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MSE3 Corrosion
MSE3 Corrosion
Division of Engineering
Session 2001-2002
Materials Science and Engineering
Corrosion of metals
Electrochemical theory of wet corrosion: fundamentals
As with dry corrosion wet corrosion reactions are only possible if the free energy
of the products of reaction is lower than the free energy of the reactants. This is
the case however for the reaction of nearly all metals with water and oxygen to
give metal hydroxides:
M H2 Ol
MOH s
2
(1)
for example
the dipolar water molecule stabilizes the free (dissociated) metal ions in
solution;
the metallic structure and water in contact with it can both conduct electric
current.
This enables reaction 1 above to proceed through the coupling of two primary
corrosion reactions:
A: M
M 2e
2
(2)
2OH
(3)
H
(4)
2e M2
M
(5)
MO 2H2e
(6)
When a metal M is placed in pure water, some ions will immediately pass into
solution:
M 2e
2
(7)
The build-up of negative charge on the metal and the build-up of metal ions in
solution makes possible a back-reaction:
M 2e
2
(8)
M 2e
2
(9)
At this stage, a steady potential difference now exists between metal and solution.
The magnitude of this potential difference depends on the metal and composition
of the solution. It is not possible to measure this potential difference for a single metal, but the potential difference (emf) between two metals dipping into a
solution can be measured. Under well-defined conditions, this enables a single
potential Em (relative to a common reference) to be assigned to every metal.
Nernst Equation
Describes how Em varies with concentration of metal ions for the electrode Mn M.
where b 0.059 V at 25 C.
For the electrode O2 4OH
b
Em Em log c
n
E O2
(10)
OH
(11)
Polarisation
In active corrosion cells, a net corrosion current flows at each electrode surface.
At the anode, the electrode reaction (see note 4 above) is no longer in equilibrium.
The rate of the forward reaction exceeds the rate of the back reaction: i f ib .
Potential
EM
logi
i0
Current
Figure 1: Ideal polarisation curve for a metal surface in contact with water.
This net anodic current requires a shift of the electrode potential to a more positive
value. This favours the forward reaction and disfavours the back reaction.
A second surface acting as a cathode is cathodically polarised, as shown in Figure
2.
Xn
X ne
Here for example X may stand for 2H2 O + O2 , with n 4, and Xn
4
(12)
4OH.
Potential
iX
EX
iX
Ecorr
iM
EM
iM
logi
i0
Current
Fe 2e
2
(13)
EFe/ V
pH
Passivity
EFe/ V
Active
corrosion
Immunity
pH
Figure 3: Pourbaix diagram for iron, showing regions of active corrosion, passivity and immunity.
Dissimilar metals
Differential aeration
Cathodic protection
Widely used in the protection of marine structures, ships, underground structures
(especially pipelines) and water filled structures. Under some circumstances used
to protect reinforcing steel in concrete structures.
Types of CP: impressed current; sacrificial anode.
Potentials (V) for cathodic protection relative to Cu CuSO4 reference electrode:
Iron and steel
Lead
Copper and alloys
Aluminium
0 85 to 0 95
0 6
0 5 to 0 66
0 95 to 1 2
Passivity
Figs 1 and 2 showed the ideal anodic polarisation curve for metal dissolution
M 2e
2
(14)
In the presence of oxygen and other oxidising agents this curve for some metals extends only a certain distance before showing a sharp drop to lower current
densities. When the anodic current density exceeds a critical value ic the metal
becomes passive or passivates. Passivity is caused by a chnage in the anodic reaction. The formation of free metal ions (reaction above) gives way to a reaction
which forms an insoluble film on the metal surface:
M H2 O
(15)
This anodic reaction proceeds more slowly because of the relatively high resistance of the film. Note however that the current density does not drop to zero
in the passive region a small residual anodic current flows and this repairs any
damage to the passivation film. The shape of the polarisation curve differs from
one metal to another. The phenomenon of passivity is especially important for
the corrosion behaviour of titanium (Ti), chromium (Cr) and stainless steels, aluminium (Al) and iron (Fe) and ferrous metals. The presence of aggressive anions,
notably chloride, may cause severe pitting corrosion by attacking or preventing
formation of a passive film.
enhancing the rate of the cathodic reaction. The bacteria make use of the H to
reduce sulphate (SO
4 to sulphide (S ).
The overall corrosion cell reaction is
8H 8e
SO
4 8H
8H
(16)
S 4H O
2
(17)
FeS
References.
See Callister Ch 18.
Supplementary reading. Fontana: Corrosion Engineering.
(18)