Applied Chemistry UNIT II: Corrosion Science
Applied Chemistry UNIT II: Corrosion Science
Applied Chemistry UNIT II: Corrosion Science
3. State and explain pilling and bed worth rule. (Or) What is pilling – Bed
worth ratio?
Pilling – Bed worth rule:
According to Pilling – Bed worth rule, if the volume of the oxide layer
formed is less than the volume of metal; the oxide layer is porous and hence
non protective.
Example: Oxides of alkali and alkaline earth metals such as Na, Mg, Ca etc.
On the other hand if the volume of oxide layer formed is greater than the
volume of the metal; the oxide layer is non porous and protective.
Example: Oxides of heavy metals such as Pb, Sn etc.
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4. What is hydrogen embrittlement? Where it is caused?
Hydrogen embrittlement is the effect of atomic hydrogen on metals at ordinary
temperature causing cracks and blisters by occupying the voids of the metals.
When metals contact to H2S at ordinary temperature causes evolution of
atomic hydrogen.
Fe + H2S FeS +2H
This atomic hydrogen diffuse readily into the metal and collects in the
voids, where it recombines to form molecular hydrogen
H+H H2
Collection of these gases in the voids causes cracks and blisters on the
metal. This process is called hydrogen embrittlement.
5. What is „decarburization‟?
9. How does the galvanic corrosion occur? How to prevent the galvanic
corrosion?
When two dissimilar metals or alloys are in
contact with each other in the presence of an
aqueous solution or moisture galvanic corrosion
occurs. It can be minimized by the using the
following steps.
1. Selecting the metals as close as possible
in the electrochemical series.
2. Providing smaller area for cathode and
larger area for anode.
3. Inserting an insulating material between the two metals.
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11. Bolt and nut made of same metal is preferred in practice. Why?
Bolt and nut made of same metal is preferred in practice in order to avoid
galvanic type corrosion.
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15. Describe the mechanism of dry (or) chemical corrosion by oxygen
Alkaline-earth metals (Mg, Ca, Sn, etc.) are rapidly oxidized at low
temperature. At high temperature, almost all metals (except, Ag, Au and Pt)
are oxidized.
Mechanism
(i) Oxidation occurs first at the surface of the metal resulting in the
M M2+ + 2e−
(ii) Oxygen changes to ionic form (O2−) due to the transfer of electron from
½ O2 + 2e− O2−
(iii) Oxide ions react with the metal ion to form the metal-oxide film.
M + ½ O2 M2+ + O2− ≡ MO
(Metal-oxide film)
1. When two dissimilar metals or alloys are in contact with each other in
the presence of an aqueous solution or moisture.
2. When a metal is exposed to varying concentration of oxygen or any
electrolyte.
The surface of iron is usually, coated with a thin film of iron oxide. However, if
the oxide film develops some crack will
come and anodic areas are created on the
surface while the remaining part acts as
cathode.
Example:
At anode:
Iron dissolves as Fe2+ with the liberation of electrons.
½ O2 + H2 O + 2e- 2OH-
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17. What is differential aeration corrosion? Write its mechanism. Give any
illustrations that show differential corrosion. (or) Discuss briefly on
differential aeration corrosion
Examples:
a) Pitting or localized corrosion.
b) Crevice corrosion.
c) Pipeline corrosion.
d) Corrosion on wire fence
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Aluminium, Zinc and Magnesium are used as sacrificial anodes.
Inert anodes used for this purpose are graphite, platinised titanium. The
anode is buried in a “back fill” (containing mixture of gypsum, coke, breeze,
sodium sulphate). The “back fill” provides good electrical contact to anode).
Applications of Impressed Current Protection
Structures like tanks, pipelines, transmission line towers, underground water
pipe lines, oil pipe lines, ships, etc., can be protected by this method.
