal surface. The portion (pit) with lower concentration of oxygen become
anode and portion with higher concentration of oxygen becomes cathode.
Corrosion Control Methods
➢ The amount of the material lost due to corrosion is substantial hence it is important to protect
the metals from corrosion.
➢ These methods rely on metal and
environment. Different corrosion control methods
are:
1. Cathodic protection
I. Sacrificial anodic protection method
II. Impressed current cathodic protection method
2. Protective coatings
A. Metallic coatings
B. Organic coatings - Paints (constituents and functions)
I. Cathodic protection
The method of protecting the base metal by making it to behave like a cathode is called as cathodic
protection.
There are two types of cathodic protection:
(a) Sacrificial anodic protection method
(b) Impressed current cathodic protection method.
Eg: A ship-hull which is made up of steel is connected to sacrificial anode (Zn-blocks) which undergoes
corrosion leaving the base metal protected.
Eg: The underground water pipelines and water tanks are also protected by sacrificial anode method. By
referring to the electrochemical series, the metal with low reduction potential is connected to the base metal
which acts as anode.
the corrosion current. Thus the anodic corroding metal becomes cathodic and protected from
corrosion. The impressed current is taken from a battery or rectified on A.C. line. The impressed
current protection method is used for water tanks, water & oil pipe lines, transmission line towers
Advantages:
❖ Large structure can be protected for long term operations.
❖ It can be applied in high resistivity environment.
❖ Effective in protecting uncoated and poorly coated structures
Limitations:
1. Requires periodic maintenance.
2. Requires external power, resulting in monthly power cost.
3. Over protection can cause coating damage.
4. It is subject to power failure.
Applications:
❖ This method is applied in protecting water tanks.
❖ Open water-box cooler.
❖ Buried oil and water pipes
❖ Transmission line towers.
❖ Marine Pipes.
METALLIC COATING
GALVANIZATION
Galvanizing is the process of coating iron or steel sheets with a thin coat of zinc to prevent
them from rusting. For carrying out galvanizing firstly the iron or steel article such as sheet,
pipe or wire is cleaned by pickling with dil H2SO4 solution for 15-20 mts at 60-900C. In pickling
any scale, dirt, oil, grease or rust and any other impurities are removed from the metal surface.
The article is washed well and then dried. It is then dipped in bath of molten zinc maintained at
425- 430oC. The surface of bath is kept covered with ammonium chloride – flux to prevent oxide
formation. The article is covered with a thin layer of zinc when it is taken out of bath. It is then
passed through a pair of hot rollers, which removes any excess of zinc and produces a thin film
of uniform thickness then it is annealed and finally collected slowly.
Uses: - Roofing sheets, wires, pipes, nails, bolts, screws, buckets, tubes etc. which are made of
iron are protected from atmospheric corrosion by galvanizing them. But galvanized utensils cannot
be used for preparing and storing food stuffs, especially acidic ores since zinc gets dissolved in all
acids forming highly toxic compound
TINNING
Tinning is a coating tin over the iron or steel articles. The process consists in first treating steel sheet in dilute
sulphuric acid (pickling) to remove any oxide film. After this, it is passed through a bath of zinc chloride flux.
The flux helps the molten metal to adhere to the metal sheet. Next, the sheet passes through a tank of molten tin
and finally through a tank of molten tin and finally through a series of rollers from underneath the surface of a
layer of palm oil. The palm oil protects the hot tin -coated surface against oxidation. The rollers remove any
excess of tin and produce a thin film of uniform thickness on the steel sheet.
Uses: tin possess considerable resistance against atmospheric corrosion. Moreover, because of non-toxic
nature of tin, tinning is widely used for coating steel, copper and brass sheets, used for manufacturing
containers for storing foodstuffs, ghee, oils, kerosene and packing food materials. Tinned- copper sheets
are employed for making cooking utensils and refrigeration equipments
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