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CORROSION AND
NON-FERROUS
METAL
PREPARED BY:
AZMARINI BINTI AHMAD NAZRI
PENSYARAH POLITEKNIK UNGKU OMAR
CORROSION
a)
b)
c)
d)
Dry Corrosion
Dry corrosion occurs in the absence of a liquid phase or
above dew point of the environment.
It is direct reaction of atmospheric gases like oxygen,
halogens, oxides of sulphur, oxides of nitrogen, hydrogen
sulphide and fumes of chemicals with metal.
Oxygen is mainly responsible for the corrosion of most
metallic substances when compared to other gases and
chemicals.
There are three main types of dry corrosion:
a) oxidation corrosion (reaction with oxygen)
b) corrosion by other gases
c) liquid metal corrosion
Dry corrosion
Corrosion occurs in the
absence of moisture.
It involves direct attack
of chemicals on the
metal surface.
The process is slow.
Corrosion products are
produced at the site of
corrosions.
The process of corrosion
is uniform
Wet corrosion
Corrosion occurs in
presence of conducting
medium.
It involves formation of
electrochemical cells.
It is a rapid process
Corrosion occurs at
anode but rust is
deposited at cathode.
It depends on the size
Electrochemical Corrosion
a)Oxidation Reduction Reaction
Eg : a piece of zinc metal placed in a beaker of dilute
hydrolic acid.
Result: the zinc dissolves or corrodes in the acid, and
zinc cloride and hydrogen gas are produced as indicated
by the chemical reaction:
Zn + 2HCl
ZnCl2 + H2
This reaction can be written in a simplified ionic form,
omitting the cloride ions, as
Zn + 2H+
Zn2+ + H2
This equation consists of two half reactions:
one for oxidation of the zinc
one for reduction of the hydrogen ions to form
hydrogen gas
Oxidation
E = -0.763 V
Reduction
E = -0.337 V
Overall Reaction
E = -1.100 V
Zn
Cu2+ + 2e-
Zn2+ + 2e-
Zn + Cu2+
Cu
Zn2+ + Cu
Assignment 2 :
A galvanic cell consists of an electrode of zinc in a 1 M
ZnSO4 solution and another of nickel in a 1 M NiSO4
solution. The two electrodes are separated by a porous
wall so that mixing of the solutions is prevented. An
external wire with a switch connects the two
electrodes. When the switch is just closed:
a)At which electrode does oxidation occur?
b)Which electrode is the anode of the cell?
c)Which electrode corrodes?
d)What is the emf of this galvanic cell when the switch
is just closed?
Types of Corrosion:
a)Pitting Corrosion
Is a form of localized corrosive attack that produces
holes or pits in a metal.
Pitting is often difficult to detect because small pits
may be covered by corrosion products.
Pitting usually requires an initiation period, but once
started, the pits grow at an ever-increasing rate.
Eg: The propagation process for a pit in an aerated
saltwater environment.
The anodic reaction of the metal at the bottom of the
pit.
The cathodic reaction takes place at the metal surface
surrounding the pit.
b) Crevice reaction
c) Intergranular Corrosion
d) Stress Corrosion
Control Corrosion
a)Anode and Cathode Corrosion
i.Anodic protection
Based on the formation of protective passive films on
metal and alloy surfaces by externally impressed
anodic currents.
Controlled anodic currents by a device called a
potentiostat can be applied to protect metals that
passivate such as austenitic stainless steels, to make
them passive and hence lower their corrosion rate in a
corrosive environment.
In this method, an external d. c. power supply is used.
The. negative terminal of power supply is connected to
underground component and positive to an inert
anode. e. g. graphite. Therefore, current passes to
b) Material Selection
Metallic Materials
i. For reducing or nonoxidizing conditions such as airfree acids and aqueous solutions, nickel and copper
alloys are often used.
ii. For oxidizing condition, chromium-containing alloys
are used.
iii. For extremely powerful oxidizing conditions,
titanium and its alloys are commonly used.
Nonmetallic Materials polymeric materials such
as plastic and rubbers are weaker, softer and in
general less resistant to strong inorganic acids than
steels. Ceramic materials are excellent corrosion
and high-temperature resistance but have the
disadvantages of being brittle with low tensile
strengths.
c) Coatings
i. Metallic Coating
the metal will be protected with applied as thin
coatings to separate the corrosive environment from
the metal.
Metal coatings are sometimes applied so that they
can serve as sacrificial anodes that can corrode
instead of the underlying metal.
Eg: the zinc coating on steel to make galvanized
steel is anodic to the steel and corrodes sacrificially.
ii. Inorganic Coatings (Ceramic and Glass)
Coat steel with a ceramic coating to attain a smooth,
durable finish.
Steel is commonly coated with a porcelain coating
that of a thin layer of glass fused to the steel
Continue.
iii. Organic Coatings
Paints, varnishes and many other organic polymeric
materials are commonly used to protect metals
from corrosive environments.
These materials provide thin, tough and durable
barriers to protect the substrate metal from
corrosive environments.
d) Design
i.
ii.
iii.
iv.
NON-FERROUS METALS
Non-ferrous naturally means a metal or alloy which
contains little or no iron.
Common non-ferrous metals are aluminum, copper and
magnesium.
Properties: as corrosion resistance, high thermal and
electrical conductivity, low density and ease of
fabrication.
Application: aluminum for cooking utensils and aircraft
bodies, copper wire for electricity, copper tubing for
residential water supply, zinc for galvanized sheet metal
for car bodies, titanium for jet-engine turbine blades and
for orthopedic implants and tantalum for rocket engines.
Aluminum
Characteristic:
a)High strength-to-weight ratio
b)high thermal and electrical conductivity
c)good corrosion resistance
d)good manufacturing properties.
Application:
a)Containers and packaging
b)Buildings and other types of construction
c)Transportation (aircraft and aerospace applications,
buses, automobiles, railroad cars and marine craft)
d)Electrical applications
e)Consumers durables (Appliances, cooking utensils
and furniture)
f)Portable tools
Copper
Copper are among the best conductors of electricity
and heat, and they have good corrosion resistance.
They can be processed easily by various forming,
machining, casting and joining techniques.
Characteristic:
a)High electrical and thermal conductivity
b)good corrosion resistance
c)good manufacturing properties.
Application:
a)Electrical and electronic components
b)Springs
c)Plumbing
d)Heat exchangers
e)Marine hardware
f)Consumer goods(such as cooking utensils, jewelry
and other decorative objects.)
Zinc
Zinc is bluish-white in color and is the metal fourth
most utilized industrially, after iron, aluminium and
copper.
Characteristic:
a)Has relatively low melting temperature about 419C
b)Fair conductor of electricity
Application:
a)Zinc serves as an anode and protects the
steel(cathode) from corrosive attack.
b)Zinc is used for galvanizing steel against corrosion
c)Alloying element; brass, for example is an alloy of
copper and zinc.
d)Zinc based alloy are used extensively in die casting
for making such products as fuel pumps.