Remember These: 1 The process of slow destruction of metals due to chemical or electrochemical attack of the environment at their surfaces

resulting into formation of compounds such as oxides carbonates, suiphides suiphates etc is called corrosion 2 Dry corrosion The direct chemical action of atmospheric gas such as oxygen halogens sulphur dioxide hydrogen sulphide with metals resulting into the formation of compounds such as oxides halides, suiphates and sulphides is referred to as chemical corrosion 3 Pilling Bedworth Rule If volume of oxide layer is less than the volume of metal, the oxide layer is porous and is non protective and if volume of oxide layer is at least equal or greater than volume of metal from which It is formed it is non porous and protective 4 Wet or electrochemical corrosion It occurs under wet or moist conditions through the formation of electrochemical cells

5 Galvanic series Galvanic series predict the corrosion tendencies of metals and non metals in actual enviroment 6 Electroplating In the electroplating coating of another metal is made on the base metal by means of passing direct current through a solution electrolytic in nature This method is used to protect the metals from corrosion 7 Sheradizing A cementation process in which iron articles is cleaned in a drum having zinc dust for 2 3 hours at 350 to 370C Fe-Zn alloy is formed at the surface of base metal 8 Passivation Passivation is the phenomenon by which a metal or alloy show high corrosion resistance due to the formation of protective coating 9 Corrosion Inhibitors Corrosion inhibitors are the substances which retard or stop the corrosion reaction. 10. Galvanic Corrosion : When two dissimilar metals are electrically connected and increase to an electrolyte, the metal higher in electrochemical series undergoes corrosion.

[SHORT ANSWER TYPE QUESTION]

Q 1. Aluminium corrodes in alkaline medium but iron does not. Explain. Ans. Acidic media are generally more corrosive than alkaline and neutral media. Metals ce aluminium and zinc dissolve and are corroded in alkaline medium. But the corrosion rate of iron in oxygen free water is slow until pH is below 5 means iron corrodes in acidic media but not in alkaline media.

Q 2. Explain the type of corrosion with evolution of hydrogen ions. Ans This type of corrosion falls under the category of wet corrosion or electrochernical corrosion. This type of corrosion usually takes place is acidic environment. Thus in acidic medium (absence of oxygen) hydrogen ions aquire electrons with the liberat!on of H2 gas in cathodic reation, whereas

the anodic metal atoms lose their electrons to the environment and pass into solution in the form of positive ions.

Q 3. Pitting corrosion is dangerous, explain. Ans. Pitting corrosion is a- localized corrosion, resulting in the fdrmation of pits or holes. An anode is formed where the film has broken, while the unbroken film (or protective film) acts as a cathode. Pitting corrosion is dangerous because the formation of small anodic and large cathodic areas results in severe corrosion of the anode region. The corrosion takes place at anode - and rust is accumulated. The rust further screens the bottom of the pit from oxygen, thus -increasing the rate of corrosion.

Q 4 What is meant by the term passivity Ans The phenomenon in which a metal or an alloy exhibits a much higher corrosion resistance than expected from the position in the galvanic series, is called passivity.

Q 5 Why alloys are more corrosion than pure metals?

resistant

to

Ans Alloys are more resistant to corrosion because they are homogenous mixture of two or more metals and do not form galvar1ic cells For example Cr is best alloying metal for iron or steel

Q 6 Aluminum is a highly corrosive metal, even that it is used freely in electrical lines for long time Justify Ans Aluminium forms a non porous protectic oxide layer on its surface which protects it from further corrosion So iron corrode faster than Aluminium even though it is below Al in the electrochemical series so it is used freely in electical lines for long time

Q 7 Iron does not rust w1ien zinc coating is broken in a galvanised iron pipe but rusting

occurs if a coating of tin over iron is broken Why? Ans This is because the electrode potential of Zn is less than that of iron (Ez = O 76 and EFe = 0 44V) when coating of Zn gets broken, due to less reduction potentral of Zn, it gets corroded and iron remains safe and does not rust On the other hand electrode potential of tin is higher as compared to Fe i e E5 = o 14 V When the coating of Sn is broken, due to its higher reduction potential it does not corrode while Fe undergoes rusting So iron does not rust when Zn coating is broken in a galvanised iron rod but rusting occurs if a coating of tin is broken

