Code No: RR411801 Set No.

1
IV B.Tech I Semester Supplimentary Examinations, February 2008
ELECTRO METALLURGY AND CORROSION
(Metallurgy & Material Technology)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
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1. (a) How are conductors classified? Define molor conductivity and discuss the
factors affecting conductivity of electrolytes.
(b) Discuss the following
i. Current density
ii. Limiting current density
iii. Cathode current efficiency. [8+8]
2. (a) Show the basic Potentiometric circuit and explain how Electrode potentials
are measured.
(b) For a cell reaction Zn + cu2+ = Zn2+ + cu , the Gibb’s free Energy change is
found to be -50> 40 cal g mm−1 . Calculate the EMF generated by the cell.
(Faradays constant: 96950) [8+8]
3. (a) Draw the potentiostatic anodic polarization curve of any metal in acid solution.
(b) Explain the phenomenon of concentration polarization considering the hydro-
gen evolution reaction. [7+9]
4. (a) What is the purpose of anodizing? Describe the various methods of anodizing
of aluminium alloys. Explain the nature of anodizing coating in each process.
(b) Deduce the conditions under which two metals can be simultaneously de-
posited on metallic surface. [8+8]
5. (a) Explain the mechanism of the growth and breakdown of passive films.
(b) Illustrate the important kinetic factors in determining the corrosion behavior
of a metal. [8+8]
6. Discuss the following
(a) Corrosion - Erosion
(b) De Zincification
(c) Fretting corrosion
(d) High temperature corrosion. [4 × 4]
7. (a) What is the principle of cathodic protection ? Suggest the method to protect
cathodically a water storage tank and a steel heat exchanger.
(b) Describe any 2 methods of altering the environment to prevent or reduce
corrosion. [8+8]

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Code No: RR411801 Set No. 1
8. (a) Explain the two types of galvanic cells i.e
i. Galvanic cells with transference
ii. Galvanic cells without transference
(b) Explain about reversible electrochemical cells & irreversible electrochemical
cells. [5+5+6]

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Code No: RR411801 Set No. 2
IV B.Tech I Semester Supplimentary Examinations, February 2008
ELECTRO METALLURGY AND CORROSION
(Metallurgy & Material Technology)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) One Cu piece and another Zinc piece are immersed in seawater and connected
by a copper wire. Indicate the galvanic cell by writing half-cell reaction.
i. for the anode
ii. for the cathode; also by indicating
iii. The direction of electron flow in the line.
iv. Direction of current flow in the electrolyte.
v. Which metal might be used in place of copper so that Zinc changes po-
larity?
(b) An electrode potential in a silver half cell is 0.78 V. What is the concentration
of Ag+ ions in the electrolyte?
(Assume any missing or standard data). [10+6]

2. (a) Calculate the Potential for the half cell reaction cadmium electrode in solution
containing 0.01 moles / liter cd2+ . (Fo = +403 volts)
(b) Write short notes on
i. Potentiometric titrations.
ii. Liquid Junction Potential. [6+5+5]

3. (a) Discuss the recovery of tin from its aqueous solutions by electrowinning process
(b) Describe as how to obtain a uniform current distribution in a plating operation.
[8+8]

4. (a) Compare and contrast different electrolytes used for anodizing of alumminium.
(b) Describe a method to measure
i. Brightness and
ii. Stress in electrodeposit [6+10]

5. (a) If all other factors are equal , which is better choice to reduce corrosion &
why.
i. Cold worked or annealed metal
ii. Single phase alloy or two phase alloy [5+5]
(b) Calculate the volume of O2 gas consumed ( at STP) in the production of 100
gm of rust (Fe(OH)3 ) [6]

6. Discuss the following

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Code No: RR411801 Set No. 2
(a) Corrosion - Erosion
(b) De Zincification
(c) Fretting corrosion
(d) High temperature corrosion. [4 × 4]

7. (a) Explain briefly how Iron tanks corrode faster if they are filled with water and
then emptied , thus being exposed to air , then if the tanks are kept full.
(b) If a sacrificial Magnesium anode corrodes with an average current of 0.80 A
for 100 days, what must be the loss of metal by the anode in this time period
be.
(Assume the missing data) [8+8]

8. (a) Explain the effect of corrosive concentration on corrosion rate with examples.
(b) Show the electrochemical reactions occurring on galvanic couple of zinc and
platinum in Hcl solution. [8+8]

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Code No: RR411801 Set No. 3
IV B.Tech I Semester Supplimentary Examinations, February 2008
ELECTRO METALLURGY AND CORROSION
(Metallurgy & Material Technology)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) One Cu piece and another Zinc piece are immersed in seawater and connected
by a copper wire. Indicate the galvanic cell by writing half-cell reaction.
i. for the anode
ii. for the cathode; also by indicating
iii. The direction of electron flow in the line.
iv. Direction of current flow in the electrolyte.
v. Which metal might be used in place of copper so that Zinc changes po-
larity?
(b) An electrode potential in a silver half cell is 0.78 V. What is the concentration
of Ag+ ions in the electrolyte?
(Assume any missing or standard data). [10+6]

2. (a) Distinguish between decomposition Potential and discharge Potential.

