Unit IV

Corrosion and its control

Dr. Prabir Khatua

Assistant Professor of Chemistry
GITAM University (Bengaluru Campus) 1
 INTRODUCTION

 CAUSES OF CORROSION

 MECHANISM OF CORROSION

 CORROSION REACTIONS

 FACTORS AFFECTING THE CORROSION

 TYPES OF CORROSION

 CORROSION CONTROL & PREVENTSION METHODS

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 Destruction of a metal by chemical or electrochemical
reaction with its environment.
 Physical or mechanical wearing away of a metal is not called

corrosion but is called erosion

 If corrosion and erosion take place together the destruction of

the metal takes place very much faster

 Corrosion is an unintentional attack on a material by reaction

with a surrounding medium

 The corrosion problem should be very seriously considered in

all those cases where the structure or the equipment is meant

to last many years say 20 years…

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Corrosion is the deterioration of materials by chemical
interaction with their environment. The term corrosion is
sometimes also applied to the degradation of plastics, concrete
and wood, but generally refers to metals.

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Chemical vs. Electrochemical Reactions
•Chemical reactions are those in which elements are added or removed from a
chemical species
•Electrochemical reactions are chemical reactions in which not only elements may be
added or removed from a chemical species but at least one of the species undergoes
a change in the number of valance electron
•Corrosion processes are electrochemical in nature

Classification of corrosion
• Dry corrosion
• Wet corrosion

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Why metals are susceptible of Corrosion?

Most of the metals (except noble metals e.g., Au, Pt, and Ag) in
nature in combined form of their oxides, hydroxides, sulphides,
chlorides, carbonates and silicates. All these metals have natural
tendency to revert back to combined state for stability.
The natural combined form of metal is more stable than the other
metals. So metals after extraction from its ore tends to revert back
to the stable natural combined form when it comes in contact with
other elements in the environment. That is why metal after
extraction from its ore tends to revert back to the stable natural
combined form. So corrosion is reverse process of metallurgy.
The process of gradual decay or deterioration of metal from its
surface by unwanted chemical or electro-chemical reaction with its
environment is called corrosion.

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 Types corrosion:
On the basis of environment to which it is exposed,
corrosion divided into two types.
a) Dry (or) Chemical corrosion
b) Wet (or) Electrochemical corrosion

Dry (or) Chemical corrosion

This occurs mainly due to the direct action of
environment or atmospheric gases like O2, CO2,
SO2, H2S, Halogens (Cl-, Br-, I-), Anhydrous in-
organic liquids with metal surface that are present in
its immediate proximity

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 Mechanism:
 At the surface of the metal, oxidation takes place and resulting metal oxide scale
form a barrier which reduce further oxidation.
 To continue oxidation, either the metal diffuses outward through the scale to the
surface or inward diffusion of O2 through scale to the underlying metal.
 Both the cases are possible, but outward diffusion of metal is normally more rapid
than inward diffusion of O2 since metal ion is appreciably smaller than the oxygen ion
and hence much of higher mobility of metal ion.

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 Wet (or) Electrochemical corrosion
Wet corrosion occurs under the following conditions
(i)When two dissimilar metals or alloys are in contact with each other in
presence of an aqueous solution or moisture.
(ii) When a metal is exposed to varying concentration of oxygen or any
electrolyte.

Mechanism:
In anodic part oxidation (or) dissolution of metal occurs, its releases electrons and
forms metallic ions.

In cathode part, reduction reaction occurs which depends on nature of the

corrosive environment.
(a) If the corrosion is acidic, hydrogen evolution occurs at cathodic part.

(b) If the corrosive environment is slightly alkaline (or) neutral, hydroxide ion
forms at cathodic part.

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Galvanic series:

 Electrochemical series gives useful information regarding chemical reactivity of

metals, however, this series doesn’t give sufficient information about corrosion
behavior of metal in a particular set of environmental conditions.
 Passivation makes effective electrode potential of some metals more passive and
makes them act like cathode and exhibits noble behavior. This behavior is exactly
opposite to electrochemical series.
 So a more practical series have been prepared by studying the corrosion of metals
and alloys in common electrolyte called sea water using calomel electrode as
reference electrode.
The arrangement of metal and alloys with their increasing order of anodic (or)
cathodic character is called galvanic series.
 A metal present high in series is more anodic & undergoes corrosion faster than
metal below.
This series gives real and useful information about corrosion behavior of metals
and alloys in a given environment.
Galvanic series predicts the corrosive tendency of both metals and alloys in actual
set of environment, where as electrochemical series predicts the displacement of
metals and non-metals in electrolytes.