Q 8 Rusting of iron is quicker in saline water than in ordinary water Why? Ans Saline water mainly contains salts like NaCl, which increases the ionization of water and electrochemical reactions are speeded up or corrosion current increases and thus rusting becomes quicker

Q 9 Explain why blocks of magnesium are often striped to the steel hulls of ocean going ships. Ans Mg is more electropositive and act as sacrificial anode and thus prevents the corrosion of ships Therefore Magnesium blocks are striped to steel hulls of ocean going ships to prevent them from corrosion

Q 10 Why does a part of nail inside the wood undergoes corrosion easily? Ans When a nail fixed in wood is not sufficiently tight a film of moisture may spread under it Due to the limited access of air under the nail server corrosion starts below the nail

Q 11 How is galvanization is different from cathodic protection?

Ans Galvanization is the process of coating iron or steel sheets with a thin coat of zinc prevent them from rusting. Whereas cathodic protection is to force the metal to be protected behave like a cathode and corrosion of metal does not occur.

Q 12. State two conditions for wet corrosion to take place. Ans This type of corrosion environment. It occurs occurs in moist

(i) When the conducting liquid is in contact with metal (ii) When two different metals are immersed or dipped partially in the solution.

Q 13. Define Corrosion. Ans. Any process of deterioration and consequent loss of solid metallic materials through an unwanted chemical or electrochemical attack by its environment, starting at its surface, is called corrosion.

Q 14. What is differential aeration? Ans. Differential aeration corrosion : It is a type of concentration cell corrosion. It occurs when one part of metal is exposed to a different air concentration from the other part. Thus a potential gradient or pot. between the differently aerated oxygenated part act as anode aeration causes flow of as differential current. difference arises areas. The poor and differential current called

Example : when a Zn rod is placed in electrolyte solution as shown in fig. the part which is immersed act as anode. So, it is less oxygenated and the part of metal which is outside thea. solution acts as cathode. Thus corrosion occurs at anodic part.

Q 15. What corrosion?

is

dry

corrosion

and

wet

Ans. Dry corrosion Corrosion caused by direct chemical action of atmospheric gases such as oxygen, halogen, sulphur dioxide, hydrogen suiphide with metal surfaces in immediate proximity. Wet corrosion A corrosion which occurs when a conducting liquid is in contact with (a) metal or (b) when two dissimilar metals or alloys are either immersed or dipped partially in a solution.

Q 16. Why does corrosion occur in steel pipe connected to copper plumbing? Ans. Corrosion occurs when electrochemical couple is formed with two dissimilar metals. Iron present in steel lies up in the electrochemical series and acts as anode whereas copper lies lower in the electrochemical series and acts as cathode. Thus a galvanic cell is set up and corrosion occurs.

Q 17. What is Galvanizing?

Ans. Galvanzing : It is the method of coating of Zn on the surface of iron to protect it from corrosion. This is done by dipping the metal in the molten Zn. A protective layer of Zn is formed on the surface of iron and ius it gets protected.

Q 18. What is electrochemical corrosion.? Ans. This type of corrosion occurs due to the existence of separate anodic and cathodic areas between which current flows through the conducting solution. At anodic area oxidation occurs and anodc part of metal is destroyed.

[LONG ANSWER TYPE QUESTION]

Q 1. Write short notes on: (a) Sacrificial anodic protection.

