Professional Documents
Culture Documents
Corrosion P
Corrosion P
Project Report On
CORROSION
submitted in partial fulfilment of the
All India Senior School Certificate Examination of Chemistry
Practical
of
CBSE-2021-22
Submitted By
PARTH DADHICH
Under the guidance of
MR. IMRAN KHAN
2021-22
1
SHREE MAHESH PUBLIC SCHOOL
2021-22
CERTIFICATE
2
ACKNOWLEDGEMENT
“There are times when silence speaks so much more loudly than words of praise
to only as good as belittle a person, whose words do not express, but only put a
veneer over true feelings, which are of gratitude at this point of time."
Every Orientation work has an imprint of many people and I hereby take this
opportunity to acknowledge all the help, guidance & moral support that I have
received for the completion of this project named “CORROSION” with supreme
sincerity and deep sense of appreciation, I express my heartily thanks to Mr.
Imran Khan (PGT-Chemistry) for his cooperation and guidance.
I express my gratitude towards our principal Mrs. Arvinder Kaur who has
guided us regarding the project and give valuable suggestions. She inspired us
and also provided all facilities needed for completion of project.
Above all, I would like to thank my beloved parents for their direct and indirect
help, moral support and blessings without which, this would not have been
possible.
I would also like to express thanks to my friends, for their help and moral support.
Lastly I would like to thank all those who directly or indirectly helped us
throughout my work.
PARTH DADHICH
3
TABLE OF CONTENTS [TOC]
01 INTRODUCTION 06
02 CORROSION 07
03 GALVANIC CORROSION 08
04 RUST IN IRON 10
05 CORROSION IN ZINC 14
06 CORROSION IN COPPER 19
07 CORROSION IN ALUMINIUM 21
10 PRACTICAL 29
11 BIBLIOGRAPHY 33
4
AIM
5
INTRODUCTION
Many structural alloys corrode merely from exposure to moisture in the air,
but the process can be strongly affected by exposure to certain substances.
Corrosion can be concentrated locally to form a pit or crack, or it can extend
across a wide area more or less uniformly corroding the surface. Because
corrosion is a diffusion-controlled process, it occurs on exposed surfaces. As a
result, methods to reduce the activity of the exposed surface, such as
passivation and chromate conversion, can increase a material's corrosion
resistance. However, some corrosion mechanisms are less visible and less
predictable.
6
CORROSION
In the most common use of the word, this means electrochemical oxidation of
metal in reaction with an oxidant such as oxygen or sulfates. Rusting, the
formation of iron oxides is a well-known example of electrochemical corrosion.
This type of damage typically produces oxide(s) or salt(s) of the original metal
and results in a distinctive orange coloration. Corrosion can also occur in
materials other than metals, such as ceramics or polymers, although in this
context, the term "degradation" is more common. Corrosion degrades the
useful properties of materials and structures including strength, appearance
and permeability to liquids and gases.
Many structural alloys corrode merely from exposure to moisture in air, but
the process can be strongly affected by exposure to certain substances.
Corrosion can be concentrated locally to form a pit or crack, or it can extend
across a wide area more or less uniformly corroding the surface. Because
corrosion is a diffusion-controlled process, it occurs on exposed surfaces. As a
result, methods to reduce the activity of the exposed surface, such as
passivation and chromate conversion, can increase a material's corrosion
resistance. However, some corrosion mechanisms are less visible and less
predictable.
7
GALVANIC CORROSION
Galvanic corrosion occurs when two different metals have physical or electrical
contact with each other and are immersed in a common electrolyte, or when
the same metal is exposed to electrolyte with different concentrations. In a
galvanic couple, the more active metal (the anode) corrodes at an accelerated
rate and the more noble metal (the cathode) corrodes at a slower rate. When
immersed separately, each metal corrodes at its own rate. What type of
metal(s) to use is readily determined by following the galvanic series. For
example, zinc is often used as a sacrificial anode for steel structures. Galvanic
corrosion is of major interest to the marine industry and also anywhere water
(containing salts) contacts pipes or metal structures.
Factors such as relative size of anode, types of metal, and operating conditions
(temperature, humidity, salinity, etc.) affect galvanic corrosion. The surface
area ratio of the anode and cathode directly affects the corrosion rates of the
materials. Galvanic corrosion is often prevented by the use of sacrificial
anodes.
8
Galvanic series
Corrosion removal
9
RUSTING OF IRON
Rusting of iron refers to the formation of rust, a mixture of iron oxides, on the
surface of iron objects or structures. This rust is formed from a redox reaction
between oxygen and iron in an environment containing water (such as air
containing high levels of moisture). The rusting of iron is characterized by the
formation of a layer of a red, flaky substance that easily crumbles into a
powder.