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The galvanic series (or electro-potential series) determines the nobility of metals and 
semi-metals. When two metals are submerged in an electrolyte, while also electrically connected
by some external conductor, the less noble (base) will experience galvanic corrosion. The rate of
corrosion is determined by the electrolyte, the difference in nobility, and the relative areas of the
anode and cathode exposed to the electrolyte. The difference can be measured as a difference in
voltage potential: the less noble metal is the one with a lower (that is, more negative) 
electrode potential than the nobler one, and will function as the anode (electron or anion attractor)
within the electrolyte device functioning as described above (a galvanic cell). Galvanic reaction is
the principle upon which batteries are based.

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 Galvanic corrosion:
 When two dissimilar metals are electrically connected & exposed to
electrolyte, metal higher in galvanic series undergoes corrosion. This is
called galvanic corrosion.
Examples: Zn –Cu couple, Fe –Cu couple etc.
Mechanism: Zn –Cu couple
 In acidic solution, corrosion occurs by evolution of H2, while in neutral & slightly
alkaline solution absorption of O2 occurs.
 The electrons flow from anodic metal to cathodic metal.

O2
H2O

Copper Zinc
Cathode: Anode:
Cu2++ 2e- → Cu Zn → Zn2+ + 2e-

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 Here Zn acts as anode where oxidation takes place,
corrosion occurs and Cu that acts as cathode, hence
it is protected.

For example: Steel pipe connected to copper plumbing

Steel screw is fitted on brass marine hardware

Galvanic corrosion controlled by

(a) avoiding galvanic couple
(b) Keeping an insulating material between two materials

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 Concentration Cell Corrosion / Differential
Aeration Corrosion
 This type of corrosion is due to electrochemical attack on metal
surface exposed to an electrolyte of varying concentrations or of varying
aeration.

 The most common type of concentration cell corrosion is differential

aeration corrosion.

 This occurs when one part of metal is exposed to different air (O2)
concentration from other part.

 This causes a difference in potentials between differently aerated

areas.

 Poorly oxygenated metallic part becomes anodic & undergoes

oxidation whereas well oxygenated part acts as cathode.

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 Example: When Zn metal is partially immersed in aqueous
neutral NaCl solution, the part above & closely adjacent to water
line are well aerated. Hence become cathodic. On the other hand,
part that is immersed to greater depth show less oxygen
concentration, thus become anodic. So a difference of potential is
created which causes flow of current between two differentially
aerated areas of same metal.
Zn metal can be dissolved at anode & releases electrons which
are accepted by O2 at cathodic area to form hydroxide ions.

(oxidation)

(Reduction)

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Factors influencing corrosion:

The intensity and rate of corrosion depends on two types of factors

1. Nature of metal
2. Nature of environment

1. Nature of metal :
Many characteristic properties of metal are responsible for corrosion.
These are:

• Position of the metal in galvanic series

• Over voltage
• Relative areas of cathode & anode
• Purity of metal
• Physical state of metal
• Nature of surface film.
• Passivity of metal.
• Solubility of corrosion product
• Volatility of corrosion product

