Title : The corrosion of different metals

in salt water and tap water

Name : Chuah Boon Sheng 970420-08-5117 SA6007/1021

Lee Chee Hooi

970324-08-5731 SA6007/1026

Loo Wooi Chun

970614-08-5051 SA6007/1028

Teh Hong Khai

960719-08-5489 SA6007/1034

Abstract
The purpose of this coursework is to study corrosion of different metal in salt water
and tap water. Corrosion of metal depends on type of metal and surrounding
condition. In corrosion process, metal will undergoes oxidation and form other
substances. Thus, its original metal mass will decrease, corrosion rate can be
calculated from the mass lost. The experiment was carried out in salt water and tap
water. After certain time, the change in mass was recorded and rate of corrosion was
determined.

In

salt

aluminium(0.30142mpy),

water,

the

corrosion

rate

brass(0.26369mpy),

of

metals

plate

for

copper(1.59325mpy),

lead(1.34400mpy), tin(0.33202mpy), zinc(0.14993mpy). While the corrosion rate in

tap water of metals plate for aluminium(0.73380mpy), brass(0.16618mpy),
copper(0.10516mpy), lead(0.35978mpy), tin(0.16359mpy), zinc(0.34907mpy). In
conclusion, metal that corroded the fastest in salt water is copper and the slowest is
zinc, in tap water, metal that corroded the fastest is aluminium and the slowest is
copper.

Introduction :
Corrosion refers to the gradual destruction of objects, typically metals, caused
by environment and chemical reaction. It accurately refers to electrochemical metal
oxidation with oxygen as oxidant. One of the best examples of this phenomenon is
formation of rust. Corrosion may also take place in non-metal materials such as
polymers and ceramics.

When metal atoms are exposed to an environment containing water molecules

they can give out electrons, themselves becoming positively charged ions, provided an
electrical circuit can be completed. This effect can be concentrated locally to form a
pit or, sometimes a crack, or it can extend across a wide area to produce general
wastage.

Localised corrosion that leads to pitting may provide sites for fatigue

initiation and additionally, corrosive agents like seawater may lead to greatly
enhanced growth of the fatigue crack. Pitting corrosion also occurs much faster in
areas where microstructural changes have occurred due to welding operations.

Corrosion theory entails that the process involves an anodic reaction. This
type of reaction is produced through dissolving metal, which generates electrons.
This is further consumed by another process called cathodic reaction. These two
processes balance the charges produced. The sites generating these processes may be
found close or far apart, depending on the situation.

The electrons generated by the process need to be consumed through cathodic

reaction. This should be closed to the process of corrosion itself. Hydrogen ions and
electrons react to build atomic hydrogen, and later, hydrogen gas. When hydrogen
forms, further corrosion can be prevented through a thin gas film at the metal surface.
This film serves as a polarizer, which is functional in decreasing metal-to-water
contact, reducing corrosion. Thus, anything that breaks the barrier film tends to
hasten the speed of corrosion.

There are some important parameters that affecting the corrosion rate of
metals such as oxidizing agent, electric conductivity of electrolyte, temperature and
concentration. To avoid the affecting of parameters, we can take some precaution
steps by using the same temperature or concentration throughout the experiment.

In conclusion,corrosion of metal can cause negative effects like rusting of iron

in an engine . So, we must use it wisely to obtain the positive results by using paint or
lubricating oil to prevent the metal from corrode faster.

Theory :
To calculate corrosion rate from weight loss coupons, use the following equation :

Where weight loss is the weight loss due to corrosion and is determined by
subtracting the weight after cleaning from the initial weight, metal density is the
density of the coupon or coupon alloy from the following table, coupon area is the
surface area of the coupon that is exposed to the corroding process, and time is the
period in days between installation and removal of the coupon.

The above equation is used for calculation of corrosion rates in mpy (miles per year)
when the area of the coupon is in inches and the time of exposure is in days.

