Corrosion OP – Monday

1 Is the electrical circuit in a corrosion reaction AC or DC?

The electrical circuit in a corrosion reaction is DC.

2 Does corrosion occur at the cathode or at the anode?

Corrosion occurs at the anode.

3 Name the three factors needed for corrosion to occur.

Anode – Cathode - Electrolyte

4 What is meant by the term electrolyte?

A substance that will conduct current and be broken down by it (dissociate to ions).

5 What is corrosion?

Corrosion is degradation of a metal due to chemical or electrochemical means.

6 In the corrosion circuit do electrons flow from anode to cathode?

No. In the corrosion circuit electrons flow from cathode to anode.

7 Which gas is released at the cathode when the electrolyte is water?

Hydrogen (H2)

8 Which is the more noble metal, steel or aluminium?

A noble metal is one that does not corrode easily. In the galvanic list (also called electrochemical series
or electromotive forces series), featuring potentials, measured in Volts, steel is higher in order than
aluminium and therefore, steel is the more noble metal.

Higher in the order/raw  More noble

Lower in the order/raw  Looses electrons more easily and therefore becomes electrochemically
unstable.

9 Which is more electronegative, steel or aluminium?

In the galvanic list, aluminum is lower rated, i.e. has a higher negative potential and therefore is more
electronegative.

10 If steel and copper were in contact in an electrolyte which would corrode?

If steel and copper were in contact in an electrolyte, steel would corrode.

11 Name two common hygroscopic salts.

Sulphuric salts and chloride salts. Sulphuric salts are present in industrial and sometimes agricultural
areas and chloride salts are present in marine environment.
12 Name three metals used as sacrificial anodes on a steel pipeline

Zinc, aluminium, magnesium. All three metals have a higher (in absolute value) potential in the galvanic
list, i.e. are electrochemically unstable.

13 What is the approximate thickness of millscale?

The approximate thickness of millscale ranges from 25-100μm.

14 Which of the two metals would corrode if steel and zinc were coupled?

If steel and zinc were coupled, zinc would corrode. That is why zinc is used in cathodic protection
systems in steel pipelines.

15 Which other names relate to the galvanic list?

Galvanic list is also known as electro-chemical series and electromotive force series.

16 In which environment are you likely to encounter chloride salts?

Chloride salts are likely to be encountered in marine environments.

17 Which three compounds together form millscale?

Millscale is formed during the rolling operation of steel sections, such as RSC (roller steel column), RSA
(roller steel angles), RSJ (roller steel joists). Millscale is formed very easily at temperatures above 580°C.
It comprises out of 3 oxides, i.e. FeO (wustite), Fe 3O4 (magnesite) and Fe2O3 (haematite). In terms of
aspect it is a bluish flaky coating.

18 If magnesium was coupled with zinc, which would corrode?

If magnesium was coupled with zinc, magnesium would corrode.

19 In which environment would sulphate salts be found?

Sulphate salts are to found in industrial or agricultural environments.

20 What is an osmotic blister?

An osmotic blister is a blister occurring when a steel surface is contaminated with hydroscopic salts and
without being cleaned it is covered with paint. The hydroscopic salts absorb air moisture, swell and build
up pressure, forming an osmotic blister on the paint’s surface. They are defined as pinhead sized water
filled blisters.

(Exact book wording: When salts are present on a surface and a coating is applied over them, water will
be drawn through the paint film and the resulting solution builds up a pressure under the film. Eventually
the film is forced to form blisters. These blisters are called osmotic or hydroscopic blisters and are
defined as pinhead sized water filled blisters).

21 What is an ion?

An ion is a charged particle, negatively or positively charged. It can be an atom or a group of atoms,
called a molecule.
22 What is meant by polarisation? Not contained anywhere in the course!

The displacement of positive and negative electric charge to opposite ends of a nuclear, atomic,
molecular, or chemical system, especially by subjection to an electric field. Atoms and molecules have
some inherent polarization. ... Polarization results in a reduction of the electric potential across the
voltaic cell.

23 Is an anode positive or negative?

An anode is positive.

24 Can corrosion occur without an electrolyte?

Corrosion requires three elements to occur: Anode – Cathode – Electrolyte. So in case of absence of an
electrolyte, corrosion cannot occur.

25 Name a sub atomic particle.

Three are the main subatomic particles: Protons, Neutrons and Electons.

26 What is millscale and when and where does it occur?

Millscale is a flaky surface, formed during the rolling operation of steel sections, such as RSC (roller steel
column), RSA (roller steel angles), RSJ (roller steel joists). Millscale is formed very easily at temperatures
above 580°C. Millscale is a combination of oxides layers on steel surface, formed together during rolling
of steel sections at high temperatures, with an approximate thickness of 25-100μm.

27 Name three factors, which can accelerate corrosion reactions.

a) Oxygen (aerobic conditions)

b) Bacteria
c) Hydroscopic salts
d) Temperature
e) Presence of other metals (bi-metallic corrosion)
f) Acids and alkalis

28 Why is it considered essential to remove millscale prior to painting?

Millscale is higher than steel in the galvanic table and therefore steel is more electrochemically unstable
(millscale is more noble). Therefore, when these two metals come in contact, steel will corrode before
millscale will.

29 Why does an un-coated steel plate corrode?

For corrosion to take place, three factors must be present at the same time: Anode – Cathode –
Electrolyte. It one is missing, corrosion will not occur. The most common element to withdraw is the
electrolyte. In order to eliminate the electrolyte, one needs to place a barrier between the anode and
the cathode. This role is played by the paint (i.e. coating). If the anode and the cathode are not in direct
contact, there can be no circuit and corrosion cannot take place.
30 If corrosion occurs at anodic areas, why does steel corrode evenly all over the surface? Not contained
anywhere in the course!

Because there is no protection at the whole steel surface.