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 Position in galvanic series: When two metals or alloys are in contact with
conducting medium the more active metal suffers corrosion. The intensity of
corrosion depends on difference in their position, the faster will be corrosion of
anodic metal /alloy.
 Over voltage:- It is defined as difference of potential between practical &
theoretical decomposition potentials for same solution.
Example: Electrolysis of H2SO4 with Pt electrode, its practical potential is about
1.70 V where as its theoretical potential is 1.229 V. The diff is 0.471 V which is
over voltage of H2SO4. Reduction in over voltage of corroding metal or alloy
accelerate corrosion rate.
 Relative areas of anode & cathode: Small anodic & large cathodic area causes
severe corrosion when two dissimilar metals or alloys are in contact the corrosion
of anode part is directly proportional to ratio of areas of cathodic & anodic part.
Example: A small steel pipe fitted in a large copper tank.
 Purity of metal: Impurities in metal cause heterogeneity and form tiny
electrochemical cells (at exposed parts) & anodic part gets corroded.
Example: Zn metal containing impurities Pb / Fe undergoes corrosion due to
formation of local electrochemical cells.
•The rate & extent of corrosion increases with increase in exposure and extent of
impurities.
• The intensity of corrosion is less when its purity is high. 18
 Physical state of metal: The rate of corrosion is influenced by physical state of
metal such as grain size, orientation of crystals, stress etc.
• If grain size is smaller, its solubility is more and hence greater will be its corrosion.
• Moreover areas under stress, even in pure metal tend to be anodic and corrosion
takes place at these areas.
 Nature of surface film: In aerated atmosphere practically all metals get covered
with a thin surface film of metal oxide.
• The ratio of volume of metal oxide to metal is called specific volume ratio (SVR).
• Greater the SVR, lesser is the corrosion rate
For example: The SVR of Ni, Cr, W are 1.6, 2.0, & 3.6 respectively.
The rate of corrosion of tungsten is least even at elevated temperature.
 Passivity of metal: Passivity is a phenomenon in which metal/alloy exhibits a
much greater corrosion resistance the resulting film is highly protective but very thin
& quite invisible film on surface of metal/alloy, which makes it more noble.
• Metal like Ti, Al, Cr, Mg, Ni & Co are passive and they exhibit much higher
corrosion resistance than expected from their positions in galvanic series. Passivity
of metal decrease corrosion rate.
Example: Corrosion resistance of stainless steel is due to passive character of Cr
present in steel.

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 Solubility of corrosion product: In electrochemical corrosion if
corrosion product is soluble in corroding medium, then corrosion
proceeds at faster rate. If corrosion product is insoluble in medium or
it forms another insoluble product which create physical barrier there
by corrosion is suppressed.
Example: corrosion of Pb in H2SO4 decreases due to formation of
insoluble PbSO4.

 Volatility of corrosion product: If corrosion product has volatile

nature, underlined metal is exposed further and causes severe
corrosion .
Example: MoO3 is volatile.

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2. Nature of the corroding environment

The process of corrosion will also decide on the basis of

environment in which the metal is working.

1.Temperature.
2. Humidity of air.
3. Presence of impurities (CO2, SO2, NO2, CO, NO) in atmosphere.
4. Presence of suspended particles in atmosphere.
5. Influence of pH.
6. Conductance of corroding medium.

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 Temperature:- With rise in temp of environment, the reaction rate and rate of
diffusion will be enhanced. Hence, the corrosion rate will be increased (directly
proportional).
 Humidity of air:- It is the deciding factor in atmospheric corrosion.
Critical Humidity is defined as relative humidity above which the atmospheric
corrosion rate of metal increases sharply.
The value of critical humidity depends on physical characters of metal & corrosion
product.
In Humid environment the rate of corrosion is higher due to gases & vapors
present in atmosphere furnish (give) water to form electrolyte, essential for setting
up an electrochemical corrosion cell.
Moreover, the oxide film on metal surface has a property to absorb the moisture,
then corrosion rate enhanced. The nature of moisture sources also play important
role.
Example: Rain water apart from supplying moisture for electrochemical attack,
may also wash away a good part of oxide film from metal surface (unless the
oxide film is exceptionally adherent).
Presence of impurities in atmosphere:
•Presence of corrosive gases like SO2, CO2, H2S, O2 etc. in atmosphere
increase the acidity and increase electrical conductivity which causes severe
corrosion. In marine atmosphere presence of Na & other chlorides leads to
increase in conductivity there by corrosion increases. 22
  Presence of suspended particles in atmosphere:
The suspended particles in atmosphere may be are of two types.
i) Chemically active:- If suspended particles are active e.g., NaCl, (NH4)2SO4 they
absorb moisture & act as strong electrolytes , thereby causing enhance corrosion .
ii) Chemically inactive:- If suspended particles are chemically inactive, in nature
(charcoal) they absorb both sulphur gas & moisture & slowly enhance corrosion rate.