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19. Explain the various factors which influence the rate of corrosion of a
metal (or) what are the factors which influence chemical corrosion and
electrochemical corrosion? (12 marks)
The nature of the oxide film formed on the metal surface decides the extent of
corrosion which can be decided by Pilling-Bedworth rule. In the case of alkali
and alkaline earth metals such as Mg, Ca, etc. form oxide, whose volume is
less than the volume of the metal. Hence the oxide film will be porous and non-
protective and bring about further corrosion. But in heavy metals like Al, Cr,
etc. form oxide, whose volume is greater than that of the metal. Hence the
oxide film will be non-porous and protective and prevents further corrosion.
(f) Nature of the Corrosion Product
If the corrosion product is soluble in the corroding medium, the corrosion rate
will be faster. Similarly, if the corrosion product is volatile (like MoO3 on Mo
surface), the corrosion rate will be faster.
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Nature of the Environment
(a) Temperature
(b) Humidity
The rate of corrosion will be more, when the humidity in the environment is
high. The moisture acts as a solvent for the oxygen in the air to produce the
electrolyte, which is essential for setting up a corrosion cell.
The acidic gases like, CO2, SO2, H2S and fumes of HCl, H2SO4, etc., produce
electrolytes, which are acidic and increases the electrochemical corrosion.
(e) Effect of pH
The rate of corrosion can also be reduced by increasing the pH of the solution
by adding alkali. Thus the rate of corrosion will be maximum when the
corrosive environment is acidic. i.e. pH is less than 7.
20. What is paint? What are the constituents of paint and their functions?
Paint:
Paint is a mechanical dispersion of one or more finely divided pigments
in a medium. When paint is applied to a metal surface, the thinner evaporates,
while the vehicle undergoes slow oxidation forming a pigmented film.
Requisites of a good paint:
1. It should spread easily on the metal surface.
2. It should have high hiding power.
3. It should not crack on drying.
4. It should adhere well to the surface.
5. The colour of the paint should be stable.
6. It should be a corrosion and water resistant.
7. It should give a glossy film.
Constituents and their functions of paint
1. Pigments2. Vehicle (or) drying oil 3. Thinners (or) solvents 4. Extenders
(or) fillers 5. Driers 6. Plasticisers 7. Anti-skinning agents
1. Pigments
Pigments are solid and colour producing substances in the paint.
Functions
(i) It gives colour and opacity to the film.
(ii) It also provides strength to the film.
(iii) It protects the film by reflecting the destructive uv rays.
(iv) It increases weather resistance of the film.
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2. Vehicle (or) Drying Oil
This is a non-volatile portion of a medium and film forming constituent of the
paint. These are high molecular weight fatty acids present in vegetable and
animal oils.
Functions
(i) They form a protective film by the oxidation and polymerisation of the oil.
(ii) They hold the pigment particles together on the metal surface.
(iii) They impart water repellency, toughness and durability to the film.
3. Thinners (or) Solvents
This is a volatile portion of a medium. It easily evaporates after application of
the paint.
Functions
(i) It reduces the viscosity of the paint, so that it can be easily applied on the
surface.
(ii) It dissolves the oil, pigments, etc. and produces a homogeneous mixture.
(iii) It increases the elasticity of the film.
(iv) It increases the penetrating power of the vehicle.
4. Extenders (or) fillers
These are white (or) colourless pigments.
Functions
(i) It reduces the cost of the paint.
(ii) It retards the settling of the pigment in all paints.
(iii) It modifies the shades of the pigments.
(iv) It prevents shrinkage and cracking.
5. Driers
These are the substances, used to accelerate the process of drying.
Functions
(i) They act as oxygen-carriers (or) catalysts.
(ii) They provide oxygen, which is essential for oxidation, polymerisation of
drying oil.
6. Plasticisers
These are chemicals added to the paint to provide elasticity to the film and to
prevent cracking of the film.
Example: Triphenyl phosphate, tricresyl phosphate, etc
7. Anti – Skinning Agents
These are chemicals added to the paint to prevent gelling and skinning of the
paint.
Example: Polyhydroxy phenol.
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