Corrosion and Electrolytes

Introduction to Corrosion

• Definition: Corrosion refers to the deterioration of metals through electrochemical processes that convert them into more chemically stable forms (e.g., oxides, hydroxides, sulfides).
• Process: It is a gradual destruction of materials (primarily metals) through chemical or electrochemical reactions with their environment.
• Common Example: Rusting of iron, a specific type of electrochemical corrosion, forms iron oxides, resulting in characteristic orange coloration.

Types of Corrosion

1. Wet Corrosion

• Definition: Involves corrosion occurring in the presence of water.
• Example: Corrosion of metal in water. Other forms include corrosion in dry or gaseous environments (e.g., titanium in dry chlorine).

2. Dry Corrosion

• Definition: Occurs in the absence of moisture; environmental gases may lead to oxidation.
• Examples: Corrosion due to furnace gases or smog.

Importance of Corrosion Maintenance

• Critical in industries such as:
  • Paper: To maintain equipment and prevent failure due to corrosion.
  • Petroleum: Protect pipelines and storage tanks from corroding.

Key Subjects for Understanding Corrosion

• Chemistry: Understanding chemical reactions involved in corrosion.
• Electrochemistry: The study of charge transfer reactions.
• Physics: Insights into material behavior and properties.
• Material Characterization: Identifying and analyzing material properties.

Specific Examples of Metal Corrosion

A. Tarnish in Silver

• Process: Silver reacts with sulfur-containing gases forming silver sulfide (Ag2S), leading to discoloration. Cleaning can be labor-intensive and may damage the silver plating.
• Oxidation Reaction:
  Ag(s) → Ag+(aq) + e- (E° oxd’n = – 0.80 V)

B. Green Patina in Copper and Brass

• Process: Copper reacts with atmospheric elements (O2, H2O, CO2) to form a green layer (patina or verdigris), primarily copper (II) carbonate (CuCO3).
• Oxidation Reaction:
  Cu(s) → Cu2+(aq) + 2e- (E° oxd’n = – 0.34 V)
• Protective Layer: The patina protects further corrosion. Example: The green surface of the Statue of Liberty.

C. Rusting of Iron

• Process: Iron oxidizes to form hydrated iron (III) oxide (rust), which flakes off allowing new metal to corrode.
• Oxidation Reaction:
  Fe(s) → Fe2+(aq) + 2e- (E° oxd’n = + 0.44 V)
• Reduction Reaction:
  O2(g) + 4H+(aq) + 4e- → 2H2O(l) (E° red’n = +1.23 V)
• Redox Reaction: Complete redox for rust: 2Fe(s) + O2(g) + 4H+(aq) → 2Fe2+(aq) + 2H2O(l)
  • Overall Cell Potential: 1.67 V, indicating a spontaneous reaction.

Preventive Measures Against Corrosion

A. Protective Coatings

• Purpose: Prevent contact between the metal and moisture/air.
• Methods:
  • Oil and Grease: Used on moving parts.
  • Paints: Protects non-scratchable items (cars, bridges).
  • Galvanizing: Coating with zinc to provide sacrificial protection.
  • Tin Plating: Used for making cans to prevent rust.

B. Alloying

• Example: Stainless steel, primarily iron alloyed with chromium and nickel, offers resistance to corrosion.
  • Properties: Protective oxide layer, aesthetic finish, and durability.

C. Sacrificial Protection

• Principle: Attaching a more electropositive metal (sacrificial metal) to iron to prevent rusting.
  • Examples: Zinc blocks on ships or magnesium bags on pipelines.
  • Function: Sacrificial metal oxidizes instead of iron, providing cathodic protection.