III.

Corrosion of metals and their protection Page 1

Topic III. Corrosion of metals and their protection

Reference Integrated Chemistry Today, L.H.M Chung, Book 1 pg. 223 – 231
Reading

Objectives 2.3
– recognise that corrosion is the destructive attack of metals due to their reaction with air and water
– deduce from experiments factors which influence the rusting of iron
– recognise that rusting is a slow chemical process
– describe methods of rust prevention: paints and other processes, e.g. galvanising, the use of tin-plating,
electroplating and sacrificial protection (Technical details are NOT required)
– explain the corrosion resistance of aluminium in terms of the presence of a protective oxide layer
– recognise that corrosive resistance of aluminium can be enhanced by anodisation

Notes III. Corrosion of metals and their protection

Corrosion is deterioration / degrading of metal in the presence of air, water or other substances. Most of the metal
suffers from this problem. e.g. iron forms reddish brown rust with oxygen and water, copper forms green copper
carbonate with oxygen, carbon dioxide and water.

A. Corrosion of iron

Corrosion of iron is called rusting. Rusting only occurs when iron is exposed to i) air (oxygen) and ii) water.

Chemically, rust is hydrated iron(III) oxide (Fe2O3· nH2O), where the H2O is called the water of crystallization.
i.e. it is found inside the iron(III) oxide crystal. Different kinds of rust have different water content, therefore n
does not have a fixed value.
III. Corrosion of metals and their protection Page 2

1. Rusting process (details not required in HKCEE)

Formation of rust is a complicate process.

Initially, Fe atom loses 2 electrons and becomes Fe2+ ion.

Fe(s) → Fe2+(aq) + 2e-

The dissolved oxygen in water accepts the electrons and becomes hydroxide ion.

O2(aq) + 2H2O(l) + 4e- → 4OH-(aq)

The Fe2+(aq) and OH-(aq) ion reacts in water to form solid iron(II) hydroxide. This is a precipitation reaction.

Fe2+(aq) + 2OH-(aq) → Fe(OH)2(s)

dirty green

Iron(II) hydroxide is then further oxidized by the dissolved oxygen to iron(III) hydroxide.

4Fe(OH)2(s) + O2(aq) + 2H2O(l) → 4Fe(OH)3(s)

reddish brown

On standing, the iron(III) hydroxide changes to a reddish brown solid – rust.

Since Fe2O3· nH2O(s) has a very loose structure, it flakes off from the iron surface and exposes the inside of the
iron block to further corrosion.

Because rusting process involves flowing of charges, rusting would be faster in the presence of an
electrolyte. i.e. iron rusts much faster in sea water (sodium chloride solution) than in distilled water.

2. Rust indicator

Since Fe2+(aq) ion is the one of the initial product in

rusting, formation of rust can be confirmed by detecting
the presence of Fe2+(aq) ion. Potassium
hexacyanoferrate(III), K3Fe(CN)6(aq), is a yellow
chemical which turns deep blue in the presence of
Fe2+(aq) ion. It serves as a very good indicator of rust.
III. Corrosion of metals and their protection Page 3

B. Rust prevention

1. Coating
2. Sacrificial protection
3. Alloying

1. Coating

Since rust is only formed in the presence of oxygen and water, iron can be protected from rusting by putting a
coating on the surface.

a) Paint or grease

Painting is the most cost effective method for large iron object but if the painted surface is scratched, iron will be
vulnerable to rusting.
Grease or oil is used in the moving part of machinery where the paint will be scratched.

b) Galvanising (zinc dipping)

Iron is dipped into a tank of molten zinc or molten zinc is sprayed onto iron so that the surface of the iron is
coated with a layer of zinc. The process is called galvanising or galvanization. The iron is called galvanised iron.
Although zinc also reacted with oxygen in the air to form zinc oxide, zinc oxide has a very tight structure and
protects the zinc underneath from further corrosion.

The bodies of many cars are galvanized before the paint is applied. This make it more resistant to rusting.

c) Tin-plating

Since zinc is toxic, it is not used in protecting the food can from rusting. Instead, tin is coated on the surface of
iron-can to exclude air and water. However, if the tin-plating is scratched and the iron underneath is exposed, the
tin-plated-can will rust even faster than an ordinary iron-can. This is because iron is more reactive than tin and
iron will lose electrons through tin quickly.

d) Electroplating of other metal

Chromium is another metal which is coated on iron to prevent rusting. Chromium is frequently used because of its
silvery appearance. e.g. Most water taps are electroplated with chromium.
III. Corrosion of metals and their protection Page 4

2. Sacrificial protection

Iron is first changed to iron(II) ion in the rusting process. If the formation of iron(II) ion can be suppressed, iron
can be protected from rusting.