 Influence of pH:-
• Generally acidic media ( pH < 7) are more corrosive than alkaline & neutral media.
• The metals are readily attacked by acid, so corrosion of metal can be reduced by
increase of pH of attacking environment.
Example: Zn rapidly corrodes in week acidic solution and suffers minimum
corrosion at pH-11.
 Conductance of corroding medium:
• Conductance of conducting media is important in case of underground & submerged
structures. Conductance of dry sandy soil is lower than those of mineralized/clayey
soils. Stray currents (from power breakages) will cause more damage to metallic
structures buried under clay & mineralized soil than those under dry sandy soils.

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Arleigh-Burke Destroyer
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Cathodic protection:
In this method of protection, a metal that acts as anode is forced to behave like
cathode there by its corrosion doesn’t occur.
This is done by two methods
1. Sacrificial anodic protection
2. Impressed current cathodic protection

1. Sacrificial anodic protection: -

 In this method of protection, metallic structure to be protected is called base
metal.
 Using more active metal called sacrificial anode, base metal is protected by
connecting it to sacrificial anode through a wire.
 Hence all corrosion is concentrated at sacrificial anode while base metal is
protected. Corroded sacrificial anode block is replaced by fresh one.
 The commonly used anodic metals are Mg, Zn, Al and their alloys. Zn is used
as sacrificial anode in good electrolytes as sea water. Mg is used in high resistive
electrolytes due to its more –ve potential & it can provide highest current output.

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2. Impressed current cathode protection

• In this method all impressed current is applied in opposite direction to

corrosion current to nullify & convert corroding metal from anode to
cathode.

• Once the metal becomes cathode it is protected from corrosion.

• The impressed current is taken from battery or rectified AC line.

• The anode may be either an inert material or insoluble material such as

graphite, Pt, stainless steel, high silica iron, scrap Fe etc.

• This protection technique is mainly used to buried structures like water

tanks, water pipelines, transmission line towers, marine pipes , laid up
ships etc.

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Electroplating:

• It is a technique by which deposition of coat metal is done on base metal

by passing direct current through electrolyte solution which contains soluble
salt of coat metal.

• If base metal is having impurities like oils or greases, it should be cleaned

with organic solvents like tetrachloride ethylene and if it contains surface
scales, oxides are removed by applying HCl (Ni or Cu plating ) or H2SO4.

• The cleaned metal is used as cathode and anode is either an inert

material of good electrical conductivity or coating metal itself. Electrolyte
is soluble salt of coat metal. The anode and cathode are dipped in
electrolytic solution kept in an electroplating cell or bath.

•When direct current passed through coating metal ion migrate towards
cathode and deposit as thin adherent film on base metal.

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 Electroplating of Ni :- Ni plating gives hard, adherent and good wear
resistant surface to base metal. After Ni plating article is finely coated
with Cr.
Requirements: -
Electrolyte bath: NiSO4(20 gm/L) , NiCl2 (450 gm/L) & boric acid (30
gm/L)
pH: 4.0 by Boric acid buffer
Operating temp: 40-700C
Current density: 20-30 m A/cm2
Additive agent: Saccharin / Coumarin derivatives
Cathode: Metal
Electroless plating:
•This is also widely used technique to protect base metal from corrosion.
It is a technique in which deposition of coat metal on base metal is done
by employing reducing substances (HCHO / Sodium Hypophosphate) in
place of electric current.
•In this method, the base metal to be coated is immersed in noble metal
salt solution used for plating. The noble metal ion is displaced from its
salt solution by base metal ion and forms thin uniform deposit on base
metal.
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FeII(OH)2  Light Green
FeIII(OH)2  Brown
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 The chemical combined state of the metal is known as “ore”

 The ore has low energy in its thermodynamical state.

 The extracted metal has high energy, thermodynamically

unstable .

 Metal converts itself into stable state by reacting with the

environment and undergoes corrosion.

 The corroded metal is thermodynamically stable.

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 The valuable metallic properties like conductivity,
malleability, ductility etc. are lost due to corrosion.

 Life span of the metallic parts of the machineries is reduced.

 The process of corrosion is very harmful and is responsible for

the enormous wastage of metal in the form of its compound.

 The failure of the machinery takes place due to lose of useful

properties of metals.

 The approximate estimate of loss of metal due to corrosion is

2 to 2.5 billion dollars per annum all over the world.

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Different types of electrochemical corrosions are

 Galvanic corrosion

 Pitting corrosion

 Intergrannular corrosion

 Water line corrosion

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 This corrosion occurs when different metals are in contact and
exposed to corrosive atmosphere.

