Mechanism of electrochemical corrosion due to evolution of H2 gas

In acidic environments.
At anode,
Fe changes to Fe+2 ions with loss of electron
Fe ----> Fe+2 + 2e- oxidation.
At cathode,
H2 gas are eliminated.
2H+ + 2e- ----> H2 reduction.

The overall reaction is

Fe + 2H+ -----> Fe2+ + H2

In hydrogen evolution type corrosion, the

anodes are very large areas, where as
cathodes are small areas.
 Factors affecting the rate of electrochemical corrosion
 Position of metal in electrochemical series :
Higher the metal in electrochemical series,
higher is its oxidation potential. Hence its
easily to oxidize and get corroded.

• Influence of pH value:
pH value of any electrolyte is lowered then rate
of corrosion increases as acids are more
corrosive to metals than neutral or alkaline
solutions.
• Oxygen concentration cell :
Less oxygen concentration part are anodic while
more oxygenated parts are cathodic form the
cell. Anodic part suffer from corrosion.
 Factors affecting the rate of electrochemical corrosion
• Uneven metal surface:
Rate of corrosion increases in case of uneven metal surfaces. Trough
becomes anode and get corroded and crest become cathode.

• Solubility of the corrosion product:

If the corrosion product is more soluble, then fast corrosion of metal will
take place.
• Presence of electrolyte:
Presence of electrolyte in water increases the rate of corrosion.
Ex. Corrosion of iron in sea water is more rapid than in ordinary water.
Corrosion Control

 Method used for prevention of corrosion –

1. Modification of Environment

2. Modification of properties of metal

3. Electrochemical protection

4. Application of protective coating

Modification of Environment –
The corrosive nature of environment can be reduced by
a) By aeration
- Removing the oxygen concentration cell by removing oxygen

b) Deactivation
-Dissolved oxygen can be removed by adding calculated quantity
of sodium sulphite (Na2SO3) or hydrazine (N2H4.H2O)

c) Dehumidification
- Moisture content of air can be reduced by adding Alumina or
silica gel

d) Alkaline Neutralization
- The acidic nature of corrosive environment can be neutralized
by adding alkaline substances such as NH3, NaOH, Lime, etc
Modification of properties of metal –
Metal can be protected from corrosion by modifying its nature and
properties.
a) Purification of metal

-If metal consist of impurities with low oxidation potential than

metal then form tiny voltaic cell and increases rate of corrosion.
While pure metal becomes anode and get corroded.
b) Alloy formation
-In alloy stable non-porous and adherent oxide film forming
constituent are added which resist further corrosion. Ex. Stainless
steel containing chromium produce oxide film protect the metal
from corrosion.
Use of protective Coating –
The inorganic protective coating of metal is very useful to minimize
the corrosion.
a) Oxide film formation
- The more active metals like aluminium, zinc, nickel, tin, chromium
form insoluble oxide film on the surface of metal and protect the
metals from corrosion.
b) Phosphate coating
- An insoluble ferric phosphate is to be formed on the surface of iron
by dipping it in phosphoric acid.
-Ferric phosphate adheres on the metal surface and protects the
metals.
c) Metal coating
- Coating of (less active Sn-Tin metal) and (more active Zn-zinc
metal) is very useful for protecting metal from corrosion.
Method of applying Metallic Coating –
Different methods given below are used for protective metallic coating.

a) Hot dipping-

1. Galvanizing

2. Tinning

b) Metal spraying

c) Sherarding

d) Metal cladding

e) Electroplating
Metallic Coating ( Galvanizing-Zn )–
Galvanizing is the process of coating iron sheet with a thin coat of
zinc by dipping it in molten zinc to prevent it from rusting and
corrosion.
Galvanizing-Zn
a) Advantages :
- In Galvanizing process, Zn becomes anodic and gives cathodic
protection to the base metal.
- The low cost of Zn is easily applied as a coat and give cathodic
protection.

b) Disadvantages :
- Zinc coated article can not be used for preparing and storing food
stuffs because of its toxic nature.

c) Applications :
- It is used for all forms of outdoor hardware, pipes, sheet for
roofing, structural parts, buckets and water tanks.
Metallic Coating ( Tinning - Sn )–
Tinning is the process of coating iron sheet with a thin coat of tin by
dipping it in molten tin to prevent it from rusting and corrosion.
Tinning-Sn
a) Advantages :
- Sn being cathode to the base metal.
- It is more resistant to the chemical attack and protect the base
metal

b) Disadvantages :
- Tin coated article gives protection only when the surface of base
metal is completely covered. But it take place corrosion after
breaking in the coating.

c) Applications :
- Tinned utensil are used as cooking utensil and refrigeration
equipment.
- Copper wire is tinned to facilitate soldering.
- Tinned container are used for storing food stuff.
 Anodic and Cathodic Protection–

 In This method, a more active metal is connected to the metal

structure to be protected. So more active metal will become anodic
and suffer from corrosion. While less active metal structure
becomes cathodic and is to be protected.
 The more active metal is called sacrificial anode.

 Ex. Underground pipeline can be protected by connecting it to

magnesium bar.