CORROSION

CONTENTS
• Introduction
• Cause
• Theories of corrosion
• Types of corrosion
• Factors affecting corrosion
• Corrosion control
Few corrosion cases in daily
life
 Corrosion: The loss of materials(metal and
alloys) or its useful properties, by chemical or
electrochemical interaction with its
environment.

Examples:
1. Rusting of iron.
2. Formation of green layer on copper surface.
Corrosion vs Rusting?

Corrosion Engineering: The branch of Engineering

dealing with the study of corrosion mechanisms and
to prevent or control it economically and safely.
FACTS ABOUT CORROSION
• Corrosion is a natural process.
• Corrosion is an electrochemical process.
• Corrosion leads to tremendous loss. It can’t be
eliminated completely. However, its extent can be
minimized.
• Corrosion is exactly the reverse of extraction of
metals and also known as weeping of metals.
 CAUSE OF CORROSION

Metal Metal salt

(higher energy state) (lower energy state)
 Theories of corrosion:
1. Direct Chemical attack , Chemical
Corrosion, Dry Corrosion.
2. Wet or electrochemical corrosion
3. The acid theory
 THEORIES OF CORROSION

1. Direct chemical attack theory (Chemical

corrosion or dry corrosion)
By direct attack of oxidizing agent (O2, S,
halogens, H2S) in absence of a liquid or electrolyte
• Insoluble corrosion product – further corrosion is
checked. E.g. Attack of Cl2 or I2 on Ag
• soluble or liquid corrosion product – further
corrosion is continued. e.g in the de-tinning of
metal cans
 Types of Chemical Corrosion
1. Oxidation corrosion
2. Corrosion by other gases
3. Liquid metal corrosion.
Types of chemical corrosion

i) Oxidation Corrosion
2M 2Mn+ + 2ne- (oxidation)
n/2O2 + 2ne- nO2- (reduction)
2M + n/2O2 2Mn+ + nO2-

Metal oxide

MO layer: FILM – thickness ≤ 300Å

SCALE - thickness > 300Å
Nature of metal oxide layer
a) Stable film –An impervious layer is formed,
which checks further oxidation corrosion.
e.g. oxide films on Al, Sn, Pb, Cu etc.

b) Unstable film-
Metal oxide Metal + O2

O2 Metal oxide
decomposes
e.g. in Au and Ag
 c) Volatile film- oxide layer volatilizes leaving the
underlying metal surface for further attack.
E.g. molybdenum oxide (MoO3) is volatile.

O2 metal oxide
volatilizes

d) Porous film- atmospheric O2 have access to the

underlying surface of metal.
Case I: When metal ion diffuses faster outward:
In this case oxide layer is formed at the metal oxide – gas or
scale – gas interface. e.g. In FeO, CoO, NiO, Cu2O
Case II: When oxygen diffuses inward:
In this case oxide layer is formed at the metal- scale
interface or metal – metal oxide interface. e.g in ZnO,
CdO, TiO2 etc
 Pilling Bedworth rule
If Volume of metal oxide ≥ volume of metal
Oxide layer is protective or non-porous
e.g. Al
If Volume of metal oxide < volume of metal
Oxide layer is porous
e.g. Alkali and alkaline earth metals

