Electrochemistry

Lesson XI
Corrosion
 Corrosion- What is it?
• Corrosion comes from the Latin word
“Corrodere” and means “To gnaw”.
• Corrosion is the gradual destruction of most
metals, this can be through a chemical or
electrochemical reaction to its environment
(oxidization with Air and water).
• The most common form of corrosion is oxidation.
• Can also be described as a transfer of electrons
from one metal to another.
 Corrosion- How it Happens?
There are many different types of corrosion:
• Galvanic corrosion
• Pitting corrosion
• Crevice corrosion
• Microbial corrosion
• High temperature corrosion
• Passivation
 Galvanic Corrosion
• Galvanic corrosion occurs when two dissimilar metals are in contact
with each other or have an electrical current passing through them
while they are both immersed in an electrolyte, (salt water).
• Because the metals are different, one will be more active (the
Anode) and one will be more noble (the cathode).
• The Anode will be the metal that corrodes while the Cathode is
protected.
• Cathodes have more electrons in their outer shell and so readily
accept electrons while anodes have less and so are ready to give up
electrons and therefore degrade.
• This type of corrosion is typically used to protect a metal by
sacrificing the Anode, typically on Steel structures.
 Galvanic Corrosion
• This is an example of
galvanic corrosion
between steel and
aluminium. Aluminium
is more active than the
steel and so is
perforated and the joint
between the steel and
aluminium.
 Galvanic Series
• This is where the resistance to corrosion is determined, also known as ‘Nobility’.
• The test ‘Electrolysis’ is used to determine the Nobility of materials.
• Electrolysis is where an anode and cathode and submerged in an electrolyte solution.
• An electrolyte solution such as salt water is exploited used to accelerate the corrosion
process. Both the anode and cathode are attached to an electrical current, the anode to the
positive terminal and cathode the negative. This test is a controlled ‘Galvanic Corrosion’
process.
• Anodic is sometimes described as being ‘Active’ because it has high corrosion potential.
Cathodic therefore is described as being ‘Less Active’ these materials have less corrosion
potential, or Nobility.

From wikipedia
• “When two metals are submerged in an electrolyte, while electrically connected, the less
noble (base) will experience galvanic corrosion. The rate of corrosion is determined by the
electrolyte and the difference in nobility. The difference can be measured as a difference in
voltage potential. Galvanic reaction is the principle upon which batteries are based.”
Electrochemical Corrosion of Iron
 Implications- Statue of Liberty
• Corrosion degrades the useful properties of materials and
structures including strength and appearance.
• In the 1980’s regular maintenance shows that galvanic
corrosion had taken place between the copper skin, and
the iron support structure. Although this was anticipated
and insulation ‘Shellac’ which was used between the two
metals also failed over time, resulting in corrosion of the
iron support structure. Renovation took place to replace
the old insulation with PTFE. The structure itself although
was partially corroded was largely unaffected and was
therefore deemed safe enough to leave it.
 Pitting Corrosion
• Pitting corrosion is a very localised form of corrosion, which causes small
holes in the metal affected.
• Pitting corrosion is a very localised form of galvanic corrosion and the
galvanic corrosion can be started by a small scratch or damage to a
protective coating.
• Pitting is more common in alloys that are protected against corrosion by
using a passivation layer. These include stainless steel, nickel alloys and
aluminium alloys. Normal carbon steel will not tend to pit as mild steel
corrodes uniformly.
 Pitting- Example
• A single pit in a critical point can cause a great deal of
damage. One example is the explosion in Guadalajara,
Mexico on April 22, 1992, when Gasoline fumes
accumulated in sewers destroyed kilometres of streets. The
vapours originated from a leak of gasoline through a single
hole formed by corrosion between a steel gasoline pipe and
a galvanised steel water pipe.
 Crevice Corrosion
• Crevice corrosion occurs in confined spaces where a gap is
large enough to allow the ingress of corrodent however are
small to allow it to stay stagnant. These could be small cracks
and seams or contact areas between parts.
• Poor design can lead to crevice corrosion such as overlapping
surfaces, under gaskets and around poorly welded areas.
• Crevice corrosion can be seen as a less severe type of
localised corrosion when compared to pitting corrosion, in
that the depth and rate of corrosion from pitting is much
greater.
 Microbial Corrosion
• This is also called bacterial corrosion and is caused by micro-
organisims, the most common being chemoautotroph.
• Microbial corrosion can effect metallic and non metallic materials.
• Some of the bacteria produce chemical compounds, and acid iron
oxides and iron hydroxides.
• Hydrocarbon utilizing microorganisms or “HUM bugs” can be a
problem in jet fuels as they can cause corrosion to plastic and
rubber parts of the fuel system. They also can corrode the metallic
parts
• FSII is an additive which is mixed with the fuel, this slows the rate
of growth of the micro-organisms.
 High temperature corrosion