 The metal which has higher electrode potential value will form
anode and undergoes corrosion. Example: Zn-Cu galvanic cell
zinc behaves as anode and corrosion occurs, copper behaves as
cathode and protected.

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 When corrosion starts on a metal surface
at certain spots they become less open to
oxygen with the result that corrosion
proceeds faster at those very spots
making deeper and deeper cavities.
 Pitting corrosion can be explained on the
basis of differential aeration.
 The pit created becomes deeper, its
bottom becomes less open to oxygen
which makes it more anodic.
 The part which has higher oxygen
concentration is cathodic.

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 The concentration of oxygen dissolved in
water is greater at the surface than deeper
down. This causes formation of a
concentration cell.

 Anode is the lower portion .

 Cathode is at the water level.

 Due to the poor conductivity of water the

ions just below the water level are
available for reaction, the metal corrodes
just below the water level.
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(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, Pt).

M  M2+ + 2e- (Oxidation)

O2 + 2e -  2O2- (Reduction)
M + O2  M2+ + 2O2- (Metal oxide)

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Mechanism:-
1. When temp increases the metal undergoes oxidation and losses e-

2M → 2M+n  + 2ne-
Metal Ion
2. Electron are gained by the oxygen molecules forms oxide ions

nO2 + 4ne- → 2n O2-

Oxide Ion
3. Scale of metal oxide formed 2M + nO2 → 2M + 2n O2
Metal Oxide

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2.) Corrosion due to other gases: This type of corrosion is due
to gases like SO2, CO2, Cl2, H2S, F2 etc. In this corrosion, the
extent of corrosive effect depends mainly on the chemical
affinity between the metal and the gas involved. The degree of
attack depends on the formation of protective or non protective
films on the metal surface which is explained on the basis of
Pilling Bedworth rule.

(i) If the volume of the corrosion film formed is

more than the underlying metal, it is strongly adherent, non-
porous does not allow the penetration of corrosive gases.
Ag + Cl2  2AgCl (protective film)

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(ii) If the volume of the corrosion film formed is less than the
underlying metal, it forms pores/cracks and allow the penetration
of corrosive gases leading to corrosion of the underlying metal.
Ex. In petroleum industry, H2S gas at high temperature reacts with
steel forming a FeS scale. Fe (steel) + H2S FeS (porous)

3) Liquid metal corrosion: This corrosion is due to chemical

action of flowing liquid metal at high temperatures on solid metal
or alloy. The corrosion reaction involves either dissolution of a
solid metal by a liquid metal or internal penetration of the liquid
metal into the solid metal.
E.g., Coolant (sodium metal) leads to corrosion of cadmium in
nuclear reactors.

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 The electrochemical corrosion occurs when
i) a conducting liquid is in contact with a metal.

ii) when two dissimilar metals or alloys are immersed

partially in the solution.

 Corrosion occurs due to the presence of anodic and

cathodic areas.

 At anode oxidation reactions takes place

 At cathode reduction reactions takes place

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Absorption of oxygen: For example, rusting of
iron in neutral aqueous solution of electrolytes
in presence of atmospheric oxygen.
 Usually the surface of iron is coated with a
thin film of iron oxide.
If the film develops cracks, anodic areas are
created on the surface.
While the metal parts act as cathodes. It
shows that anodes are small areas, while the
rest metallic part forms large cathodes.
The released electrons flow from anode to
cathode through iron metal.
.
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At anode: Fe Fe2+ + 2e- (Oxidation)
At cathode: ½ O2 + H2O + 2e- 2OH- (Reduction)
Overall reaction: Fe2+ + 2OH-  Fe (OH)2

The product called yellow rust corresponds to

Fe2O3. 3H2O

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1. Purity of the metal: Heterogeneity of the metal is due to the
presence of impurities which form tiny electrochemical cells
at the exposed parts. The anodic parts get corroded.

2.Electrode potentials: metals with higher reduction potentials

do not corrode easily. They are noble metals like gold,
platinum and silver. Whereas the metals with lower reduction
potentials readily undergo corrosion (e.g.. Zn, Mg, Al etc.).

3.Position of metal in Galvanic series: Metals which possess

low reduction potentials and occupy higher end of galvanic
series undergo corrosion easily.