(b) Erosion corrosion. Ans. (a) Sacrificial anodic protection : The metal structure can be saved from corrosion by connecting it with wire to a more active (i.e. more anodic) metal, so that all the corrosion is concentrated at the more active metal. As the more active metal is sacrified in the process of saving from corrosion, hence it is known as sacrificial anode. Metals commonly used as sacrificial anodes are Zn, Al, Mg and their alloys. Zinc is used as sacrificial anode in good electrolytes such as sea water. Magnesium is used in high resistivity electrolytes such as soils due to its most negative potential and it can provide highest current output. Applications 1. Protection of underground cables and pipelines from soil corrosion. 2. Protection of ships and boat hulls from marine corrosion. 3. The formation of rusty water is prevented by the insertion of Mg sheets or rods into domestic water ooilers or tanks.

(b) Errosion Corrosion : Whenever streams of gases, vapours or liquids emerge from an opening and strike with high velocities on the side walls (like in condenser tubes, agilators etc.) the combined effect of the abrading action of turbulent flow and the mechanical rubbing action of particles over a metal surface leads to the break down of a protective film at the spot of impingement. It results in the formation of differential cells at such areas and localized corrosion takes place at the anodic region. This type of corrosion is known as erosion corrosion.

Q 2. What is corrosion of metals? Explain electro-chemical corrosion with its mechanism. OR Explain rusting of Iron with the help of electrochemical theory of corrosion. Ans. Corrosion: The eating-away of the metal surface, when it come in contact with moisture and atmospheric gases like CC2, SO2, 02, H2 to form carbonate, sulphates oxides hydride etc. is called

corrosion for example rusting of iron, tarnishing of silver etc. In this way the metal gets disintegrated. According to electrochernical theory, any corrosion process may- be regarded as an lectro-chemical process in which cathode and anode are formed on the surface of metal and an electrolyte which may be watei acid or salt solution, must be present to allow the flow of electrons current to form-the corrosion products.it should be noted that higher the metal in the electrochemical series, the more easily it is corroded. Mechanism of electro-chemical corrosion : In neutral aq. solution of electrolytes such as NaCI solution in presence of atmospheric oxygen, in presence of which surtace of iron is coated with a thin film of oxide.- However, if this iron oxide film develops some cracks, anodic area are developed on the surface of iron metal. These anodic areas are small surface parts and almost whole of the rust metal surface forms larger cathodic part. At anode areas, iron dissolves as Fe2 ions with the liberation of electrons (oxidation). The liberated electrons flow from anodic to cathodic areas through the iron metal, where electrons are intercepted by the dissolved oxygen.

Q 3 How does sacrificial anode method helps in prevention of submerged oil pipe lines in sea Explain wiLn mechanism Ans In this method the submerged oil pipe line is connected by a wire to a more electro positive or anodic metal and results in the formation of electrochemical cell The more active anodic metal gets corroded slowly but for the time being it will protect the pipe line till it is there This type of anodes are known -as sacrificial anodes Sacrificial anodes are replaced by fresh ones time to time Metals commonly used as sacrificial anodes are Mg, Zn Al and their alloys Mechanism Its mechanism is like galvanic corrosion But here sacrificial anode is corroded not the iron article So protective metal or sacrificial anode gets corroded but metal/pipe line is protected from corrosion

Q 4 Describe various methods employed for protection of metals from corrosion Ans Corrosion methods can be prevented by following

1 By proper designing and selection of material The following points are to be remembered during desiging of a material (i) The direct contact of two dissimilar metals must be avoided (ii) Sharp edges and corners should be avoided (iii) It should be designed in such a way that cleaning and flushing can be done easily (iv) Active metal used should be insulated from more active metals (v) If two dissimilar metals are in contact with each other, then they should be close to each other in electrochemical series i e they should not lie far away from each other in these series (vi) Material used should not be costly (vii) Moist and humid environment should be avoided

2 By using Pure Metal Rate of corrosion decreases if pure metal is used This because in impure metal the impurities are present which increase rate of corrosion So to retard rate of corrosion the impure metal must be replaced with pure metal

3. By changing environment: Corrosion can be reduced by changing environmental rditions which lead to corrosion. For this, following processes are usually done (I) De-aeriation : In this process, 2 is removed to decrease corrosion. (ii) De-humidification : During this process, moisture is reduced to decrease rate of corrosion.

