CORROSION IN METALS

(ERASMUS PROGRAMME-SALFORD UNIVERSITY)

Professor Fevzi Ylmaz / Istanbul - TURKEY
Fatih Sultan Mehmet Vakif University
Faculty of Engineering and Architecture
Halic Campus, Stlce Mah. Karaaa Cad.
No:12 Beyolu / Istanbul TURKEY
Phone: +90 212 369 8162
Fax: +90 212 369 8164
E_mail: f.yilmaz@fsm.edu.tr

Erasmus Lecture 2013, March

07, Salford University

CORROSION IN METALS
The composition and physical integrity of a solid
material are altered in a corrosive environment.
1. Dissolving of Material
2. Formation of oxides or other compounds.

The atom gives

up electrons

The Electrochemical Cell

An electrochemical cell is formed
when two pieces of metal in contact
with one another are placed in a
conducting liquid or electrolyte.
Electrochemical cell leads either
electrochemical
corrosion
or
electroplating.

The Electrochemical Cell

The Electrochemical Cell

Anode: The anode gives up electrons to the
circuit and corrodes.
Cathode: The cathode receives electrons from
the circuit
Physical contact: To permit the electrons to
flow from anode to the cathode.
Electrolyte: A liquid electrolyte is conductive,
thus completing the circuit.
Metallic ions leave the anode surface and
assures that ions move to the cathode to accept
the electrons.

The Electrochemical Cell

Anode Reaction :Oxidation reaction
The metal ions enter the electrolytic
solutions electrons leave the anode
through the electrical connection.

Because metal atoms leave the anode, the

anode corrodes.

The Electrochemical Cell

Cathode Reaction in Electroplating
A reduction reaction, which is the reverse of
the anode reaction, occurs at the cathode.
The metal then plates out and cover the
cathode surface.

Cathode reaction in corrosion

The reduction reaction forms a gas, liquid or
solid by-product (e.g. rust) at the cathode.

The Electrochemical Cell

Example of Anode Cathode Reaction
(Corrosion of Zinc)
Consider zinc metal immersed in an acid
solution containing H+ ions.
Zinc will experience oxidation or
corrosion.

Electroplating (electrorefining)

Anode

Catho
de

Electroplating (electrorefining)
Anode:

Ag e-
Ag+

Cathode: Ag+ + e Ag

Silver coating

The Electrochemical Cell

Protective Oxide Layer
Many metals form protective oxide layers (e.g. Al 2O3, Cr2O3
and TiO2 etc.)
If the oxide layer becomes scratched and aluminium metal
exposed, more oxide is formed and the protected layer is
renewed.

Iron oxidizes and forms the familiar red-orange rust.

However, rust takes up a greater volume than the iron.
Consequently layer splits and cracks.

Types of Electrochemical Corrosion (Galvanic

Attack)

Galvanic attack occurs when certain

areas always act as anodes, while
other areas always act as cathodes.
Uniform attack
Composition cells
Stress cells
Concentration cells
Erosion corrosion

Types of Electrochemical Corrosion

(Galvanic Attack)
Uniform Attack
When a metal is placed in an electrolyte,
some regions are anodic to other
regions.
Anode and cathode regions continually
shift
The extent of uniform attack can be
given as weight loss per unit area or by
the average penetration.

Types of Electrochemical
Corrosion (Galvanic Attack)

Rusting
of iron

Rusting of iron or tarnishing of

silver. Fogging of nickel and
high-temperature oxidation of
metals are also examples of
uniform attack.

Types of Electrochemical Corrosion

(Galvanic Attack)

Types of Electrochemical Corrosion

(Galvanic Attack)
Rate of uniform attack is reported in various units,
an accepted terminology being, for example;

Millimetres penetration per year (mm/y)

Micrometer penetration, m, per year i.e. m/y
Inches penetration per year (ipy)
Grams per square meter per day (gmd)
Grams per square meter per year (gmy)
Milligrams per square decimetre per day (mdd)

Types of Electrochemical Corrosion

(Galvanic Attack)

Types of Electrochemical Corrosion

(Galvanic Attack)
Composition Cells (bi-metallic or dissimilar metal
corrosion)

Corrosion cell in bimetallic

corrosion

In a corrosion cell
having
two
different
metal
electrodes
the
more noble metal
will be the cathode
and the less noble
the anode.

Types of Electrochemical Corrosion

(Galvanic Attack)
Examples of dissimilar metal
corrosion

b)

a) Magnesium shell that was cast around a steel core

Magnesium alloy aircraft fuel pipe coupling which seized after it
had been lubricated with graphite grease

Types of Electrochemical Corrosion

(Galvanic Attack)
Precautions (to avoid bimetallic corrosion)
1. Chose metals that are close together in
galvanic series
2. When required insulate, if possible, dissimilar
metals from each other with age-resistant
plastic or rubber

Types of Electrochemical
Corrosion (Galvanic Attack)

Bimetallic Corrosion

Types of Electrochemical Corrosion

(Galvanic Attack)

Precautions (to avoid bimetallic corrosion)

3. Design the construction so that
moisture cannot collect and remain at
the point of contact
4. Coat the area corrosion-preventing
paint or equivalent.
5. Electrically connect a third, anodic,
metal to the other two(Cathodic
protection).

Types of Electrochemical Corrosion

(Galvanic Attack)
Stress Cells
Local Stresses.
The most highly stressed, or high
energy, regions act as anodes.

Types of Electrochemical Corrosion

(Galvanic Attack)