The exposure of iron (or an alloy of iron) to oxygen in the presence of moisture
leads to the formation of rust. This reaction is not instantaneous; it generally
proceeds over a considerably large time frame. The oxygen atoms bond with
iron atoms, resulting in the formation of iron oxides. This weakens the bonds
between the iron atoms in the object/structure.
The reaction of the rusting of iron involves an increase in the oxidation state of
iron, accompanied by a loss of electrons. Rust is mostly made up of two
different oxides of iron that vary in the oxidation state of the iron atom. These
oxides are:
10
1. Iron (II) oxide or ferrous oxide. The oxidation state of iron in this compound
is +2 and its chemical formula is FeO.
2. Iron (III) oxide or ferric oxide, where the iron atom exhibits an oxidation
state of +3. The chemical formula of this compound is Fe2O3.
Fe → Fe2+ + 2e–
The oxidation state of iron is further increased by the oxygen atom when
water is present.
Now, the following acid-base reactions occur between the iron cations and the
water molecules.
The hydroxides of iron are also formed from the direct reaction between the
iron cations and hydroxide ions.
Rusting causes iron to become flaky and weak, degrading its strength,
appearance, and permeability. Rusted iron does not hold the desirable
properties of iron. The rusting of iron can lead to damage to automobiles,
railings, grills, and many other iron structures.
The collapse of the Silver Bridge in 1967 and the Mianus River Bridge
in 1983 is attributed to the corrosion of the steel/iron components of the
bridge. Many buildings made up of reinforced concrete also undergo structural
failures over long periods of time due to rusting.
Rusted iron can be a breeding ground for bacteria that cause tetanus.
Cuts from these objects that pierce the skin can be dangerous.
Since rusting occurs at an accelerated rate in humid conditions, the
insides of water pipes and tanks are susceptible to it. This causes the pipes to
carry brown or black water containing an unsafe amount of iron oxides.
Many factors speed up the rusting of iron, such as the moisture content in the
environment and the pH of the surrounding area. Some of these factors are
listed below.
The size of the iron object can also affect the speed of the rusting process. For
example, a large iron object is likely to have small deficiencies as a result of the
smelting process. These deficiencies are a platform for attacks on the metal
from the environment.
12
How can Rusting be prevented?
Iron and its alloys are widely used in the construction
of many structures and in many machines and objects. Therefore, the
prevention of the corrosion of iron is very important. Some preventive
methods are listed below.
Galvanization
Cathodic Protection
• Providing the metals with an electric charge can help inhibit the
electrochemical reactions that lead to rusting.
• This can be done by making the iron/steel a cathode by attaching a
sacrificial anode to it.
• This sacrificial anode must have an electrode potential that is more
negative than that of iron.
• Metals that are commonly used as sacrificial anodes are magnesium, zinc, and
aluminum. Once they are corroded away, they must be replaced in order to
protect the iron/steel.
13
CORROSION OF ZINC
Zinc is more corrosion resistant than steel in most natural atmospheres, the
exceptions being ventilated indoor atmospheres where the corrosion of both
steel and zinc is extremely low and certain highly corrosive industrial
atmospheres.
Coatings of metallic zinc are generally regarded as the most economical means
of protecting against corrosion. Seven methods of applying a zinc coating to
iron and steel are in general use: hot dip galvanizing, continuous-line
galvanizing, electro-galvanizing, zinc plating, mechanical plating, zinc spraying,
and painting with zinc-bearing paints.
Zinc is more corrosion resistant than steel in most natural atmospheres, the
exceptions being ventilated indoor atmospheres where the corrosion of both
steel and zinc is extremely low and certain highly corrosive industrial
atmospheres. For example, in seacoast atmospheres the corrosion rate of zinc
is about 1/25 that of steel.
14
Zinc owes its high degree of resistance to atmospheric corrosion to the
formation of insoluble basic carbonate films. Environmental conditions that
interfere with the formation of such films may attack zinc quite rapidly.
The important factors that control the rate at zinc corrodes in atmospheric
exposures are:
In dry air, zinc is slowly attacked by atmospheric oxygen. A thin, dense layer of
oxides formed on the surface of the zinc, and outer layer then forms on top of
it. Although outer layer breaks away occasionally, the under layer remains and
protects the metal restricting its interaction with the oxygen. Under these
conditions, which occur in some tropical climates, the zinc oxidizes very slowly.
15
The corrosion of zinc in water is largely controlled by the impurities present in
the water. Naturally occurring waters are seldom pure. Even rainwater, which
is distilled by nature, contains nitrogen, oxygen, CO2, and other gases, as well
as entrained dust and smoke particles. Water that runs over the ground carries
with it eroded soil, decaying vegetation, living microorganisms, dissolved salts,
and colloidal and suspended matter. Water that seeps through soil contains
dissolved CO2 and becomes acidic. Groundwater also contains salts of calcium,
magnesium, iron, and manganese. Seawater contains many of these salts in
addition to its high NaCl content.
