INTRODUCTION

Metals and alloys undergo rusting and corrosion. The process by which
some metals when exposed to atmospheric condition i.e., moist air, carbon
dioxide form undesirable compounds on the surface is known as corrosion,
Corrosion is the disintegration of an engineered material into its constituent
atoms due to chemical reactionswith its surroundings. In the most common
use of the word, this means electrochemical oxidation of metals in reaction
with an oxidant such as oxygen. Formation of an oxide of iron due to
oxidation of the iron atoms in solid solution is a well-known example of
electrochemical corrosion, commonly known as rusting. This type of
damage typically produces oxide(s) and/or salt(s) of the original metal.
Corrosion can also refer to other materials than metals, such
as ceramics or polymers, although in this context, the term degradation is
more common.

In other words, corrosion is the wearing away of metals due to a chemical

reaction.

Many structural alloys corrode merely from exposure to moisture in the air,
but the process can be strongly affected by exposure to certain substances
(see below). Corrosion can be concentrated locally to form a pit or crack, or
it can extend across a wide area more or less uniformly corroding the
surface. Because corrosion is a diffusion controlled process, it occurs on
exposed surfaces. As a result, methods to reduce the activity of the exposed
surface, such as passivation and chromate-conversion, can increase a
material's corrosion resistance. However, some corrosion mechanisms are
less visible and less predictable.
CORROSION CAN BE CATEGORIZED IN SOME COMMON
TYPES

• uniform corrosion

• pitting corrosion

• galvanic corrosion

• crevice corrosion

• concentration cell corrosion

• graphitic corrosion

Uniform or General Corrosion

The metal loss is uniform from the surface.

Often combined with high-velocity fluid erosion, with or without abrasives.

Pitting Corrosion
The metal loss is randomly located on the metal surface.

Often combined with stagnant fluid or in areas with low fluid velocity.

Galvanic Corrosion
Occurs when two metals with different electrode potential is connected in a
corrosive electrolytic environment.

The anodic metal develops deep pits and groves in the surface.

Crevice Corrosion
Occurs at places with gaskets, bolts and lap joints where crevice exists.

Crevice corrosion creates pits similar to pitting corrosion.

Concentration Cell Corrosion

Occurs where the surface is exposed to an electrolytic environment where the
concentration of the corrosive fluid or the dissolved oxygen varies.

Often combined with stagnant fluid or in areas with low fluid velocity.

Graphitic Corrosion
Cast iron loosing iron in salt water or acids.
 DRIVING FORCE FOR CORROSION

Most metals used in the construction of facilities are subject to

corrosion. This is due to the high energy content of the elements in
metallic form. In nature, most metals are found in chemical
combination with other elements.

These metallic ores are refined by man and formed into metals and
alloys. As the energy content of the metals and alloys is higher than
that of their ores, chemical re-combination of the metals to form ore
like compounds is a natural process.

FUNDAMENTAL MECHANISM OF ATTACK

Corrosion of metals takes place through the action of electrochemical

cells. Although this single mechanism is responsible, the corrosion can
take many forms. Through an understanding of the electrochemical cell
and how it can act to cause the various forms of corrosion, the natural
tendency of metals to corrode can be overcome and equipment that is
resistant to failure by corrosion can be designed.
 RUST

The process of slowly eating away of the metal due to attack of the atmospheric gases
on the surface of metals; forming oxides, carbonates, sulphides is called corrosion
(e.g., tarnishing of Ag, development of a green coating on Cu and bronze etc.)
Corrosion of iron is called rusting
Rust is Fe2O3x.H2O
Rusting is an electrochemical process.

Theory of rusting
1) Water on the metal surface dissolves CO2 and O2 from the air.

fig 5.16 - Corrosion of iron

2) Fe in contact with dissolved CO2 and O2 undergoes oxidation.

3) Electrons lost by Fe are taken by H+

On multiplying the first equation by 4 and adding to the second,

The dissolved O2 can take electrons directly also

4. Fe2+ reacts with dissolved O2 and water

Rust (Hydrated ferric oxide)

Factors which Promote Corrosion

1) Reactivity of metal
2) Presence of impurities
3) Presence of air, moisture, gases like SO2 and CO2
4) Presence of electrolytes
 Prevention of Rusting

Barrier protection
The metal surface is not allowed to come in contact with moisture, O2 and CO2.
i) Coating the metal surface with paint.
ii) Applying oil or grease.
iii) Electroplating with non-corroding metals like Ni, Cr, Al, Sn, Zn.
iv) Coating with alkaline phosphate (anti rust) solution.

Sacrificial protection
Covering the surface with a more electro positive metal than Fe. The more electro
positive metal loses electrons and as long as this coating is present Fe is protected.
Example:
Galvanization - Covering with zinc.
The zinc also forms a protective coating of ZnCO3.Zn(OH)2.

Electrical protection (Cathodic protection)

The iron object is connected to a more active metal either directly or through a wire. Fe
acts as the cathode. The more reactive metal is the anode. It loses electrons and
gradually disappears.
Example: Fe can be connected to Mg, Zn or Al which are called the sacrificial anodes.
Used for protecting under ground pipes from rusting.
 AIM OF THE EXPERIMENT

In this project the aim is to investigate effect of the

metals coupling on the rusting of iron. Metal coupling
affects the rusting of iron . If the nail is coupled with a
more electro-positive metal like zinc, magnesium or
aluminium rusting is prevented but if on the other hand,
it is coupled with less electro – positive metals like
copper , the rusting is facilitated.
 REQUIREMENT:

 Two Petri dishes

 Four test – tube

 Four iron nails

 Beaker

 Sand paper

 Wire gauge

 Gelatin

 Copper, zinc & magnesium strips

 Potassium ferricyanide solution

 Phenolphthalein
 PROCEDURE

1)At first we have to clean the surface of the iron nails with the
help of sand paper.

2) After that we have to wind zinc strip around one nail, a clean
copper wire around the second & clean magnesium strip around
the third nail. Then to put all these three and a fourth nail in
Petri dishes so that they are not in contact with each other.

3) Then to fill the Petri dishes with hot agar agar solution in such
a way that only lower half of the nails are covered with the
liquids .Covered Petri dishes for one day or so.

4) The liquids set to a gel on cooling. Two types of patches are

observed around the rusted nail, one is blue and the other pink.
Blue patch is due to the formation of potassium ferro-
ferricyanide where pink patch is due to the formation of
hydroxyl ions which turns colourless phenolphthalein to pink.
 OBSERVATION

S.No. Metal Pair Colour of the patch Nails rusts or not

1 Iron- Zinc
2 Iron -Magnesium
3 Iron- Copper
4 Iron – Nail
 CONCLUSION

It is clear from the observation that coupling of iron with

more electropositive metals such as zinc and magnesium
resists corrosion and rusting of iron. Coupling of iron
with less electropositive metals such as copper increases
rusting.
 BIBLIOGRAPHY

For our project we have taken help from following

sources ;

1) Comprehensive (Practical Chemistry – XII)

2) Internet- www.wikipedia.com
www.encylopedia.com

3) NCERT Chemistry Textbooks

4) PRADEEP chemistry textbooks for 11th and 12th