4. By use of corrosion inhibitors : To reduce the process of cOrrosion, some chemicals e used, which are called corrosion inhibitors. These are of two types: (i) Anodic inhibitors : These. inhibit corrosion of anode e.g. some inorganic salts like metal silicates and borates.

(ii) Cathodic inhibitors : These are those chemicals which inhibit corrosion oF cathode e.g. some reducing agents like sodium thiosuiphate and some salts of Ni, Mg etc.

5. Barrier protection : In this method, a barrier is made between metal and environment protect it from corrosion. This can be done by following (i) By applying paint (ii) By applying oil r grease (Ni) By use of varnishes (iv) By Electroplating.. 6. Galvanic protection or Sacrificial protection In this method, the metal to be rotected is coated with other metal which is more active e.g. Fe (having electrode potential = 0.44 V) is coated with Zn (reduction potential E = 0.76 V). Since electrode potential of is less, it will act as anode and undergoes corrosion and Fe being less active

remains rotected. This process of coating Zn over Fe is called galvanisation. Since Fe remains safe because of Zn, so it is called sacrificial method.

Q 5. Explain briefly: (i) Galvanic cell corrosion (ii) Pitting corrosion. Ans. (I) Galvanic Corrosion : It is also called Bimetallic Corrosion. It occurs when vo different metals are in direct contact with each other in the presence of an electrotype. ut of these two metals, the metal which is ranked higher in electrcschemical series behaves s anode and the other metal as cathode. Anode undergoes oxidation and cathode undergoes duction. For example, consider a Zn-Cu cell. Here Zn behaves as anode and Cu as cathode. the Zn metal electrons as: undergoes oxidation and loses

Thus, Zn corrodes away and these electrons flow to cathode which remains protected.

(ii) Pitting corrosion : This type of corrosion is localised accelerated attack, resulting the formation of cavities or pin holes in the metals. The pitting corrosion may be due to following reasons : (1) Metal surfaces are not homogeneous (ii) Protective fNms are not homogeneous. (iii) Environment is not homogeneous. This corrosion is due to difference in concentration of Oxygen in two areas. The ar having crack acts as anode and is having less concentration of 02 while other exposed ar has more concentration of 02 and this exposed part acts as cathode. Due to difference concentration of 02, the corrosion of anodic part occurs which lead to formation of caviti With the passage of time, the pits and cavities become more and more deep. This type corrosion rusins pipes, tubes and vessels.

Q 6. What is corrosion and why is it undersirable? Explain the rusting ro with the help of electrochemical theory of corrosion. Ans. Corrosion : The process of slowly eating away of the metal due to the attack the atmospheric gases on the surface of metal resulting in the forming of compounds such oxides, sulphides, carbonates, suiphates etc. is called Corrosion. for eg. Rusting of iron. Tarnishing of silver. Electrochemical Theory of Corrosion The formation of rust on iron can be explained on the basis of formation of electrochemic cells on the surface of metal. Steps involved are. 1. Water vapours on the surface dissolve CO2 and 2 from air and surface of metal covered with carbonic acid 2. Thus iron when come in contact with H+ ions and dissolved CO2 then oxidises to form. This site is known as anode. Q 7. Discuss the importance of design and material selection in controlling corrosion.

Ans; Proper designing and selection of material plays an important role mV prevention of corrosion. Some importance points are (i) During the selection of material the chemical properties and its reactions with environmental conditions should be kept in mind. (ii) Prevent the formation of electrochemical couples when two dissimilar metals are present n corroding environment. (iii) Sharp edges and corners should be avoided. (iv) Two dissimilar metals in contact with each other should Vbe close to each other in electrochemical series i.e. difference in their electrode potentials should be least. (v) By adjusting pH of solution (i.e. acidic or Valkaline) corrosion can be prevented. (vi) The material which act Vas anode, should have large area as compared to the area of metal acting as cathode.

