FFACTORS AFFECTING CORROSION

RATES

1. The position of the metal in the emf

series

emf means the electro-motive-force for

the metal M in a solution of the metal ions
itself (M/M+).
If emf for (M/M+) is high:

This means that this metal has a

high corrosion-resistance for most
of the corrosion types in most
environments:

Gold, Platinum, Silver.

Sodium reacts violently with water

but platinum is not attacked by
water or even strong acid.
Three of the common standard reference
electrodes are:

1. copper-copper sulfate electrode,

2. calomel half-cell electrode,

3. hydrogen electrode.
2. Passivity

Passivity in a metal refers to a relatively

inactive state in which it (the metal) displays a
more noble behavior than thermodynamic
considerations predict. It is the reason a metal
does not corrode when it should.
A normal metal is a metal which does not show
passivity effect.
If chromium is added to iron to make a high
chromium (over 12%) steel, this alloy should
be less corrosion resistant than ordinary steel.

Chromium and the stainless steels become

passive, or exhibit passivity, because of the
formation of a protective film on the surface
of the metal.
Aluminum quickly forms a surface coating of
aluminum oxide, which stops further corrosion by
many environments.

Lead is below hydrogen in the emf series, but it

shows excellent resistance to sulfuric acid at
concentrations below 90%. Lead sulfate quickly
forms when lead is exposed to sulfuric acid and
corrosion stops.
In strong, concentrated sulfuric acid, lead
corrodes because lead sulfate dissolves in this
acid and the metal cannot become passive or
passivity is destroyed

Titanium forms a protective film of TiO2,

and high-silicon cast iron forms a protective
silica (SiO2) coating.
It must be emphasized that passivity is a relative
term.

A stainless steel may exhibit passive behavior in

nitric acid and in water, but it would be attacked
by strong hydrochloric acid.

In other words, a metal or alloy is passive or

active only in relation to particular environments.
3. METALLURGICAL STATE:

It means:

The type and number of phases in the

alloy, the shape of the particles and their
distribution.

It also depends on:

The chemical composition of the alloy:
types of elements and their percentages,
types of thermal and mechanical
treatment.
Solid-solution alloys are usually more corrosive
resistant than alloys with two (or more) phases,
since galvanic coupling effects are not present.
Effect of purity of aluminum on corrosion rate by
HCl:

99.998% Al relative corrosion = 1

99.97% Al relative corrosion = 1000

92.2% Al relative corrosion = 30000

4. SURFACE CONDITION:

- Smooth or rough, has oxide films or not, has

other contaminants.

- Grain-boundaries and cracks are high-

energy areas and more active chemistry.
5. COMPOSITION OF ENVIRONMENT:

-Types of elements in the solution and their

concentrations such as O2, H+, oxidant ions such
as Fe3+ or any ions accept electrons (i.e.,
reduced).

6. EFFECT OF TEMPERATURE

Temperature increases the rate of almost all

chemical reactions, as shown in curve A
7. EFFECTS OF CORROSIVE CONCENTRATION
-As acid is increased further,
corrosion rate reaches a maximum
and then decreases,

because at very high concentrations

of acids ionization is reduced.
Because of this, many of the
common acids such as
sulfuric, acetic, hydrofluoric,
and others- are virtually inert
when in the pure state, or
100% concentration, and at
moderate temperature.
8. EFFECT OF OXYGEN AND
OXIDIZERS

Although iron can be made to

passivate in water, the solubility of
oxygen is limited, and in most cases
it is insufficient to produce a passive
state.
 - It is clear that the effect of
oxidizer additions or the
presence of oxygen on
corrosion rate depends on
both the medium and the
metals involved
9. EFFECT OF VELOCITY

For corrosion processes that are controlled by

activation polarization, agitation and velocity
have no effect on the corrosion rate as
illustrated in curve B.
If the corrosion process is under cathodic
diffusion control, then agitation increases the
corrosion rate as shown in curve A, section 1.
If the process is under diffusion control and the
metal is readily passivated, then the behavior
corresponding to curve A, section 1 and 2, will be
observed.
It is believed that both lead and steel are
protected from attack in sulfuric acid by insoluble
sulfate films. When materials such as these are
exposed to extremely high corrosive velocities,
mechanical damage or removal of these films can
occur, resulting in accelerated attack as shown in
curve C. this is called corrosion-errosion.
10. EFFECT OF GALVANIC COUPLING
Since platinum is inert in this
medium, it tends to increase the
surface at which hydrogen
evolution can occur.
Hydrogen evolution occurs much
more on the surface of pt than on
Zn.
These two factors increase the rate of the
cathodic reaction and consequently increase the
corrosion rate of Zn.

11. EFFECT OF TIME

Corrosion rate is not linear with time.

12. OTHER EFFECTS

1. Differential Aeration: it occurs due to the

formation of different oxygen concentrations on
the metal surface.

2. Concentration Cell: it occurs due to the

difference in the oxidizing ions concentration on
the surface of the metal.

3. Biological Effect: Due to the presence of

bacteria in the environment.
 Corrosion Control

Corrosion is normally controlled by one or more

of the follwing:

Material choice
Protective coatings
Cathodic protection
Inhibition
Treatment of environment
Structural design including corrosion allowances
Scheduled maintenance and inspection