Basically said, metal corrosion will occur when two or more different metals are electrically connected together. (I.e. equipment and/or the metal is subjected to oxidizing forces such as air, humidity, and chemical reactions) This creates an electrochemical reaction or "corrosion", or
GALVANIC CELL. The electrochemical oxidation, iron or steel results in the formation of ferrous ions as the initial product (result as rust)
When two or more metals form an electrochemical cell, the metal with the more negative reduction electrode potential in the electromotive series become the
ANODE (RustBustRÔ
). It loses electrons and forms positive ions, which go into the other metals. The more positive or nobel metals in the cell (YOUR EQUIPMENT) forms the cathode and is given cathodic protection (replacing lost electrons due to oxidation), while the anodic metal (RustBustRÔ
) IS PREFERENTIALLY CORRODED IN ANY RESULTING ELECTROCHEMICAL REACTION. What this means is
"
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The process is accelerated when moisture and salt are present. This is why you see more rust and oxidation in the NE USA and coastal areas of the world.
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CORROSION
HOW IT WORKS
We lose millions of dollars are lost each year because of corrosion. Much of this loss is due to the corrosion of iron and steel. The problem with iron as well as many other metals is that the oxide formed by oxidation does not firmly adhere to the surface of the metal and flakes off easily causing "PITTING". Extensive pitting eventually causes structural weakness and disintegration of the metal.
Corrosion occurs in the presence of moisture. For example when iron is exposed to moist air, it reacts with oxygen to form rust,
Fe2O3 = XH2O
The amount of water compelled with the iron (III) varies as indicated by the letter "X". The amount of water present also determines the color of rust, which may vary from black to yellow to orange brown. The formation of rust is a very complex process which is thought to begin with the oxidation of iron to ferrous (iron "+2") ions.
Fe -------------à
Fe +2 + 2 e-
Both water and oxygen are required for the next sequence of reactions. The iron (+2) ions are further oxidized to form ferric ions (iron "+3") ions.
Fe+2 ---------------à
Fe+3 + 1e-
The electrons provided from both oxidation steps are use to reduce oxygen as shown
O2 (g) + 2 H2O + 4e- ------à
4OH-
The ferric ions then combine with the oxygen to form ferric oxide [iron (III) oxide] which is then hydrated with varying amounts of water. The overall equation for the rust formation may be written as:
4Fe+2(ag) + O2(g) + [4 + 2 XH2O(1) 1 ---à
2Fe2O3 ×
X H2O (s) + 8H + (aq)
The formation of rust can occur at some distance away from the actual pitting or erosion of iron as illustrated below. This is possible because of electrons produced via the initial oxidation of iron can be conducted through the metal and the iron ions can diffuse through the water layer to another point on the metal surface where oxygen is available. This process results in an electrochemical cell in which iron serves as the anode, oxygen gas as the cathode, and the aqueous solution of ions serving as a "salt bridge".