(vii) Moist and humid environment should be avoided. Suitable inhibitors should be used if required. (viii) A proper design and structure can avoid the stress in some parts of equipments. (ix) Insulators can be used in between two dissimilar metals when their contact is unavoidable. (x) Using pure metal (xi) A proper design and structure can avoid the stress in some parts of equipments.(2 In this by proper designing and selection of material, corrosion can be prevented.

Q 8. Discuss briefly (i) Galvanic corrosion (ii) Stress corrosion.

Ans. Galvanic Corrosion : Also known as bimetallic corrosion when two different metals are in contact and exposed to atmosphere, the metal with lower reduction potential i.e. higher position in the electrochemical series gets corroded. This type of corrosion is called galvanic corrosion eg Zn and Cu, Zn and Ag, Fe and Cu. Zn with higher oxidation potential than Cu act as anode and the electrons flow from anodic metai to cathodic metal. The anodic metal is corroded, while the cathodic metal remains protected. it can be minimized by (I) Avoiding galvanic couples (ii) Providing insulating material between the two reactive metals. Example is plumbing. steel pipe connected to copper

Stress Corrosion : During the manufacturing of metals, metals undergo certain processes such as bending. pressing, annealing, quenching, rolling etc. Which cause stress on some areas of the metal such areas under stress can act as anode, where as other areas act as cathode. The potential

difference is developed between the strained and unstrained part of the metal. This accelerates the corrosion of strained part of the metal. For stress corrosion mainly two requirements are there : (i) Stressed metallic areas (ii) Corrosive environment. For example acidic chloride solutions are stainless steel and traces of ammonia for brass and alkaline environment for steel. Example of stress corrosion is season cracking i.e. stress corrosion of brass. Main components of brass are Zn and Cu. Both are prone to stress corrosion in ammonical en,ironrnent. Metal lose s to form ions at the stressed protion.

Q 9. Discuss types of metallic coatings with examples Ans. Protective Coatings : Proctecting Coatings are used to protect the base metal from corrosion. These coating can be 1. Metallic Coatings

2. Nonmetallic Coatings 1. Metallic Coatings : The metals oftenly used to protect the base metal are Zn, Al, Cr etc. There are two types of metallic coatings. (a) Anodic Coatings (b) Cathodic Coatings (a) Anodic Coatings : In this coating is done with the metal which lies above in the electrochemical series or we can say that which is more anodic already discussed in sacrificial anodes. The coated metal protect the base metal till it is present there and so termed as sacrificial anode example Al and Zn on the surface of steel. (b) Cathodic Coatings : in this coating is done with the metal Which is noble and homogeneous. These metals have more corrosion resistance characteristics: The coating should be tree from scratches, holes, discontinuity. If any of these appear then corrosion starts. e.g. coating of Tin on iron.

2. Non metallic coatings. These coatings are done with the help of inorganic materials. These can be done with many inorganic acids, salts etc. (a) Surface coatings: In this coating is made on the surface of metalmaking it corrosion resistant. ThIs can be done by various materials. For example phosphate coatings, chromate coatings or chemical oxide coatings. (b) Oxide coatings : In this corrosion resistant oxide layer is formed by some metals like Zn, Mg, Al and their alloys. These coatings are iisually coloured, thick due to organic dyes and inorganic salts. (c) Porcelain enamel coatings : The enamel coatings are made on clean surface by the material made up by mixing quartz and feldspar with additives like borax, cryolite, soda- ash flourspur etc. These materials are known as frit. These coatings prevent corrosion by chemical and electrochemical mechanism. The dry process is better but expensive.