ii) Corrosion by other gases- by CO2, SO2,Cl2,H2S,

etc
•Nature of chemical Interaction
•Film formed
 protective or non-porous.
E.g. AgCl layer formed by the attack of
Cl2 on Ag
Film
non-protective or porous.
E.g. i) formation of volatile SnCl4 by the
attack of dry Cl2 on Sn.
ii) in petroleum industry, H2S at high T
attacks steel forming porous FeS scale
iii) Liquid metal corrosion- occurs due to the
chemical action of flowing liquid metal at high T on
solid metal or alloy.
Possible processes are:
• Dissolution of a solid metal by a liquid metal
• Internal penetration of the liquid metal into the solid
metal
2. Wet or electrochemical corrosion
(electrochemical theory): Also called ‘immersed
corrosion’.
Two essential requirements are:
i) Formation of anodic and cathodic areas
ii) Electrical contact between the cathodic and anodic
parts to enable the conduction of e-
Mechanism
i)Anodic reactions
M(s) Mn+(aq) + ne- (oxidation)
Fe(s) Fe2+(aq) + 2e- (oxidation)
Fe2+(aq) + 2OH-(aq) Fe(OH)2
 ii) Cathodic reactions
a)Electroplating
Cu2+(aq) + 2e- Cu(s)
b) In acidic solution in the absence of O2
2H+ + 2e- H2
c) In acidic solution in the presence of O2
O2 + 4H+ + 4e- 2H2O
d) In neutral or alkaline medium in the absence of O2
2H2O + 2e- H2 + 2OH-
(e)In neutral or alkaline medium in the presence of O2
O2 + 2H2O + 4e- 4OH-
(such type of corrosion involving O2 is called oxygen
type corrosion)
e.g. Rusting of iron occurs by O2 in the presence of
aqueous solution
At anode Fe Fe2+ 2e-
At cathode 1/2O2 + H2O + 2e- 2OH-
Overall reaction Fe + 1/2O2 + H2O Fe2+ + 2OH- or Fe(OH)2
(i)In excess supply of oxygen: In excess supply of
oxygen, ferrous hydroxide is easily oxidized to ferric
hydroxide.
2Fe(OH)2 + H2O + 1/2O2 2Fe(OH)3

Fe2O3.xH2O
Yellow rust
(ii) In limited supply of oxygen: In limited supply of
oxygen, black magnetite Fe3O4 or ferroferric oxide is
formed.
Fe(OH)2 Fe2O3.FeO.6H2O
Black
 Wet corrosion Dry corrosion
•It takes place in presence of water It takes place in absence of liquid or
• or an electrolyte. electrolyte. Gases and vapours are
• the corrodants.

•It is an electrochemical attack. It is a chemical attack.

•It generally takes place at low It takes place at high temperature.

• temperature.

•It is also known as low It is also known as high

•temperature corrosion. temperature corrosion.

•It is generally fast. It is generally slow.

•Eg. Rusting of iron in water. Eg. Attack of steel furnace by gases at

• high temperature.

•
 3) The Acid Theory – applicable particularly to
rusting of iron
2Fe + O2 + 4CO2 + 2H2O 2Fe(HCO3)2
2Fe(HCO3)2 + H2O + [O] 2Fe(OH)CO3+2CO2+ 2H2O
2Fe(OH)CO3 + 2H2O 2Fe(OH)3 + 2CO2
 TYPES OF CORROSION
[I] Galvanic Corrosion (Bimetallic corrosion):
E.g. Zinc and copper couple
More reactive Zn Zn2+ + 2e- At anode
(Corrodes)
Less reactive Cu2+ + 2e- Cu At Cathode
(protected)
Factors affecting galvanic corrosion:
(i) Potential difference between the two metals
coupled
(ii) Relative area of cathode and anode

e.g. a) Steel pipe connected to copper plumbing.

b) Steel screw in brass marine hardware
 Electrochemical series Galvanic series
The arrangement of metals and non-metals in increasing order The arrangement of metals and alloys in
their standard reduction potential is known as decreasing order of their corroding
electrochemical series tendency in an unpolluted
sea water is known as galvanic series.

It contains metals and non-metals It contains metals and alloys.