Fe(s) d Fe2+(aq) + 2e-

A reactive metal loses electron more readily than a less reactive metal. By connecting iron to a more reactive
metal, formation of Fe2+(aq) can be retarded. Once a Fe2+(aq) ion is formed, it will acquire the electrons from the
more reactive metal and changes back to Fe. Consequently, iron is protected from corrosion but the more reactive
metal is sacrificed instead.

This method is preferable for the iron object which is hard to be repainted e.g. iron pipe under the ground, hull of
ship.

Sacrificial protection by galvanization

Besides isolating iron from air and water, Zn (s) also protects iron by sacrificial protection because Zn (s) is more
reactive than Fe(s).

For the same reason, the body of a car is always connected to the negative terminal of the car battery. This make
the car body negatively charged and less vulnerable to rusting.

3. Alloying

Pure iron rust easily in moist air. But if appropriate amounts of carbon, chromium and nickel are added, iron will
become stainless steel which is more resistant to rusting.
III. Corrosion of metals and their protection Page 5

C. Corrosion resistance of aluminium

Presence of oxide layer

Aluminium is a very reactive metal, it is even more reactive than iron. Surprisingly, aluminium object seldom
corrodes. When aluminium is exposed to air, a layer of very dense aluminium oxide will form at the surface. The
oxide layer is so dense that it is not permeable to oxygen and protects the core of the aluminium object from
corrosion.

Mercury(II) chloride is a chemical which can dissolve aluminium oxide. A piece of aluminium has no reaction
with air but reacts vigorously with air if the surface is rubbed with a little mercury(II) chloride solution. HgCl2(aq)
dissolves the oxide layer and expose Al(s) to air.

4Al(s) + 3O2(g) → 2Al2O3(s)

1. Anodisation of aluminium

The corrosion resistance of aluminium can be enhanced by anodisation. The oxide layer of an aluminium object
can be thickened by connecting it to the anode of an electrolytic cell containing dilute sulphuric acid.

Water breaks down into hydrogen and oxygen during electrolysis. Water undergoes self dissociation into hydrogen
ion and hydroxide ion. They are discharged at the cathode and anode to form hydrogen and oxygen gas.

H2O(l) d H+(aq) + OH-(aq)

550,000,000 1 1
molecules ion ion

At cathode 2H+(aq) + 2e- → H2(g)

At anode 4OH-(aq) → O2(g) + H2O(l) + 4e-

2H+(aq) + 2e- → H2(g) ×2 (to make the number of e- conserve)

+ 4OH-(aq) → O2(g) + H2O(l) + 4e-
———————————————————
Overall reaction 2H2O(l) → 2H2(g) + O2(g)

However, pure water has only very low

conductivity because only 1 out of
550,000,000 molecules will dissociate into a
pair of hydrogen and hydroxide ions.
Sulphuric acid is added into the water to
increase the conductivity of water.

Glossary corrosion deterioration rusting hydrated water of crystallization

precipitation reaction electrolyte rust indicator potassium hexacyanoferrate(III) coating
sacrificial protection alloying galvanising / galvanization tin-plating food can
Electroplating vulnerable alloying mercury(II) chloride electrolytic cell anodisation
self dissociation
III. Corrosion of metals and their protection Page 6

Past Paper 90 I 5 a i ii iii iv

Questions 91 I 2 c i iii iv
92 I 1 b ii
93 I 1 a ii
96 I 4
97 I 1 a
98 I 8 b i
99 I 7 a i