Q 10. Write in brief about pitting and soil corrosion. Ans. Pitting corrosion: Pitting corrosion is a localised accelerated attack at some places on the metal surface, esulting in the formatiQn of pits, holes or cavities. Pitting corrosion thus results in the formation of pinholes, pits as well as cavities in the metal, and these irregularities may penetrate deep into th metal causing destruction of pipes and tubes of various types. The pitting corrosion may be due to the following important reasons. (a) Metal surface are not homogeneous. (b) External environment is not homogeneous. (c) Films are not perfectly uniform. (d) Crystallography directions are not equal in the reactivity (e) Environment are not uniform with respect to concentration Soil corrosion Corrosion of soil is very important in case of water mains electric cables and other

underground structures ihich are embended in the soil The corrosiveness of the soil depends upon various factors such as (a) Its activity (b) Degree of aeration (c) Electrical conductivity (d) Its moisture and salts contents (e) Soil texture (f) Presence of bacteria and micro organisms etc (a) The corrosion of soil depends upon the content of oxygen, moisture and soluble matter (solid, liquid and gas) The greater the contents the greater is the corrosion (b) The corrosion increases with increase in the concentration of H ions

(c) Greater the electrical conductivity the greater is the corrosion (d) Certain types of bacterial in the soil are responsible for the oxidation of organic matter and other oxidisable matter and produce gases which may cause corrosion It has been found that if the metal is not electrically stimulated from outside and there is no corrosion caused by bacteria, the rate of corrosion decreases with time This is due to stifled anodac process that is caused itself with the passage of time (e) Presence of strong currents may also stimulate electrolytic corrosion (f) Soil corrosion is purely electro-chemical in nature. The mechanisms of soil corrosion is similar to hydrogen evolution corrosion if the soil are acidic in nature The rate of corrosion in acidic soil depends upon the pH or acidity of soil the presence of salts and the content of oxygen etc

Q 11. What is corrosion and how it can be prevented?

Ans. Corrosion The eating away of the metal surface, when it come in contact with moisture and atmospheric gases like C02, so2 02, H2 to form carbonate,, suiphates oxides hydride etc. is called corrosion for example rusting of iron, tarnishing of silver etc. In this way the metal gets disintegrated. Corrosion can be controlled by following methods. (I) By proper designing and material selection. (ii) By using pure metal (iii) By using metal alloys (iv) Cathodic protection (v) By Galvanisation (vi) Anode protection or sacrificial anodes (vii) By changing enviroi,ment (viii) By barrier protection or Protective coatings (ix) By using anti rust solutions.

(x) By use of inhibitors.

Sacrificial Anodic Protection : In thistype of corrosion ihe metal to be protected is connected to a more electropositive metal so the metal to be protected act as cathode and other more reactive metal act as anode and corrosion occurs on the more active metal known as sacrificial anode. Zn, Al, Mg are the electropositive metals which are widely used. For high resistivity electrolytes like soils, Mg is used as sacrificial anode. For sea water Zn is best suited as sacrificial anode: With the passage of time, the more active metal gets consumed but s long as it is present there, it will protect the metal from corrosion and does not allow even the nearly exposed surface of metal to react. Proper designing and selection of material plays ah important role in prevention of corrosion. Some importance points are (i) During the selection of material the chemical properties and its reactions with environmental conditions ,should be kept in mind.

(ii) Prevent the formation of electrochemical couples when two dissimilar metals are present in corroding environment. (iii) Sharp edges and corners should be avoided. (iv) Two dissimilar metals in contact with each other should be close to each other in electrochemical series i.e. difference in their electrode potentials should be least. (v) By adjustng pH of solution (i.e. acidic or alkaline) corrosion can be prevented. (vi) The material which act as anode, should have large area as compared to the area of metal acting as cathode. (vii) Moist and humid environment should be avoided. Suitable inhibitors should be used if required. (viii) A proper design and structure can avoid the stress in some parts of equipments.

(ix) Insulators can be used in between two dissimilar metals when their contact is unavoidable. (x) Using pure metal. (xi) A proper design and structure can avoid the stress in some parts of equipments. In this by proper designing and selection of material, corrosion can be prevented. Galvanic corrosion can be minimized by (i) Avoiding galvanic couples (ii) Providing insulating material b/w the two reactive materials. Example is steel pipe connected to copper plumbing.