Alloy
Actinium
Aluminum
Brass
Carbon steel
Copper
Copper-Nickel. 90/10
Copper-Nickel, 70/30
Lead

Density (g/cm3)
10.07
2.71
8.52
7.86
8.91
8.94
8.94
11.34

Alloy
Nickel 200
Iron
Magnesium
Silver
Tin
Titanium
Vanadium
Zinc

Density (g/cm3)
8.89
7.85
1.74
10.49
7.28
4.50
5.49
7.13

Literature Review :
According to http://science.howstuffworks.com/question445.htm , Rust is the
common name for a very common compound, iron oxide. Iron oxide, the chemical
Fe2O3, is common because iron combines very readily with oxygen -- so readily, in
fact, that pure iron is only rarely found in nature. Iron (or steel) rusting is an example
of corrosion -- an electrochemical process involving an anode (a piece of metal that
readily gives up electrons), an electrolyte (a liquid that helps electrons move) and a
cathode (a piece of metal that readily accepts electrons). When a piece of metal
corrodes, the electrolyte helps provide oxygen to the anode. As oxygen combines with
the metal, electrons are liberated. When they flow through the electrolyte to the
cathode, the metal of the anode disappears, swept away by the electrical flow or
converted into metal cations in a form such as rust.

For iron to become iron oxide, three things are required: iron, water and
oxygen. Here's what happens when the three get together: When a drop of water hits
an iron object, two things begin to happen almost immediately. First, the water, a good
electrolyte, combines with carbon dioxide in the air to form a weak carbonic acid, an
even better electrolyte. As the acid is formed and the iron dissolved, some of the water
will begin to break down into its component pieces -- hydrogen and oxygen. The free
oxygen and dissolved iron bond into iron oxide, in the process freeing electrons. The
electrons liberated from the anode portion of the iron flow to the cathode, which may
be a piece of a metal less electrically reactive than iron, or another point on the piece
of iron itself.

The chemical compounds found in liquids like acid rain, seawater and the saltloaded spray from snow-belt roads make them better electrolytes than pure water,
allowing their presence to speed the process of rusting on iron and other forms of
corrosion on other metals.

In short, corrosion depends on type of metal, type of solution and surrounding

condition.

Problem Statement :
Generally we know that metal corrode faster at sea side. The factor that could
affect the corrosion rate is type of water, so the experiment is carried out by using
different type of water. Different metal have different lifespan because their corrosion
rate are different, so experiment is carried out with different metal to determine which
metal corrode fastest and slowest in two different types of water, namely tap water
and salt water.

Objectives :
-

To determine whether aluminum, brass, copper, lead, tin and zinc metal
corrode in tap water and salt water

To inverstigate which metal corrode faster in tap water and salt water

To determine which metal suitable to use at sea side

Materials and apparatus :

-

Copper plate (9.9cm x 7.4cm)

Lead plate (13.4cm x 6.8cm)
Aluminum plate (11cm x 7.3cm)
Zinc plate (5.4cm x 5.2cm)
Brass plate (9.9cm x 7.1cm)
Tin plate (13.5cm x 4.5cm)
12x100ml container
4 teaspoon of salt
Tap water
Electronic balance (0.01g)

Procedure :
1. Cut two pieces of each type of metal plates which is aluminum, brass, copper,
lead, tin and zinc metal.
2. Measure the length of the metal plates and calculate the area of the metal
3.
4.
5.
6.

plates.
Measure the weight of the metal plates before the experiment is carried out.
Fill the six 100ml containers with 2/3 full of tap water.
Fill the six 100ml containers with 2/3 full of salt water.
Immerse one piece of aluminum plate in container which filled with tap water

and another aluminum plate in container which filled with salt water.
7. Repeat step 6 with brass, copper, lead, tin and zinc metals.
8. Take photographs of the metal plates at the beginning of the experiment.
9. Observe the metal plates at least once a day for 4 weeks.
10. Take photographs of the metal plates at the end of the experiment.
11. At the end of the experiment, compare the weight loss of 5 set of metal plates
which kept in tap water and salt water.
12. The metal plates is taken out from solution and dry the metal plates by using
hair dryer and the weight of the metal plates is measured to find out the weight
loss.
13. Calculate the corrosion rate of the metal plates by using the results of weight
loss that has found.
14. Record the change in the mass of the metal plates in tap water and salt water.

Observations :

Photo 1 : The metal plates in salt water before the experiment

Photo 2 :

The

metal

plates in
tap water before the experiment

In salt water

Tin

Brass

Lead

Zinc

Copper Aluminum

Photo 3 : The metal plates in tap

experiment

Metal plate
Aluminum
Brass
Copper
Lead
Tin
Zinc

In tap
water

Tap water
White precipitate is formed.
No change.
No change.
White precipitate is formed.
No change.
White precipitate is formed.

water and salt water after the

Salt water
White precipitate is formed.
White precipitate is formed.
Greenish precipitate is formed.
White precipitate is formed.
White precipitate is formed.
White precipitate is formed.