– High Temperature Corrosion – Is a type of corrosion which occurs

in machinery which comes into contact with hot gases which
contain contaminants. Fuel sometimes contain sulphates which
melt at very low temperature during combustion. The liquid salts
are extremely corrosive for stainless steel and other alloys which
are usually resistant to corrosion and high temperatures.
• Typical there are two type of sulphate induced high temperature
corrosion, type 1 and type 2.
• Type 1 takes place above the melting point of sodium sulphate.
• Type 2 takes places below the melting point of sodium sulphate, but in
the presence of SO3.
Preventing Corrosion
 Applying Protective Coatings
• Putting a barrier of material between the metal to be protected
and the corroding environment.
• Painting
– Exposed metal can be primed and painted to stop air and water coming
into contact with the metal.
– A break in the paint such as a scratch will expose the metal and corrosion
will start.
• Electroplating
– Metals can be plated with other metals which provide corrosion
resistance.
– Two metals are submerged in a solution called an electrolyte, a current is
passed through which causes the anode to be dissolved and plated onto
the cathode.
 Electroplating
• Electroplating Materials
– Copper
– Gold – Excellent corrosion resistance
– Silver
– Nickel – Good corrosion resistance
– Tin – Good corrosion resistance
– Solder – Good corrosion resistance
– Brass
– Cadmium
– Palladium
– Zinc – Good corrosion resistance
• Some of these materials are not used to prevent corrosion but are still
plated onto other metals due to their other properties such as
conductivity.
 Galvanising
• Galvanising is when a protective coating of zinc is
applied to steel or iron to prevent rust.
• Hot-dip galvanisation is when the iron or steel to be
coated is passed through a molten bath of zinc.
• Galvanisation can also be done using an
electroplating method but the coating will not be as
thick as the hot-dip method.
• If the zinc coating is scratched, the zinc will act as an
anode and will still corrode before the steel or iron.
 Galvanising

Image from http://upload.wikimedia.org/wikipedia/commons/0/03/Galvanized_surface.jpg

 Corrosion Inhibitors
• Corrosion inhibitors can be added to a liquid or
gas to suppress their corrosive properties.
• Such as anti-freeze and water in the radiator and
cooling system for an engine.
• This method for preventing corrosion is usually
used in closed loop situations such as a cooling
loop.
• Some chemicals that prevent corrosion are
chromates, phosphates and polyaniline.
 Passivation
• Passivation occurs naturally or can be applied
with other methods.
• In air, most metals will form a natural hard layer
of oxide or nitride.
• These layers are more noticeable on aluminium,
zinc, titanium and copper.
• By forming an outer layer of oxide or nitride,
corrosion is prevented from penetrating further.
 Anodising
• Anodising is usually used for aluminium and is a method of
passivation
• Uses electrolytic passivation to increase the thickness of the
natural oxide layer.
• The aluminium acts as an anode in an electrolytic solution as a
current is passed through it.
• After the electrolytic passivation process is complete the
aluminium needs to be sealed with a dye which is why anodised
components can come in many colours.
• If the layer is scratched normal corrosion will occur at that location.
• The layer is fairly resistant, but should be cleaned regularly to avoid
panel edge staining.
 Anodising

Image from http://upload.wikimedia.org/wikipedia/commons/f/fd/Belaying8.jpg

 Sacrificial Anodes
(Passive Cathodic Protection)
• Sacrificial anodes are a passive method of protection and are
usually used when submerged in water or another liquid that
conducts electricity.
• A sacrificial metal is attached to the metal to be protected.
• The sacrificial metal acts as an anode and the metal to be
protected acts as a cathode.
• The two metals must have good electrical contact.
• The sacrificial anode should have a more negative electrical
potential than the cathode. Which is shown on the galvanic series.
• Since the cathode has more electrons in the outer shell than the
anode, the cathode will accept electrons from the anode via
electrical current, preventing it from corroding.
 Sacrificial Anodes

Image from http://upload.wikimedia.org/wikipedia/commons/3/38/Electrode_protecting_a_screw.jpg

 Active Cathodic Protection
• Works on the same principle as passive
cathodic protection
• The anode and cathode are connected to a
low voltage DC power source.
• Active protection can protect a larger area
than passive protection.
• The voltage provided by the power source can
be adjusted to provide optimum protection.
Active Cathodic Protection
 Preventing Corrosion by Design
• Corrosion tends to start in small crevices and
confined spaces first.
• Careful consideration should be taken when
designing a component that will be open to
the elements.
• Older cars tend to be prone to corrosion
where moisture can collect.
THANK YOU