Corrosion

What is Corrosion

• Corrosion is the changing of

the surface of the metal from
an element into a compound.
Corrosion is an example of
oxidation because it involves a
loss of electrons.
• Fe ----------> Fe2+ + 2e-

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 Rusting
• Rusting is the special name given to the
corrosion of iron. As iron, in the form of
steel, is the most commonly used metal in
the world, the corrosion of iron is
important.
 Speeding up Rusting
• Rusting can be sped up by the use of
sulphur dioxide which causes acid
rain.
• The quantity of air and water affects
the speed.
 Iron and Other Metals
• If a nail and a carbon rod are connected by a wire and dipped into
salt solution containing ferroxyl indicator, a blue colour quickly
appears around the nail, and a pink colour around the carbon rod.
This means that electrons are flowing from the nail to the carbon.
When electrons flow from iron, it rusts.
• In Topic 10 it was found that metals higher in the electrochemical
series could push electrons onto metals lower in the
electrochemical series.
Magnesium stops iron rusting, while copper makes iron rust quicker.
• Metals that push electrons onto iron stop rusting, but metals that
let electrons flow from iron increase the speed of rusting.
 Corrosion potential calculation
• Reduction Reaction must have higher
potential than the oxidation reaction or they
will not form a cathodic cell
Fe 2  2e   Fe -0.440 V

Zn 2  2e   Zn -0.763 V

V  .440   .763  0.323V Relative measure of

corrosion
 Passivation
• A protective film in oxidizing atmospheres
– chromium,nickel, titanium, aluminum
• Metal oxide layer adheres to parent metal
– barrier against further damage
– self-healing if scratched
• Sensitive to environmental conditions
– passivated metal may have high corrosion rates
 Cathodic Protection
• Iron has to lose electrons
in order to rust.
The negative terminal of
the battery is pushing
electrons onto this nail
and this prevents this
nail from losing any
electrons. This nail
cannot rust.
Electrons flowing to the
nail stop rusting.
 Galvanising
• Galvanising is when
galvanised iron in
made by dipping iron
into molten zinc
which coats the iron
with zinc. It is used
to protect dustbins,
car exhausts and
special nails.
 Sacrificial Protection
• Sacrificial
protection is when a
more reactive metal
sacrifices itself to
protect the less
reactive metal in
the electrochemical
series.
 Ways to Protect Iron
• painting e.g. the Forth Rail Bridge.
• greasing or oiling - protects moving
parts of machinery.
• coating with plastic - dish drainers
have a metal core and a plastic
coating.
• coating with other metals such as tin,
zinc, silver, gold.
 Rusting
• Corrosion is an example of oxidation because it
involves a loss of electrons.
• Fe ----------> Fe2+ + 2e-
• The rusting process continues when iron(II) ions
lose another electron to form iron(III) ions.
• Fe2+ ----------> Fe3+ + e-
• Oxygen and water accept the electrons lost by the
iron.
• 2H2O + O2 + 4e- ----------> 4OH-
 Commonly Affected Structures
 Buried Piping
 Steel Piles
 Storage Tanks - Above Ground / Underground
 Reinforcing Steel in Concrete
 Ships/Boats

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 Ships/Boats

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 Methods to Control Corrosion
 Use of Corrosion resistant materials (plastic, stainless
alloys, fiberglass).
 Use of the same or similar metals per the galvanic
series.
 Altering the environment (utilizing homogeneous
high resistivity backfill or inhibitors).
 Utilize coatings and linings that electrically insulate
the structure from the electrolyte (paints, plastic
films, etc).
 Use of Cathodic Protection.
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 Fundamentals of Cathodic
Protection
 Cathodic Protection (CP) Defined - Minimize
corrosion by utilizing an external source of
electrical current which forces the entire
structure to become a cathode.

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1824: Earliest practical use of cathodic
protection

 Sir Humphrey Davy’s work on protecting the

copper sheathing on wooden hulls in the
British Navy by sacrificial zinc or iron anodes
is generally considered to be the earliest
example of practical cathodic protection.

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 Galvanic CP
 When metals such as magnesium or zinc are
placed in the environment in contact with a
more noble metal such as steel, a current flows
from the more active anode to the noble
cathode (corrosion cell).

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 Anodes Used for Galvanic CP
 Magnesium – Magnesium is often used in soil
to protect small electrically isolated structures,
such as underground storage tanks, and well
coated pipelines.
 Zinc – Zinc is often used in marine
environments. They are commonly found on
boats.
 Aluminum – Aluminum can be used for a
variety of marine applications.
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 Keys to obtaining enough cathodic
protection
 Determine amount of current required
Theoretical calculations based on coating quality

and environment
Or, perform current requirement testing

 Calculate output expected from anode and

determine number of anodes required.

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 Galvanic CP
Pros of Galvanic CP
 Inexpensive

 Little Maintenance cost

 No external Power source

 A variety of install methods can be used. For

example, many UST’s are shipped with anodes
attached.

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 Galvanic CP
Cons of Galvanic CP
 Typically work best with electrically isolated
structures.
 No external power source, limited driving potential
(driving potential based on the galvanic series)
 Limited output makes it ineffective when trying to
protect large uncoated surfaces.
 Require a low resistivity electrolyte to function well.

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 Impressed Current CP
 Utilize an external power source to develop a
high potential difference between the surface
to be protected and an anode.

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 Impressed Current CP
IMPRESSED CURRENT SY

Anode Groundbed

Pos i ti v e Cabl e
Recti fi er
AC Power Suppl y
Negati v e Cabl e

Pi pel i ne