90 I 5 a i ii iii iv
5a The set-up below was used to investigate the corrosion of iron: 9

After some time, the solution from each tube was tested with potassium hexacyanoferrate(III) solution. It was
found that corrosion of iron occurred only in tubes A and B.
i State the colour change when the solution from tube A was tested with potassium hexacyanoferrate(III) solution. 1
from colourless (or pale yellow) to blue 1 mark
ii When the iron nail in tube B corroded, 4
(1) indicate what cation and anion were produced, and
(2) write the half equation to show the formation of each ion.
(1) Fe2+ (or iron(II) ions) 1 mark
OH- (or hydroxide ions) 1 mark
[If more than one cation/anion is given, only mark the first one.]
(2) Fe(s) → Fe2+(aq) + 2e- 1 mark
2H2O(l) + O2(g) + 4e- → 4OH-(aq) 1 mark
or H2O(l) + ½O2(g) + 2e- → 2OH-(aq)
C (1) Some candidates were confused about the meaning of the terms 'cation' and 'anion'. As a result they gave
Fe2+ as the anion and OH- as the cation.
iii In which of the tubes would bubbles of gas be observed ? Write an equation for the reaction involved. 2
tube A 1 mark
[Also accept: tubes A and B; A and C; A and B and C]
Fe(s) + 2H+(aq) → H2(g) + Fe2+(aq) 1 mark
or Fe(s) + 2HCl(aq) → FeCl2(aq) + H2(g)
[Ignore other equations.]
[Award 1 mark for the equation only when tubes A and / or B is / are given above.]
iv Explain why corrosion of iron did not occur in 2
(1) tube C.
(2) tube D.
(1) zinc gives up electrons more readily than iron / zinc is higher than iron in the activity series / zinc is more
reactive than iron / sacrificial protection by zinc / etc. 1 mark
[Do not accept simply that zinc is present.]
(2) absence of water / air / oxygen 1 mark
[Do not accept: absence of electrolyte / ions]
C A lot of candidates thought that the absence of rusting in tube D (containing methanol and an iron nail) was due
to the unavailability of an electrolyte or ions, not realising the fact that water/oxygen/air was absent.

91 I 2 c i iii iv
2c Iron sheets can be tin-plated by electrolysis of either tin(II) or tin(IV) compounds before they are used to make
food cans.
i In the above electrolysis, what material should be used as the anode ? 1
Tin 1 mark
iii Give one reason to explain why iron is first tin-plated before food cans are made from it. 1
Prevent rusting (corrosion) of iron 1 mark
III. Corrosion of metals and their protection Page 7
iv If the tin-plated iron sheet has been scratched to expose the iron, can it still be used to make a food can ? Explain. 2
No, because iron is higher than tin in the electrochemical series, so iron will give up electrons more readily in
this case / iron is more reactive than tin 1 mark
and rusting (corrosion) is accelerated / faster / easier. 1 mark
OR
Yes, because the scratched face can be used as the inner surface. (1 mark)
Rusting does not occur due to the absence of air inside the food can. (1 mark)
C Many were able to suggest that rusting of iron would occur but failed to realise that rusting would be accelerated
since iron is higher than tin in the electrochemical series.

92 I 1 b ii
1b The table below gives some information about three metals A, B and C :
Metal Rate of corrosion of moist air Electrical conductivity Strength of metal Cost per tonne
A fast very good moderate $ 13400
B fast good good $ 13800
C slow very good moderate $ 37000
ii Suggest one method to reduce the rate of corrosion of metal in moist air. 1
Coating / plating / painting / sacrificial protection / galvanizing / tin-plating / electroplating / greasing / oiling
1 mark

93 I 1 a ii
1a Aluminium and iron can be used in making window frames.
ii Although aluminium is more reactive than iron, explain why most window frames are now made of anodized 3
aluminium instead of painted iron.
Anodized aluminium provided a protective oxide layer. 1 mark
The paint coated on iron can be scratched off (peeled off) easily / the oxide layer on aluminium is impervious to
oxygen (water). 1 mark
Thus corrosion occurs more readily in iron. 1 mark
C Many candidates did not know that the oxide layer on 'anodized aluminium' was coated by electrolysis rather
than by direct reaction of aluminium with oxygen in air, and that 'painted iron', with a layer of paint on the
surface, would not rust unless the paint was scratched off.

96 I 4
4 Briefly describe an experiment, using the following apparatus and materials, to show that air is necessary for the 8
rusting of iron.
2 test tubes, a test tube holder, a Bunsen burner, 2 clean iron nails, paraffin oil and tap water
Chemical Knowledge (5 marks)
Boil some tap water in a test tube to expel / remove any dissolved oxygen (air). 1 mark
Place one nail in a test tube containing some tap water (Tube 1) and the other nail in a test tube containing the
boiled water (Tube 2). 1 mark
Add some paraffin oil on top of the boiled water in tube 2 to prevent air to dissolve into the water / to get in
contact with the nail. 2 marks
After a few days / some time, rusting occurs / reddish solid can be seen in tube 1 / no chance in tube 2.
(Award zero marks for the observation, if it is contradictory to the procedure.) 1 mark
Effective communication (3 marks)
C Many candidates did not seem to understand how to carry out the experiment. They suggested various
experimental procedures which were neither feasible nor able to meet the aim of experiment. Instead of putting
one clean iron nail in a test tube of tap water and another nail in a test tube containing boiled tap water covered
with a layer of paraffin oil, some candidates suggested putting one iron nail in tap water and the other nail in
paraffin oil. Some wrongly proposed adding paraffin oil to a test tube containing tap water and an iron nail, and
then heating the test tube. Some wrongly suggested using a Bunsen burner to provide a source of heat which
would speed up the rate of rusting.
Candidates were also weak in their communicative skill. Many did not present their ideas in a systematic and
coherent manner. Some candidates could not even express their ideas using full sentences.

