Corrosion of Metals and their Protection

&hen a meta# artic#e has corroded, it does not appear shiny, and may no #onger function proper#y. 'orrosion is the gradua# destructive process occurs when a meta# is exposed to the air, water or other substances in the surroundings. ( surface coating (usua##y a meta# oxide) is formed. "he coating may f#a)es off or is porous to both air and water. *o the meta# wou#d be +eaten away+. In genera#, the higher the meta# in the reactivity series, the more rapid#y it corrodes to form meta##ic ions.

Corrosion of Iron (Rusting)

For rusting to occur, air and water have to be present. Iron is oxidized by oxygen and water to form hydrated iron(III) oxide, Fe 2O x!2O (rust). "he presence of e#ectro#ytes, acids and heat speed up the rusting of iron. Chemistry of Rusting ,usting is a s#ow chemica# process which starts as iron #oses e#ectrons. Oxygen and water gain e#ectrons and combine with iron(II) ions, fo##owed by a series of reactions to form rust (Further oxidized). "he overa## reaction-

Factors Affecting the Rate of Rusting

$xperiment showing the factors inf#uence the rusting of iron. %repare the fo##owing tubes, and they are #eft for two days.

Results and explanations:

Tube
A

Result
no rusting

Explanation
It is because anhydrous calcium chloride absorbed the water vapour in the tube. It is because oxygen was driven out by boiling the distilled water. It is because acidic medium is favour for rusting. It is because al aline medium suppresses rusting. It is because sea water contains electrolytes which enhance the conductivity of the solution. #oderate rust was observed as tap$water contained dissolved oxygen.

no rusting

serious rusting

no rusting

serious rusting

"

no rusting

Conclusions: %I& "or rusting to occur' oxygen %air& and water must be present. %(& Acidic medium and electrolytes %salt& speed up rusting. Interpretations: %)& At the seashore' the moisture contains salt ions %electrolytes&' thus the iron ob*ects nearby will rust at much faster rate. %(& In the industrial area' the acid fume released from the factories dissolved in water vapour' which speeds up rusting of iron ob*ects nearby.

Besides' uneven or sharply pointed regions in the iron piece rust at a faster rate. An increase in temperature would always increase the rate of reaction therefore' increase the rate of rusting. a less reactive metals in contact with iron would also increase the rate of rusting' and it is illustrated

Test of Rust

"he fo##owing experiment is set up and they are stood for two days.

"he rust indicator (potassium hexacyanoferrate(III) so#ution) is used, which turns b#ue when rust is present. ,esu#t-

'onc#usions*ma## b#ue patches were formed at the head and tai# of the nai#. "hat meant /is) (- rusting occurred at both ends of the nai#. 1arger b#ue patches were seen around the head and tai# of nai#, it can be /is) 0- conc#uded that the rusting of nai# was more serious as nai# was wrapped with tin. "here was no observab#e change. "here was no rusting when the nai# was /is) '- wrapped with zinc.
Interpretations-

(2) Iron in contact with a meta# (such as tin) #ower in the reactivity series than itse#f wi## speed up its rusting. It is because iron tends to #ose e#ectrons more readi#y than tin. (2) Iron in contact with a meta# (such as zinc) higher in the reactivity series than itse#f wi## prevent it from rusting. It is because zinc tends to #ose e#ectrons more readi#y than iron. "hus iron is prevented to #ose e#ectron.

Protection from Rusting

( number of methods are deve#oped to prevent iron from rusting. *ince rusting re.uires both air and water, remova# of any one or both of them wi## prevent rusting.

Coated with paint, oil or greases

(a) Ob3ects which are un#i)e#y to be scratched can be coated with paint such as bridges, ships and car body. (b) 4nderbody of a car, rac) and coat hangers can be coated with p#astic. (c) "he moving part of machines and too#s can be protected by app#ying a #ayer of oi# or grease. "hese parts cannot be painted as it wi## be easi#y scratched by the moving action.

Using alloys of iron

*ome e#ements for examp#e +'arbon+ are carefu##y added to iron to form a##oys such as stain#ess stee#.

Sacrificial protection
&hen iron is connected to a more reactive meta#, the more reactive meta# wi## #ose e#ectrons in preference, which prevent the iron from #osing e#ectrons. "he more reactive meta# corrodes (sacrifices) first to prevent iron from rusting. "his protection is usua##y emp#oyed in #arge iron ob3ects such as hu## and oi# dri##ing p#atform. (nother examp#e of sacrificia# protection-

Galvanizing (zinc-plating)
"he iron ob3ects are dipped into the mo#ten zinc and a zinc #ayer is coated on the iron ob3ects. *ince zinc is more reactive than iron, zinc re#eases e#ectron to iron. "hus zinc is corroded first to save iron even when the zinc coating is scratched. !owever, ga#vanized iron is not used in ma)ing food cans as zinc is toxic.

Tin-plating (not a sacrificial protection) (a) "he method is simi#ar to ga#vanizing. !owever, when the tin5
p#ate is scratched, the rusting wi## occur more .uic)#y. It is because tin is #ower in the reactivity series than iron.

(b) "in5p#ated food can is used because tin is non5poisonous but zinc
ions are poisonous.

Co parison between r!st and al! ini! Electroplating

o"ide

Rust Aluminium oxide 6eta#s (such as chromium and nic)e#) can be coated on iron ob3ects by Fe2O2 - 2x H2O Al(-. nature . e#ectrop#ating permeability hardness permeab#e to both air and water porous and #oose#y bound to the meta# impermeab#e to both air and water hard and strong, c#ose#y bound to the meta#

Electrical but tough protection oxide #ayer which sea#s the meta# surface. "his protective

(#uminium is corrosion resistant. It is because a#uminium forms a thin

#ayer prevents further reaction. "he protective #ayer of a#uminium can "he ob3ects are connected to the negative termina# of a d.c.is be iron thic)ened by anodising (anodisation) so that anodised a#uminium source, in order to prevent the iron from #osing e#ectrons. For more corrosion resistant and can a#so be dyed to different attractive instance, car body is connected to the negative termina# of battery. co#ours.

The process of anodisation (by electrolysis)

"he a#uminium ob3ects are made anode and e#ectro#ysed in di#ute su#phuric acid. "he oxygen produced reacts with a#uminium anode to form a protective a#uminium oxide coating. Summary of Protection Methods Method
coated with paint coated with plastic electroplating %Cr' +i& galvani,ing iron tin plating

Relative cost
low

Protection
fair

Appearance
colour of paint colour of plastic bright shiny dull silvery dull silvery

Remark
usually apply to large iron ob*ects' not suitable at high temperature not suitable at high temperature hard coating' not easily scratched for large sheet' sacrificial protection non$poisonous layer

low high medium medium

fair good good fairly good

Corrosion of Aluminium
(#uminium is more reactive than iron, however it is corrosion resistant. It is because once an oxide #ayer formed on the a#uminium surface, the a#uminium meta# underneath is protected, and further oxidation is stopped. It is tota##y different from that of iron.