Professional Documents
Culture Documents
Corrosion
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
Example 22.1
Half-Cell Potential for Copper
Suppose 1 g of copper as Cu2+ is dissolved in 1000 g of water
to produce an electrolyte. Calculate the electrode potential of
the copper half-cell in this electrolyte.
Example 22.1 SOLUTION
From chemistry, we know that a standard 1-M solution of Cu2+
is obtained when we add 1 mol of Cu2+ (an amount equal to the
atomic mass of copper) to 1000 g of water. The atomic mass of
copper is 63.54 g/mol. The concentration of the solution when
only 1 g of copper is added must be:
Example 22.2
Design of a Copper Plating Process
Design a process to electroplate a 0.1-cm-thick layer of copper
onto a 1 cm 1 cm cathode surface.
Example 22.2 SOLUTION
In order for us to produce a 0.1-cm-thick layer on a 1 cm2
surface area, the weight of copper must be:
10
10
11
11
Example 22.3
Corrosion of Iron
An iron container 10 cm 10 cm at its base is filled to a height
of 20 cm with a corrosive liquid. A current is produced as a
result of an electrolytic cell, and after 4 weeks, the container
has decreased in weight by 70 g. Calculate (1) the current and
(2) the current density involved in the corrosion of the iron.
Example 22.3 SOLUTION
1. The total exposure time is:
12
12
13
13
Example 22.4
Copper-Zinc Corrosion Cell
Suppose that in a corrosion cell composed of copper and zinc,
the current density at the copper cathode is 0.05 A/cm2. The
area of both the copper and zinc electrodes is 100 cm2.
Calculate (1) the corrosion current, (2) the current density at
the zinc anode, and (3) the zinc loss per hour.
Example 22.4 SOLUTION
1. The corrosion current is:
14
14
15
15
Example 22.8
Effect of Areas on Corrosion Rate for
Copper-Zinc Couple
Consider a copper-zinc corrosion couple. If the current
density at the copper cathode is 0.05 A/cm2, calculate the
weight loss of zinc per hour if (1) the copper cathode area
is 100 cm2 and the zinc anode area is 1 cm2 and (2) the
copper cathode area is 1 cm2 and the zinc anode area is
100 cm2.
16
16
17
18
18
Example 22.5
Corrosion of a Soldered Brass Fitting
A brass fitting used in a marine application is joined by
soldering with lead-tin solder. Will the brass or the solder
corrode?
Example 22.5 SOLUTION
From the galvanic series, we find that all of the copper-based
alloys are more cathodic than a 50% Pb-50% Sn solder. Thus,
the solder is the anode and corrodes. In a similar manner, the
corrosion of solder can contaminate water in freshwater
plumbing systems with lead.
19
19
20
20
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
21
21
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
22
22
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
23
23
Example 22.6
Corrosion of Cold-Drawn Steel
A cold-drawn steel wire is formed into a nail by additional
deformation, producing the point at one end and the head at
the other. Where will the most severe corrosion of the nail
occur?
Example 22.6 SOLUTION
Since the head and point have been cold-worked an additional
amount compared with the shank of the nail, the head and
point serve as anodes and corrode most rapidly.
24
24
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
25
25
Example 22.7
Corrosion of Crimped Steel
Two pieces of steel are joined mechanically by crimping
the edges. Why would this be a bad idea if the steel is
then exposed to water? If the water contains salt, would
corrosion be affected?
Example 22.7 SOLUTION
By crimping the steel edges, we produce a crevice. The
region in the crevice is exposed to less air and moisture,
so it behaves as the anode in a concentration cell. The
steel in the crevice corrodes.
Salt in the water increases the conductivity of the
water, permitting electrical charge to be transferred at a
more rapid rate. This causes a higher current density and,
thus, faster corrosion due to less resistance polarization.
26
26
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
27
27
28
29
30
Protection Against
Electrochemical Corrosion
Inhibitors - Additions to the electrolyte that preferentially
migrate to the anode or cathode, cause polarization, and
reduce the rate of corrosion.
Sacrificial anode - Cathodic protection by which a more
anodic material is connected electrically to the material
to be protected. The anode corrodes to protect the
desired material.
Passivation - Producing strong anodic polarization by
causing a protective coating to form on the anode
surface and to thereby interrupt the electric circuit.
31
31
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
32
32
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
33
33
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
34
34
35
35
Example 22.9
Design of a Corrosion Protection System
Steel troughs are located in a field to provide drinking water
for a herd of cattle. The troughs frequently rust through and
must be replaced. Design a system to prevent or delay this
problem.
Example 22.9 SOLUTION
We might, for example, fabricate the trough using stainless
steel or aluminum. Either would provide better corrosion
resistance than the plain carbon steel, but both are
considerably more expensive than the current material.
We might suggest using cathodic protection; a small
magnesium anode could be attached to the inside of the
trough. The anode corrodes sacrificially and prevents
corrosion of the steel.
36
36
37
37
38
39