All of these foreign substances in natural waters affect the structure and
composition of the resulting films and corrosion products on the surface, which
in turn control the corrosion of zinc. In addition to these substances, such
factors as pH, time of exposure, temperature, motion, and fluid agitation
influence the aqueous corrosion of zinc.
Corrosion in dissolved salts, acids and bases. Zinc is not used in contact with
acid and strong alkaline solutions, because it corrodes rapidly in such media.
Very dilute concentrations of acids accelerate corrosion rates beyond the limits
of usefulness. Alkaline solutions of moderate strength are much less corrosive
than corresponding concentrations of acid, but are still corrosive enough to
impair the usefulness of zinc.
16
Organic Compounds. Many organic liquids that are nearly neutral in pH and
substantially free from water do not attack zinc. Therefore, zinc and zinc-
coated products are commonly used with gasoline, glycerin, and inhibited
trichloroethylene. The presence of free water may cause local corrosion
because of the lack of access to oxygen. When water is present, zinc may
function as a catalyst in the decomposition of such solutions as
trichloroethylene with acid attack as the result. Some organic compounds that
contain acidic impurities, such as low-grade glycerin, attack zinc. Although
neutral soaps do not attack zinc, there may be some formation of zinc soaps in
dilute soap solutions.
Gases. Zinc may be safely used in contact with most common gases at normal
temperatures if water is absent. Moisture content stimulates attack. Dry
chlorine does not affect zinc. Hydrogen sulfide (H2S) is also harmless because
insoluble zinc sulfide (ZnS) is formed. On the other hand, SO2 and chlorides
have a corrosive action because water-soluble and hygroscopic salts are
formed.
Rapid corrosion can occur where the temperature decreases and where visible
moisture that condenses on the metal dries slowly. This is related to the ease
with which such thin moisture films maintain high oxygen content because of
the small volume of water and large water/air interface area.
17
Zinc Coating Processes
Coatings of metallic zinc are generally regarded as the most economical means
of protecting against corrosion. Seven methods of applying a zinc coating to
iron and steel are in general use: hot dip galvanizing, continuous-line
galvanizing, electro-galvanizing, zinc plating, mechanical plating, zinc spraying,
and painting with zinc-bearing paints.
There is usually at least one process that is applicable to any specific purpose.
Because the processes are complementary, there are rarely more than two
processes to be seriously considered as the best choice for a particular
application.
Hot Dip Galvanizing. In hot dip galvanizing, the steel or iron to be zinc coated is
usually completely immersed in a bath of molten zinc. It is by far the most
widely used of the zinc coating processes and has been practiced commercially
for almost two centuries. The modern hot dip galvanizing process is conducted
in carefully controlled plants by applying the results of scientific research, and
it is far removed from that of years ago although it is still dependent on the
same basic principles.
18
CORROSION OF COPPER
There are two known types of copper corrosion which are uniform copper
corrosion and non-uniform copper corrosion.
19
❖ Modeling Corrosion and Corrosion Protection
Certain conditions can cause copper corrosion when the copper is exposed
to particular soils, including:
20
CORROSION OF ALUMINIUM
Corrosion is the chemical reaction of a metal, in this case aluminum, with its
environment, which leads to the deterioration of the properties of metals,
aluminum in this case. Aluminum is a very reactive metal, but it is also a
passive metal. This contradictory nature is explainable because nascent
aluminum reacts with oxygen or water and forms a coherent surface oxide
which impedes further reaction of aluminum with the environment.
21
Aluminum alloys may corrode via several different pathways. Recognizing the
pathway or the forms of aluminum corrosion is an important step to determine
the appropriate remedy for each probe.
Atmospheric Corrosion
Uniform Corrosion
Galvanic Corrosion
Crevice Corrosion
22
between a bolt and a structure. When aluminum is wetted with the saltwater
and water enters the crevice, little happens initially. Over time, inside the
crevice oxygen is consumed due to the dissolution and precipitation of
aluminum.
Pitting Corrosion
23
Deposition Corrosion
The more important heavy metals are copper, lead, mercury, nickel, and tin.
The effects of these metals on aluminum are of greatest concern in acidic
solutions; in alkaline solutions, they have much lower solubilities and therefore
much less severe effects.
Intergranular Corrosion
The location of the anodic path varies with the different alloy systems. In 2xxx
series alloys, it is a narrow band on either side of the boundary that is depleted
in copper; in 5xxx series alloys, it is the anodic constituent Mg2AI3 when that
constituent forms a continuous path along a grain boundary; in copper-free
7xxx series alloys, it is generally considered to be the anodic zinc- and
magnesium- bearing constituents on the grain boundary. The 6xxx series alloys
generally resist this type of corrosion, although slight intergranular attack has
been observed in aggressive environments.