Table 1 : The observation of metal plates in tap water and salt water

Result :
Metal plate

Area of metal
Initial weight
Final weight
Weight loss
2
plate ( in )
( g/grams )
( g/grams )
( g/grams )
Aluminum
7.80
1.06
1.04
0.02
Brass
7.09
1.49
1.44
0.05
Copper
7.63
1.90
1.56
0.34
Lead
8.57
4.17
3.76
0.41
Tin
6.59
4.89
4.84
0.05
Zinc
2.98
0.40
0.39
0.01
Table 2 : The area of metals plate and the weight loss of metals plate after 70 days in
salt water

Metal plate

Area of metal
Initial weight
Final weight
Weight loss
2
plate ( in )
( g/grams )
( g/grams )
( g/grams )
Aluminum
8.01
1.06
1.01
0.05
Brass
6.75
1.45
1.42
0.03
Copper
6.80
1.61
1.59
0.02
Lead
9.37
4.21
4.09
0.12
Tin
5.35
4.65
4.63
0.02
Zinc
2.56
0.36
0.34
0.02
Table 3 : The area of metals plate and the weight loss of metals plate after 70 days in
tap water

Weight loss of metals

Metals

Graph 1 : The weight loss of metals plate after 70 days in salt water and tap water

Calculation :
The corrosion rate of metals plate in salt water :
For Aluminum plate,

= 0.30142 mpy

For Brass plate,

= 0.26369 mpy

For Copper plate,

= 1.59325 mpy

For Lead plate,

= 1.34400 mpy

For Tin plate,

= 0.33202 mpy

For Zinc plate,

= 0.14993 mpy

The corrosion rate of metals plate in tap water :

For Aluminum plate,

= 0.73380 mpy

For Brass plate,

= 0.16618 mpy

For Copper plate,

= 0.10516 mpy

For Lead plate,

= 0.35978 mpy

For Tin plate,

= 0.16359 mpy

For Zinc plate,

= 0.34907 mpy

Corrosion rate of metals

Metals

Graph 2 : The corrosion rate of metals plate in salt water and tap water

Discussion :

In salt water, there is white precipitate formed on the surface of aluminum

metal plate. The corrosion rate of aluminum metal plate in salt water is 0.30142mpy.
Aluminum is a reactive metal. Aluminum and its alloys have excellent corrosion
resistance which is predominantly due to the presence of passive film, Al 2O3 , which is
thin, insoluble if broken in the presence of oxygen, on their surfaces. However, this
film can be breakdown and result in localized corrosion in certain environments,
especially when exposed to a solution containing chloride ions and dissolved oxygen.
In the presence of chloride ions environment the oxide film losses its stability.

In tap water, there is a white layer formed on the surface of aluminum metal
plate. The corrosion rate of aluminum metal plate in tap water is 0.73380 mpy. Pure
aluminum is very reactive. Aluminum resists corrosion because of the formation of a
thin layer of aluminum oxide, Al2O3. Aluminum oxide is impervious to water and
adheres tightly to the surface of the metal, thus protecting the inner metal from further
attacks by water and acids.

In salt water, there is white precipitate formed on the surface of brass metal
plate. The colour of brass metal plate turns from yellow to grey and then to reddish
brown. The corrosion rate of brass metal plate in salt water is 0.26369 mpy. Salt
water is sodium chloride solution. Brass is made up of copper and zinc. When brass
react with salt water, brass will undergo dezincification, when the zinc dissolves
out of the brass to leave behind spongy copper. Salt water is very good conductor
because it contains a lot of dissociated ions. So there are a number of electrolysis
reaction that tremendously accelerate the corrosion rate of brass in salt water.

There is no change of brass metal plate in tap water. The corrosion rate of
brass metal plate in tap water is 0.16618 mpy. The pH value of both solution which is
salt water and tap water is 7. The colour of brass metal plate is remain in gold. The
salt water which contains sodium chloride solution which is corrosive salt in presence
of water, it cause the brass metal plate to corrode.