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 When two metals are in electrical contact in presence of an
electrolyte, then the metal which is more active undergoes
corrosion.
The rate of corrosion depends on the difference in their
position in Galvanic series. Greater the difference more will
be the extent of corrosion at anode.

4.Relative areas of anodic and cathodic cells: When two

dissimilar metals or alloys are in contact, the corrosion of the
anodic part is directly proportional to the areas of the cathodic
and anodic parts. i.e, the relative areas o of corrosion is
influenced by cathodic to anodic cells.

5. Physical state of metal: Metals with small grain size have

more tendencies to undergo corrosion. Metal with more
stress/strain also undergoes corrosion easily.
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6. Hydrogen over voltage: when a cathode reaction is hydrogen
evolution type, the metal with lower hydrogen over voltage on
its surface is more susceptible for corrosion, since the liberation
of hydrogen gas is easy at this condition. Hence the cathodic
reaction is very fast which in turn makes anodic reaction fast.
Hence the rate of corrosion increases. Higher the over voltage,
lesser is the corrosion.

7. Nature of surface film: If the corrosion product formed is more

stable, insoluble and non porous, it acts as protective layer and
prevents further corrosion (E.g.. Ti, Al and Cr). If the corrosion
product is porous, volatile and soluble, it further enhances the
corrosion (Fe, Zn and Mg).

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1. Temperature: the rate of corrosion reactions increases with
increase in temperature.

2. Humidity in air: the moisture or humidity present in atmosphere

furnishes water to the electrolyte which is essential for setting up
of an electrochemical cell. The oxide film formed has the tendency
to absorb moisture which creates another electrochemical cell.

3. Presence of impurities: Atmosphere is contaminated with gases

like CO2, SO2, H2S; fumes of H2SO4, HCl etc. and other suspended
particles in the vicinity of industrial areas. They are responsible
for electrical conductivity, thereby increasing corrosion.
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4. pH value: pH value of the medium has the greater effect on
corrosion. Acidic pH increases the rate of corrosion.

5. Amount of oxygen in atmosphere: As the percentage of

oxygen in atmosphere increases, the rate of corrosion also
increases due to the formation of oxygen concentration cell.
The decay of metal occurs at the anodic part and the cathodic
part of the metal is protected.

6.Velocity of ions which flow in the medium: As the velocity of

the diffusion of the ions in the medium increases, the rate of
corrosion increases .

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CORROSION CONTROL METHODS
The various measures taken for corrosion protection are

I) CATHODIC PROTECTION

II) SURFACE COATINGS

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 The method of protecting metals and alloys from corrosion
making them completely cathode.

 To achieve this auxilary anode is provided in the corroding

medium which is connected to the structure.

 Cathodic protection is of two types

i) Sacrificial anodic method

ii) Impressed current cathodic method

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Force the metal to be protected to behave like cathode.
(i) Sacrificial anodic protection:
 Metal to be protected from corrosion connected to more

anodic metal
 Commonly used metals Mg, Zn, Al and their alloys

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.
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 Direct current is applied in opposite direction to nullify the
corrosion current
 Converts the corroding metal from anode to cathode.

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 The metal surface is covered with a coating to protect it from
corrosion.
 These may be
i) Metallic
ii) Organic

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The metals used for coatings may be placed under two categories
i) metals which are anodic to the metal i.e., metals above it in
galvanic series.

ii) metals which are cathodic to the metal i.e., metals below it in
galvanic series.

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 Hot dipping: This technique is most widely used to control
corrosion. Hot dipping is used for producing a coating for low
melting metals such as Zn, Sn, pb ,Al.
 on Iron, steel, copper which are having high melting point
usually underwent into corrosion due to their oxidising
property.
 The process in general consisting of immersed a metal in a
bath of its molten coating& covered by a molten layer.
 The flux cleans the base metal& prevent oxidation of metal
coating with molten solution.

 Hot dipping is widely applied either by

(1)GALVANIZING (2)TINNING

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 It is the process in which iron or steel is protected from
corrosion by coating with a thin layer of zinc.
 Iron or steel is first cleaned by pickling with dil. H2SO4
solution for 15-20 mts at 600-900C. The steel is then washed
well and dried .
 Then the metal sheet is dipped in bath of molten Zinc
maintained at 4250- 4300C.
The surface of bath is kept
covered with a ZnCl2 flux to prevent oxide formation.
 Then the metal sheet is passed through a pair of hot rollers
which removes excess of Zinc and maintain uniform
thickness of Zinc on metal sheet.

