CHM578/674 2020

Experiment 3: Corrosion Rate (Weight Loss Method) (20 marks)

Name: Nurul Husna binti Ibrahim ID: 2018226626 Group: AS2224M1

(Refer Lab manual Exp. 3 CHM674 prior to answering the following Post-Lab
Questions)

Objectives

a) To study the corrosion of steel in two different acid solutions.

b) To study the corrosion resistant efficiency of steel alloy (ie: stainless steel).

Background:

Steel will corrode when exposed to acid solutions. Electrochemical reactions involved for
steel in two different acids are as follows:
Anodic reaction:
Fe → Fe2+ + 2e Eo = -0.44 V
Cathodic Reaction:
NO3- + 4H+ + 3e ↔ NO + 2H2O Eo = +0.96 V
2- +
SO4 + 4H + 2e ↔ SO2 + 2H2O Eo = +0.17 V

The simplest, and longest-established method of estimating corrosion losses in plant and
equipment is weight loss analysis. A weighed sample (coupon) of the metal or alloy under
consideration is introduced into the process, and later removed after a reasonable time
interval. The coupon is then cleaned of all corrosion product and is reweighed. The weight
loss is converted to a corrosion rate (CR) as follows:

Density: steel = 7.86 g/cm3 , Stainless Steel = 7.0 g/cm3 , Exposed Area : 2 x 2 x 2 = 8 cm2,
K–factor (corrosion rate in mm/yr) = 8.76 x 104

Procedure:

All metal specimens (steel and stainless steel) must be in the same size. All the metal
specimens were polished with emery paper to remove all dusts and impurities and then rinsed
with alcohol. 12 vials or containers were labeled as S1(a)- (c), S2(a) – (c), SS1(a) – (c) and
SS2(a) – (c).
All the metal specimens were weighed prior to immersion in acidic solution using a 4-
decimal analytical balance. Each of the specimen was put into the right labelled container
containing the right acidic solution as in the report table. All samples were taken out after 1
hour; and dried before re-weighing.

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The corrosion resistance efficiency of stainless steel is calculated using the following
equation:

Corrosion Protection/Resistance Efficiency (η%) = CR steel - CR stainless steel x 100

CR steel
Results (4 marks)

1. Immersion of Steel in 1M H2SO4 for 1 hour

Metal specimen Weight before Weight after Weight loss (g)

immersion (g) immersion (g)
S1(a) 3.0570 3.0250 0.0320
S1(b) 3.0621 3.0301 0.0320
S1(c) 3.0562 3.0254 0.0308
Observation: All solutions turned to cloudy with a lot of bubbles formed on the steel
surface.

0.0320+0.0320+0.0308
Average weight loss (WL): =0.0316 g
3

2. Immersion of Steel in 1M HNO3 for 1 hour

Metal specimen Weight before Weight after Weight loss (g)

immersion (g) immersion (g)
S 2(a) 3.0560 2.8592 0.1968
S 2(b) 3.0630 2.8707 0.1923
S 2(c) 3.0521 2.8668 0.1853
Observation : All solutions turned to green-black solution, a lot of bubbles evolved.

0.1968+0.1923+0.1853
Average weight loss (WL): =0.1915 g
3

3. Immersion of Stainless Steel in 1M H2SO4 for 1 hour

Metal specimen Weight before Weight after Weight loss (g)

immersion (g) immersion (g)
SS 1(a) 3.0156 3.0155 0.0001
SS 1(b) 3.0293 3.0290 0.0003
SS 1(c) 3.0179 3.0170 0.0009
Observation: No changes in the solution and on the surface of specimen.

0.0001+ 0.0003+0.0009
Average weight loss (WL): =0.4333 ×10−3 g
3

4. Immersion of Stainless Steel in 1M HNO3 for 1 hour

Metal specimen Weight before Weight after Weight loss (g)

immersion (g) immersion (g)
SS 2(a) 2.9980 2.9978 2×10-4

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SS 2(b) 3.0188 3.0178 1×10-3

SS 2(c) 3.0298 3.0290 8×10-4
Observation: No changes in the solution and on the surface of specimen.

( 2× 10−4 ) + ( 1× 10−3 ) +(8 ×10−4 )

Average weight loss (WL): =6.6667× 10−4 g
3

Post- Laboratory Questions (16 marks) :

1. Calculate the corrosion rate of steel and stainless steel in both acids for 1 hour.
Exposed Area : 8 cm2

Corrosion rate (mm/yr) of steel in 1M H2SO4:

Weight loss ( g ) × K
Corrosion rate=
Alloy Density ¿ ¿

0.0316 g × 8.76 ×1 04
¿
7.86 g
3
× 8 cm2 ×1 hr
cm

44.02 mm
¿
yr

Corrosion rate (mm/yr) of steel in 1M HNO3:

Weight loss ( g ) × K
Corrosion rate=
Alloy Density ¿ ¿

0.1915 g ×8.76 ×1 0 4
¿
7.86 g
3
× 8 cm2 ×1 hr
cm

266.78 mm
¿
yr

Corrosion rate (mm/yr) of stainless steel in 1M H2SO4:

Weight loss ( g ) × K
Corrosion rate=
Alloy Density ¿ ¿

0.0004 g × 8.76 ×1 04
¿
7. 0 g
3
× 8 cm2 ×1 hr
cm

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0.63 mm
¿
yr

Corrosion rate (mm/yr) of stainless steel in 1M HNO3:

Weight loss ( g ) × K
Corrosion rate=
Alloy Density ¿ ¿

0.0007 g × 8.76× 1 04
¿
7.0 g
3
× 8 cm2 ×1 hr
cm

1.095mm
¿
yr

2. Why corrosion rate of steel is higher in nitric acid than in sulfuric acid?

- The corrosion rate for steel in nitric acid is higher than in sulfuric acid because
any additional chlorides or fluorides in nitric acid may increase the corrosion rate
by pitting in the steel.

3. Why corrosion rate of stainless steel is lower than of steel?

- Stainless steel will not corrode as fast as the corrosion rate for steel because
stainless steel is less corrosiv because of their better composition and physical
properties because stainless steel is made up of alloy that have a better resistant

4. Calculate the corrosion resistance efficiency of the alloy (ie: stainless steel) in nitric
acid.

Answer:
CR steel−CR stainless ×100
Corrosion Resistance Efficiency ( % )=
CR steel
266.78−1.095
Corrosion Resistance Efficiency= × 100 %
266.78
¿ 99.59 %