97 I 1 a
1 For each of the tasks listed in the table below, decide which substance on the right is the best to use to accomplish
the task. Explain your answer in each case.
For each of the following, award 1 mark for the correct choice and 2 marks for the explanation; (must involve a
sense of comparison); disregard the explanation for a wrong choice. i.e. zero mark is given to a wrong choice.
Task Substance
III. Corrosion of metals and their protection Page 8
1a To attach a substance to the iron hull of a tanker to calcium, copper, zinc 3
prevent the hull from rusting

zinc 1 mark
both zinc and calcium are stronger reducing agent / more reactive than iron / occupy higher positions in the
electrochemical series / can prevent iron from rusting by sacrificial protection. 1 mark
or, copper is weaker reducing agent / less reactive than iron. It cannot prevent iron from rusting. (1 mark)
Calcium reacts readily with water. 1 mark
C Most candidates chose the correct substances to accomplish the tasks in (a), but they failed to give sound
arguments to explain their choices. In making their arguments many candidates cited properties of the substances
chosen. They did not compare these properties with those of the other substances. This indicated that these
candidates were weak in presenting arguments based on known facts.

98 I 8 b i
8b The photograph below shows a can of fruit juice. The body of the can is made of iron coated with another metal.
The top of the can and the ring-pull are made of aluminium.

i (1) Suggest ONE reason why the iron body is coated with another metal. 2
(2) Name ONE metal commonly used for coating the iron body.

99 I 7 a i
7a The table below lists the key components of three alloys.
Alloy Key components
bronze copper, tin
steel iron, carbon
solder tin, metal X
i Suggest an explanation for each of the following statements:
(1) Although the amount of iron in the earth crust is greater than that of copper and tin, the Iron Age occurred
after the BronzeAge.
(2) During the Bronze Age, people used bronze instead of copper to make tools and weapons.
(3) After being exposed to air for a period of time, the surface of bronze objects turns green.
III. Corrosion of metals and their protection Page 9
90 15
B 15 The reddish-brown rust that forms on the surface of iron
can be removed by using
A. paraffin oil.
B. dilute sulphuric acid.
C. concentrated ammonia solution.
D. dilute sodium hydroxide solution.

90 49
A 49 Sea water can corrode ships more quickly than fresh water. Sodium chloride in sea water speeds up the corrosion of
iron.

93 20 21
Directions : Q.20 and Q.21 refer to the following
experiment :
Three different pairs of metal wires are placed separately in
petri dishes (as shown in the diagram below) containing a
mixture of gelatin, potassium hexacyanoferrate(III) solution
and phenolphthalein solution.

A 20 Which of the following statements are correct ?

(1) The iron wire in Dish I does not corrode readily.
(2) The iron wire in Dish II corrodes readily.
(3) The iron wire in Dish III do not corrode.
A. (1) and (2) only
B. (1) and (3) only
C. (2) and (3) only
D. (1), (2) and (3)
B 21 In Dish II, which of the following colours will develop
around the iron wire and the copper wire ?
iron wire copper wire
A. pink blue
B. blue pink
C. pink no colour
D. blue no colour

95 45
D 45 When a piece of iron wire coupled with a piece of tin wire Tin prevents iron from corrosion by sacrificial protection.
is left in the air for a long period of time, the iron wire
does not corrode.

96 8
A 8 Zinc blocks are often attached to the steel legs of off-shore
oil platforms because
A. zinc can protect steel from corrosion.
B. zinc is more resistant to corrosion than steel.
C. zinc is harder than steel.
D. zinc does not react with crude oil.

96 47
C 47 The resistance of aluminium to corrosion can be enhanced During anodisation, aluminium oxide on the metal surface
by anodisation. is reduced to aluminium.

97 27
A 27 Consider the following chemical equation:
O2(g) + 4Fe(OH)2(x) → 2Fe2O3(y) + 4H2O(z)
Which of the following combinations is correct ?
III. Corrosion of metals and their protection Page 10
x y z
A. s s l
B. s aq aq
C. aq s aq
D. aq aq l

97 48
A 48 The body of a motor car will corrode faster if common salt Common salt and water form a conducting solution.
is sprinkled on roads after a heavy snow.

99 22
C 22 In which of the following situations is iron prevented from
rusting by sacrificial protection ?
A. Iron plates are joined together with copper rivets.
B. Iron pipes are connected to lead blocks.
C. Iron sheets are plated with zinc.
D. Iron cans are coated with tin.