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The sheet is subjected to annealing process at 650c and
cooled slowly.

Uses of Galvanization: It is used to protect Iron used for

roofing sheets, wires, pipes, nails, bolts, screws, buckets,
and tubes.
Defects :Galvanised utensils are not used for
cooking because of solubility of Zn.
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 TINNING
Tinning is the process of coating of tin over the Iron sheet or
steel articles
 A cleaned iron sheet is passed through a bath of molten flux,
then passes through a tank of molten tin and finally through a
layer of palm oil which protect hot tin coated surface against
oxidation.
Uses: (1)It is widely used for coating of steel, copper, brass
& bronze etc. It is used to store food stuff, ghee oils, kerosene
& pickles and used for refrigerators equipment.

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 ELECTROPLATING

Deposition of coating metal on the base metal by passing

direct current through an electrolytic solution which contain
the soluble salts of the coating material.
Pure metal is made as cathode and base metal as anode.
Electrochemically coat metal is deposited on base metal.
This metal gives smooth, fine and uniform coating
It depends on
(i) Temperature

(ii) Current density

(iii) Electrolyte Concentration

(iv)Nature of base metal (v) Time 66

 It is most important & frequently used technique in industries to
produce metallic coating

 Both metals & non metals can be electroplated.

 In metals the electroplating increases resistance to corrosion,

chemical attack, hardness, wear resistance and surface properties.

 In non metals electroplating increases strength and decorates the

surface of non metal like plastics, wood, glass.

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 Pre treatment of surface:

 (1) CO, Ni, steel and Al can be directly plated.

 (2)Pb, Cd and Sn are first electroplated with Ni prior to

electroless plating.

 (3)Non conductors are activated in Sncl2 & HCl followed by

dipping in Pdcl2,Hcl.on drying thin pd layer is formed.

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 Organic coatings protect the surface as they act as
physical barriers between the metal to be protected and
the corroding environment and are decorative.

 The extent of protection given by the organic coatings

depends on
A) Impermeability to gases ,salts and water
B) Chemical inertness to the corrosive environment
C) Good surface adhesion

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 Paints form a protective layer over the surface of the metal to
prevent corrosion.
The main constituents of the paints are
 Pigment
 Vehicle
 Thinner
 Driers
 Fillers
 Plasticizers
 Anti skinning agents

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 It is a solid constituent that obscures the surface and provides
a decorative color.

 A liquid binds the pigment to the surface and protects it from

decay.

 It usually comprises of 60 to 80% of the weight of the paint

film.

 Increases the life of paint film since it prevents the entry of

ultra violet rays.

 E.g.; lead oxide, red lead, lead chromate etc.,

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 Film forming constituent of the paint.

 They hold the pigment on the metal surface.

 They give metal adhesion to the metal surface.

 They impart durability and toughness to the film.

 They isomerize , polymerize and condense to form

characteristic tough, elastic ,coherent, highly cross linked
structured macromolecular film.

 E.g.: mustard and sunflower oil etc.,

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 Viscosity is reduced by the addition of thinners.
 It is a volatile solvent helps to adjust the consistency of the paint.
 Thinner being volatile evaporates.
 They remain permanently in paints and varnishes.
 They improve elasticity of the film.
 They suspend the pigments in the paints.
E.g. Turpentine, mineral spirits, xylol, kerosene.

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 They are inert materials.
 They are used to improve the properties of the paints.
 They reduce the cost of paints.
 They serve to fill the voids in the film.
 Increases the random arrangement of pigment particles.
 Improves the durability of the film.
 E.g.: talc, chalk, silica etc.,

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 Drying of the oil film is accelerated or catalyzed by
driers.

 To reduce the drying time a drier is added.

 They are oxygen carrier catalyst.

 To improve the drying quality of oil film.

 This is done by condensation , oxidation and

polymerization.
E.g. linoleates , borates, resinates etc.,
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 They remain permanently in paints and varnishes.

 They improve elasticity of the film.

 To prevent cracking of the film.

 Anti skinning agents prevent the gelling and skinning of

the paint film.

E.g.: tricresyl phosphate, tri phenyl phosphate,

di butyl tartarate etc.,

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