Corrosion and Its Prevention
1. Introduction to Corrosion
Corrosion is the slow and continuous eating away of a metal by the action of environmental factors.
For example, pure iron, which is silvery white, corrodes when exposed to moist air, forming a reddish-
brown mass known as rust.
Corrosion is not limited to iron; other metals also corrode in different ways:
Aluminium reacts with oxygen to form a protective layer of aluminium oxide (Al₂O₃).
Copper forms a greenish layer of copper carbonate (CuCO₃), which protects it from further
corrosion.
Silver develops a blackish layer of silver sulphide (Ag₂S) when it comes in contact with foodstuffs.
2. Chemistry of Rust Formation
Rust formation occurs due to a reaction between iron, water, and oxygen in the presence of air. The
rust of iron is chemically hydrated iron(III) oxide. The process involves the formation of small
electrolytic cells on the metal’s surface:
Anode (Pure Iron): Oxidation occurs, producing Fe²⁺ ions and electrons.
Cathode (Impure or Strained Portion): Electrons react with water and oxygen to form hydroxyl
(OH⁻) ions.
Final Reaction: Fe(II) hydroxide is further oxidized to Fe(III) hydroxide, which dehydrates to form
rust.
The rust is porous and non-protective, allowing further atmospheric action until the entire iron piece
is corroded.
3. Methods to Prevent Corrosion
Several methods are used to prevent corrosion and rust formation:
1. Coating with Paint or Grease – Forms a barrier to block moisture and oxygen.
2. Galvanizing (Zinc Coating) – Protects iron by coating it with zinc.
3. Tinning (Tin Coating) – Prevents corrosion by covering iron with tin.
4. Phosphate Treatment – Iron is dipped into a phosphate bath containing zinc and manganese
phosphates.
5. Alloy Formation (e.g., Stainless Steel) – Adding metals like chromium or nickel to iron to increase
its resistance.
6. Electroplating – Applying a thin layer of corrosion-resistant metal through electrolysis.
7. Cathodic Protection – Making the metal act as a cathode in an electrochemical reaction to
prevent oxidation.
4. Electroplating: A Corrosion Prevention Technique
Electroplating is the process of coating a metal with a thin layer of another, more stable metal through
an electrochemical deposition process.
Process of Electroplating:
The metal to be coated acts as the cathode in an electrolytic cell.
The pure metal to be deposited acts as the anode.
A metal salt solution serves as the electrolyte.
When electric current is applied, metal ions from the solution are deposited onto the cathode
surface.
Metals Commonly Used for Electroplating:
Gold
Silver
Tin
Zinc
Copper
Chromium
Nickel
Platinum
Purpose of Electroplating:
Improves corrosion resistance
Enhances strength and durability
Provides decorative shine and finish
Increases wear resistance
5. Galvanizing: A Protective Coating Method
Galvanizing is a type of electroplating where zinc is coated on iron objects to protect them from
rusting.
Process of Galvanizing:
The anode is a zinc metal piece.
The cathode is the iron object to be coated.
Zinc salt solution (e.g., zinc sulfate) is used as the electrolyte.
When an electric current passes through, zinc from the anode dissolves and gets deposited on the
cathode, forming a protective zinc coating.
Zinc protects the iron object by acting as a sacrificial metal, preventing oxidation of the underlying
iron.