24
METALS WHICH ARE RESISTANT TO CORROSION
Resistance to corrosion
Some metals are more intrinsically resistant to corrosion than others (for some
examples, see galvanic series). There are various ways of protecting metals
from corrosion (oxidation) including painting, hot dip galvanizing, and
combinations of these.
Intrinsic chemistry
The materials most resistant to corrosion are those for which corrosion is
thermodynamically unfavorable. Any corrosion products of gold or platinum
tend to decompose spontaneously into pure metal, which is why these
elements can be found in metallic form on Earth and have long been valued.
More common "base" metals can only be protected by more temporary
means.
Some metals have naturally slow reaction kinetics, even though their
corrosion is thermodynamically favorable. These include such metals as zinc,
magnesium, and cadmium. While corrosion of these metals is continuous and ongoing,
it happens at an acceptably slow rate. An extreme example is graphite, which releases
large amounts of energy upon oxidation, but has such slow kinetics that it is effectively
immune to electrochemical corrosion under normal conditions.
Passivation
Pitting corrosion
26
can interfere with a given alloy's ability to re-form a passivating film. In the
worst case, almost all of the surface will remain protected, but tiny local
fluctuations will degrade the oxide film in a few critical points. Corrosion at
these points will be greatly amplified, and can cause corrosion pits of several
types, depending upon conditions. While the corrosion pits only nucleate
under fairly extreme circumstances, they can continue to grow even when
conditions return to normal, since the interior of a pit is naturally deprived of
oxygen and locally the pH decreases to very low values and the corrosion rate
increases due to an autocatalytic process. In extreme cases, the sharp tips of
extremely long and narrow corrosion pits can cause stress concentration to the
point that otherwise tough alloys can shatter; a thin film pierced by an invisibly
small hole can hide a thumb sized pit from view. These problems are especially
dangerous because they are difficult to detect before a part or structure fails.
Pitting remains among the most common and damaging forms of corrosion in
passivated alloys but it can be prevented by control of the alloy's environment.
Rate of corrosion
27
CORROSION PROTECTION METHODS
28
PRACTICAL
• Aim :
To study of the effect of metal coupling on the rate of corrosions.
• Materials required:
Apparatus: Beakers-15, Iron sheets of 2 size-6, Aluminum rods of 2 size-6, Brass
rods of 2 size-6, Zinc sheets of 2 size-6, Measuring cylinders, Chemical Balance,
Weight Box. Chemicals: Hydrochloric acid and Sodium hydroxide.
• Theory:
Corrosion is a serious problem of some metals like iron, zinc, aluminum and
alloys like brass which are commonly used in day to day life.
Apart from reducing the life of articles made up of these metals or alloys
the chemical substances formed out of corrosion have serious public
health problems.
Replacement of machines or their parts and many other articles in industrial
and public dealing lead to huge expenditure. Hence, how to reduce or avoid
corrosion of articles made up of metals or alloys has been a major subject of
study in the field of chemistry and electro-chemistry.
• Procedure:
▪ Mix 9 ml. of conc. HCl with 241 ml. of water to form 250 ml. of solution.
▪ Take this solution in seven different beakers
▪ Mark each beaker serially from 1 to 7.
▪ Take the weights of three iron sheets, three aluminum rods, three brass
rods and three zinc sheets.
▪ Now keep iron sheets, aluminum rods, zinc sheets and brass rod in separate
beakers. Then take iron + brass, iron + aluminum, iron + zinc, aluminum +
zinc and brass + zinc and keep them in different beakers.
▪ Allow the reactions to occur for 24 hours Note the maximum and minimum
temperatures.
29
▪ Now at the end of reaction take out the metals and keep them in sun for
sometime so that they get dried up quickly take the weights of each
specimen and note the difference. Similarly repeat 1,2,3,4,5,6,7 and 8 steps
in a basic solution.
• Observations:
30
• Results :
31
• Conclusions:
▪ Corrosion is a serious problem of some metals like iron, zinc, aluminum and
alloys like brass which are commonly used in day to day life
▪ Apart from reducing the life of articles made up of these metals or alloys
the chemical substances formed out of corrosion have serious public health
problems.
▪ Replacement of machines or their parts and many other articles in
industrial and public dealing lead to huge expenditure
▪ Hence, how to reduce or avoid corrosion of articles made up of metals or
alloys has been a major subject of study in the field of chemistry and
electro- chemistry.
▪ The study of the rate of corrosion of different metals or alloys showed
gradual decrease in their masses in acidic medium. The decrease is in the
order of brass, iron, zinc, aluminum.
▪ The present experiments are in full agreement with the well-known electro-
chemical reaction. Some of the typical reactions as occur with iron are
illustrated.
32
BIBLIOGRAPHY
33