(b) Explain the importance of EMF and NERNST Equation. [8+8]

3. (a) Draw the potentiostatic anodic polarization curve of any metal in acid solution.
(b) Explain the phenomenon of concentration polarization considering the hydro-
gen evolution reaction. [7+9]

4. Discuss the following methods of anodizing treatments.

(a) BENGOUGH [Chromic acid process]

(b) ALUMILITE [Sulphuric acid process] [8+8]

5. (a) Illustrate the important kinetic factors in determining the corrosion behavior
of a metal.
(b) Explain how the potential theory is possible to estimate corrosion behavior.
[8+8]

6. Differentiate between

(a) Galvanizing and tin plating methods of corrosion prevention.

(b) Anodic coating and cathodic coating
(c) Anodic inhibitors and cathodic inhibitors
(d) H2 Evolution mechanism and O2 absorption mechanism of corrosion. [4 × 4]

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Code No: RR411801 Set No. 3
7. (a) Explain briefly how Iron tanks corrode faster if they are filled with water and
then emptied , thus being exposed to air , then if the tanks are kept full.
(b) If a sacrificial Magnesium anode corrodes with an average current of 0.80 A
for 100 days, what must be the loss of metal by the anode in this time period
be.
(Assume the missing data) [8+8]

8. (a) Give a few examples of corrosion fatigue in service and explain them.
(b) What is impingement corrosion? Explain the factors that influence corrosion
attack. Give some examples of impingement corrosion failure in service [8+8]

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Code No: RR411801 Set No. 4
IV B.Tech I Semester Supplimentary Examinations, February 2008
ELECTRO METALLURGY AND CORROSION
(Metallurgy & Material Technology)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) Explain the following terms

i. Current efficiency
ii. Energy efficiency.
(b) Suppose that a certain current passes for a given time through three baths
connected in series
i. An acid copper bath used as a coulometer and assumed to have an effi-
ciency of 100%.
ii. A Nickel bath and
iii. A Zinc bath. The respective weights of the 3 metals deposited were 35.6
gm of copper, 29.2 gm of Ni & 34.8 gm of Zinc. What are the cathode
efficiencies of Ni & Zn deposition (Hint: 1 amp Hr deposits 1.86 g of Cu,
1.095 gm of Ni & 1.22 g of Zinc). [6+10]

2. (a) Explain why it is impossible to measure a single electrode potential.

(b) How a single electrode potential can be measured.
(c) Explain the conditions that must be specified to maintain standard hydrogen
potential to be zero. [4+6+6]

3. (a) What do you mean by polarization? What are the three kinds of polarization?
Discuss the importance of polarization in electrolysis.
(b) What is electrowinning? Compare electrowinning with electro refining. [6+10]

4. Discuss the following methods of anodizing treatments.

(a) BENGOUGH [Chromic acid process]

(b) ALUMILITE [Sulphuric acid process] [8+8]

5. (a) A piece of corroded metal alloy plate was found in a submerged occur vessel.
It was estimated that the original area of the plate was 800 cm2 and that
approximately 7.6 kg had corroded during the submersion. Assuming the
corrosion penetration rate of mm/year for this alloy in seawater, estimate the
time of submersion in years. The density of the alloy is 4.5 gm/cc.
(Assume any necessary data suitably)
(b) Briefly describe the phenomenon of passivity. Name two common types of
alloys that passivate. [10+6]

6. Discuss the following

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Code No: RR411801 Set No. 4
(a) Corrosion - Erosion
(b) De Zincification
(c) Fretting corrosion
(d) High temperature corrosion. [4 × 4]

7. (a) Explain briefly how Iron tanks corrode faster if they are filled with water and
then emptied , thus being exposed to air , then if the tanks are kept full.
(b) If a sacrificial Magnesium anode corrodes with an average current of 0.80 A
for 100 days, what must be the loss of metal by the anode in this time period
be.
(Assume the missing data) [8+8]

8. (a) Explain what is meant by sensitization and stabilization of stainless steels.[8+8]

(b) What is weld decay? How do you avoid intergranular corrosion in stainless
steels.

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