In salt water, there is greenish precipitate formed on the surface of copper

metal plate and the salt water had changed in the colour which is from colourless to
slightly blue colour. The corrosion rate of copper metal plate in salt water is 1.59325
mpy. In a salt water of sodium chloride, NaCl solution, the dominant species of ions
are sodium, Na+ and chloride ions, Cl-. There is a greenish precipitate obtained
through the application of salt water to copper metal plate or the natural patina formed
when copper is in the salt water over a period of time. It is usually a basic copper
chloride.

There is no change of copper metal plate in tap water. The corrosion rate of
copper metal plate in tap water is 0.10516 mpy. The pH of value in tap water is 7.
The ph of 7 which is almost neutral is very difficult to cause the copper metal plate to
be corroded. In tap water, the amount of water is strong enough to ionised the copper
metal plate.

In salt water and tap water, there is a white precipitate formed on the surface
of the lead metal plate. The corrosion rate of lead metal plate in salt water and tap
water is 1.34400mpy and 0.35978mpy respectively. When lead metal plate react with
salt water which is sodium chloride solution, the surface of metallic lead is protected
by a thin layer of lead oxide, PbO. Lead react slowly with chloride ions in salt water
to produced lead (II) chloride, PbCl2. When lead metal plate in tap water, the surface
of metallic lead is protected by a thin layer of lead oxide, PbO. It does not react with
water under normal conditions.

In salt water, there is a white precipitate is formed on the surface of tin metal
plate. The corrosion rate of tin metal plate in salt water is 0.33202mpy. When salt
water react with tin metal plate, tin will react with chloride ions in salt solution to
form white precipitate which is tin (IV) chloride. There is no change of tin metal plate
in tap water. The corrosion rate of tin metal plate in tap water is 0.16359mpy. Tin is
stable to water under ambient conditions.

In salt water and tap water, there is white precipitate is formed on the surface
of zinc metal plate. The corrosion rate of zinc metal plate in salt water and tap water
is 0.14993 and 0.34907 respectively. In salt water, sodium chloride is dissolved in
water. So it dissociated as sodium ions and chloride ions. Zinc can attracted towards
chloride ions. So it forms zinc chloride, ZnCl 2 which is white precipitate. Zinc metal
plate does not react with water molecules in tap water. The ion does form a protective
layer, water insoluble zinc hydroxide, Zn(OH)2 layer with dissolved hydroxide ions.

Conclusion :
In salt water, the corrosion rate of metals plate for aluminium(0.30142mpy),
brass(0.26369mpy),

copper(1.59325mpy),

lead(1.34400mpy),

tin(0.33202mpy),

zinc(0.14993mpy). While the corrosion rate in tap water of metals plate for

aluminium(0.73380mpy),brass(0.16618mpy),copper(0.10516mpy),
lead(0.35978mpy), tin(0.16359mpy), zinc(0.34907mpy). In conclusion, metal that
corrode fastest in salt water is copper and slowest is zinc, in tap water, metal corrode
fastest is aluminium and slowest is copper. The corrosion rate of metal used in this
coursework maybe not accurate. To improve the result and calculation which include
of corrosion rate, can try to use the metal plate which is have same surface area, or
use the salt solution which is concentrated to get the observation easily. Recommend
relevant action in this coursework is using the metal which is easily to corrode and
filter the precipitate found in the corrosion process so that can identified the product
which produced by different metal in corrosion process.

References :
1. Chinwko Emmanuel Chuka, Odio B. O., Chukwuneke J.L., Sinebe J. E.,
Investigation Of The Effect Of Corrosion On Mild Steel In Five Different
Environments

(2014)

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http://www.ijstr.org/final-

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2. K.Zakowksi, M. Narozny, M. Szocinski, and K.Darowicki, Influence of Water
Salinity On Corrosion Risk-The Case Of The Southern Baltic Sea Coast
(2014)

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2016

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http://www.ncbi.nlm.nih.gov/pmc/articles/PMC4064120/
3. Howard A. Porte, Ph.D., The Effect Of Environment Of The Corrosion Of
Metals In Sea Water (1967) viewed 2016 from www.dtic.mil/cgibin/GetTRDoc?AD=AD0820155
4. How
Does
The
Rust

Works

http://science.howstuffworks.com/question445.htm

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2016

from