It is an ideal series It is a practical series

ECS is based upon the electrode potential which This series is based on actual
is determined by using Nernst equation corrosion rate

Position of metals is fixed in ECS Position of a given metal in Galvanic

series may change

It gives no idea about the position of alloys It gives clear idea about the position of
alloys

It gives information about the It gives information about the

displacement tendencies relative corrosion tendencies
[II] Erosion Corrosion:
Due to abrading action of flow of gases or
mechanical rubbing action of solids over the
metal surface.
[III] Crevice Corrosion:
Due to cracks in paint coating
[IV] Pitting Corrosion:
Most dangerous form of corrosion as it leads to
sudden failure of material due to formation of
holes.
Facts about pitting corrosion
• Pitting corrosion is autocatalytic, self
stimulating and self propagating.
• It takes place exclusively in chloride and
chloride containing environment.
 [IV] Differential aeration Corrosion
(Oxygen Concentration Cell Corrosion)

• One part of the metal is exposed to a different

air/O2 concentration from the rest of the part.
• Portion with lesser O2 = Anode
• Portion with more O2 = Cathode
• e.g. A iron nail inside the wood undergoes
corrosion easily
[V] Waterline Corrosion
[VI] Micro-Biological Corrosion :
Due to metabolic activity of various micro-
organisms
[VII] Stress-Corrosion Cracking
•Metal under stress becomes more anodic and
tend to increase the rate of corrosion.
•The stress can be due to non-uniform
deformation by unequal cooling from high
temperature as in welding
 Factors affecting chemical corrosion
1. Nature of the metal
i) Position in the Galvanic series
ii) Relative areas of anode and cathode
iii) Purity of metal
iv) Solubility of corrosion products
vi) Volatility of corrosion products
(vii) Nature of surface film :
Specific volume ratio = Volume of metal oxide
volume of metal

(viii) Passive character of metal: Tl, Al, Cr, Mg etc form

thin layer of passive metal oxide.
e.g. Cr present in stainless steel
2. Nature of environment

i) Temperature: Rate of chemical reaction and rate of

diffusion increases with temperature
ii) Presence of moisture:
Critical humidity is the relative humidity above which
the atmospheric corrosion rate of metal increases
sharply
(iii)Presence of impurities in atmosphere: due to
CO2, H2S, SO2 etc in the vicinity of industrial area
(iii) Effect of pH
(iv)Nature of ions present: Chloride ions present in
the medium destroy the passive film, while silicate
in the medium leads to the formation of insoluble
film over the metal surface.
(v) Concentration of O2
 PROTECTION FROM CORROSION
[I] Design and Material Selection
 When contact of dissimilar metals is unavoidable,
suitable insulator should be inserted between them
to reduce current flow and attack on the anode.
[II] Cathodic Protection
(i) By appropriate galvanic coupling:
(ii) By impressed current
 advantages over sacrificial cathodic
protection
• It is controlled from outside.
•No anode has to be replaced.
[III] Modifying the Environment
i) Deaeration
ii) Deactivation : addition of chemicals, capable of
combining rapidly with O2 in aqueous solution
iii) Dehumidification: by using alumina or silica gel
iv) Alkaline neutralization
v) Use of inhibitors
a. By forming a layer in between which acts as a
barrier between the material and environment.
b. Or by retarding the anodic or cathodic or both
processes
4. Metallic coatings
i. Electroplating
ii. Hot dipping
iii. Vaporising
iv. Metal spraying
v. Cementation: The base metal articles are packed
in the powdered coating metal and is heated to a
temperature just below the m.p. of more fusible
metal, so that an alloy layer is formed over the
surface.
Metallic coating are of two types:
Sacrificial coating
Noble coating

Sacrificial coating Noble coating

Base metal is coated with a metal which is Base metal is coated with a
more reactive than the base metal. metal which is more noble than the
base metal.

Protects the underlying base metal sacrificially. Protects the underlying base metal
due to its noble character and
higher corrosion resistance.

This is known as anodic coating as the reduction This is known as cathodic coating as
potential of coating metal is less than that the reduction potential of coating
the base metal. Metal is more than that of the base
metal

Zn, Cd, Al are generally used as sacrificial coating Ni, Ag, Cr, Pb, Au etc. are generally
used as noble coating
E.g. Galvanised iron i.e. coating of Zn E.g. coating of Sn on Fe
on Fe.
5. Inorganic non-metallic coatings
i. Chemical dip coating or surface conversion
ii. Anodized oxide coating

6. Organic coatings