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Types of corrosion:
1) Dry corrosion: Corrosion in the absence of moisture/aqueous medium.
It is a direct chemical action of atmosphere gases like CO2, SO2, Cl2,
etc or to strong acids, Alkali. on Metals,
Ex: Most of the Alkali (Li, Na, K, Rb, Cs) and alkaline earth metals( Mg, Ca,
Ba) undergo dry corrosion
Oxidation by Oxygen in absence of moisture
Liquid metal corrosion: Molten metal passing through another metal (at
High temperature during metallurgical refining process)
Metal exposed to strong acids, Alkali.
At Cathodic area:
H2 Evolution O2 Absorption
(absence of O2) (Presence of O2)
Acidic (pH˂7) 2H+ + 2e H2 2H+ +1/2 O2 + 2e H 2O
Overall Reaction:
Fe2+ + 2OH- Fe(OH)2↓ (it precipitates near cathode)
When it is further exposed to air
Rust-Reddish brown
Ti Pb-Sn alloy
Metal-1 Metal-2
Small anodic area and large cathodic area results into intense corrosion at
anode.
Weight loss is marginal but effect is more.
6) Temperature:
If the temperature increases,
conductivity of the medium increases
adherence property of the film decreases
passivation decreases
volatility of the corrosion product increases
solubility of the corrosion product increases
Hence corrosion also increases
3) Organic Coating:
a) Paints b) Enamels c) Lacquers
Before coating:
1) Cleaning of the Object:
a) Sand blasting, polishing, Grinding : removing dust, making surface uniform.
b) Washing with organic solvents like toluene, CCl4, and CH2Cl2: to remove grease
and other organic dust.
c) Washing with NaOH: to remove acidic impurities
d) PICKLING: it is the process of removing rust from the object using 10% H2SO4 at
75°C.
e) Washing with water and then drying the object for COATING.
Dr. MANJUNATHA.C Asst. Prof CHEMISTRY,
10/9/2019 28
RVCE
Metallic Coating:
Methods of metallic coating: 1) Hot dipping, 2) Electroplating, 3) Metal cladding 4)
cathodic sputtering 5) Metal Spraying 6) Vacuum coating 7) Cementation;
Hot Dipping method:
a) Anodic metallic coating: It is the process of coating the metal, which is more anodic
nature, on the surface of base metal (cathodic).
Ex: Galvanization: It is the process of coating of Zn layer on Fe/steel objects.
Anodic: Zn, Cathode: Iron/steel.
Process: 1) Cleaning, Drying of iron/steel object to be coated.
2) The cleaned Fe/steel object is made to pass through molten zinc (m.pt=419°C) taken
in a container as shown below. The surface of molten zinc is covered with NH4Cl flux,
which prevents the oxidation of melted Zn. The Fe/steel object coated with Zn is further
passed through rollers to make surface smooth and uniform.
1) Phosphating:
In this process metal surface is converted to metal phosphate using
phosphoric acid, in the presence of catalyst.
Chemicals required:
H3PO4, which reacts with surface Fe, converts to Fe3(PO4)2.
Mn/Zn-phosphates increases adherence property and decreases porosity of
the layer.
Peroxide, nitrates, chromates as Catalyst.
Conditions: temp:35-40°C, pH=3
The Al object is made as anode by connecting to Pb/steel cathode, both are placed in
chromic acid at 40°C. The current of voltage 40-60V from DC source is induced, Al
surface under goes oxidation as follows:
2Al + 3H2O Al/Al2O3 + 3H2
Electroplating:
Definition: Electroplating is the process of electrolytic deposition of a metal on the surface of
another metal; the substrate may be another metal, a polymer, a ceramic or a composite
DC power
Supply ne-
ne-
Anode + __ Cathode
__
__
__ Electroplated
__
Metal layer
Electrolyte
1. Current density: When the current density is low, the metal is deposited
slowly. There is enough time for the metal nuclei to grow, and there is little scope
for the creation of new nuclei. Thus the deposits produced are gross grained.
Within certain limits, an increase in current density increases the rate of
deposition and decreases the crystal size. This results in fine grained uniform
deposit.
When the current density is high (below the limiting value), a bad deposit
with rough and powdery texture results.
When the current density is very high (above the limiting value), hydrogen
evolution also occurs at the cathode. This results in the formation of OH- ions in
the vicinity of cathode. These OH- ions react with the metal ions forming
insoluble metal hydroxides. When these hydroxides are included with in the
electrodeposit, a burnt and spongy deposit results.
In general, for a particular bath, the optimum current density is
experimentally determined and applied.
4. Complexing agents: Complexing agents are used to maintain a low metal ion
concentration. (e.g. addition of NaCN to CuCN to get low concentration of Cu+ ).
Low metal ion concentration decreases the crystal size and results in fine deposit.
Complexing agents are also used to improve the throwing power of the bath.
Higher the throwing power, more uniform is the deposit.
8. Throwing power of the plating bath: Higher the throwing power of the
plating bath, more uniform is the deposit.
b) Alkali cleaning: Residual oil and grease from the surface is removed by
treatment with alkaline solutions (NaOH, Na2CO3 etc.) Alkali cleaning is made
more effective by making the metal cathodic in a hot alkali solution. The hydrogen
gas liberated at the cathode helps to dislodge the greasy matter.
Dr. MANJUNATHA.C Asst. Prof CHEMISTRY,
10/9/2019 53
RVCE
2. Removal of inorganic substances – descaling process:
a) Mechanical cleaning: It is used to remove oxide scales and rust from the
metal surface. Simple mechanical cleaning involves hand cleaning using sand
paper, bristle brush etc. Other methods involve polishing the surface i) using
grinding wheels, ii) by sand blasting and iii) by electropolishing.
b) Pickling: It is used to remove oxide scales and rust present on the metal
surface by dissolution. Pickling involves dipping the object in dilute acids (HCl,
HNO3, H2SO4 or a mixture) for considerable period of time.
3) Rinsing with water: The object is finally rinsed with deionized water.
ELECTROLESS PLATING
Definition of electroless plating: Electroless plating is a method of depositing a
metal over a substrate by controlled chemical reduction of metal ions by a
suitable reducing agent without using electrical energy.
1. A source of electroactive metal in the form of a soluble salt. e.g. NiCl2, CuSO4
2. Reducing agent to reduce metal ions into metal atoms. e.g. Sodium
hypophosphite, formaldehyde.
3. Complexing agents to form complex compounds with metal ions.
4. Exaltant (accelerator) to increase the rate of plating.
5. Stabilizer to give more stability to solution.
6. Addition agents such as brighteners.
7. Buffer to control pH.
Insulting base
Copper foil
Etching of copper to produce
tracking
Drilling of through-holes
properties.