Chemistry 化学

Discussion Examples for Corrosion Experiments | Redox Reactions, Metal Ionization Tendency, and Corrosion Protection

A corrosion experiment is an experiment that investigates the phenomenon in which a metal reacts with its surrounding environment, becomes oxidized, and undergoes surface changes or dissolution.
Rusting of iron, discoloration of copper, and surface changes of zinc and aluminum are common examples of corrosion seen in everyday life.
Corrosion is not merely surface contamination but can be understood as an electrochemical phenomenon in which an oxidation reaction, where a metal loses electrons, is combined with a reduction reaction, where oxygen, hydrogen ions, or other species accept electrons.

In a discussion of a corrosion experiment, it is not sufficient simply to write that “the metal rusted” or “the metal changed color.”
It is necessary to explain which metals are more easily oxidized, why oxygen and water are necessary, why chloride ions accelerate corrosion, why corrosion tends to progress when different metals are brought into contact, and what methods are available for corrosion protection.
The central concepts are redox reactions, the ionization tendency of metals, and the concept of local cells.

This article clearly explains, as examples of discussions that can be used in corrosion-experiment reports, the principles of metal corrosion, rusting of iron, the roles of oxygen, water, and electrolytes, the ionization tendency of metals, galvanic corrosion caused by contact between dissimilar metals, sacrificial protection, corrosion protection by painting and plating, experimental errors, and points for improvement.

Note:
This article is a reference intended to assist with discussions of corrosion-experiment results obtained in inorganic chemistry experiments, electrochemistry experiments, materials chemistry experiments, and basic chemistry experiments at universities and similar institutions.
For the actual metal samples, solution concentrations, immersion time, pH, temperature, observation methods, and safety precautions, always follow the instructions in your university’s laboratory manual and those given by your instructor or TA.

  1. What Is a Corrosion Experiment?
  2. Main Items to Include in the Results
    1. Main Items to Include in the Results
  3. Reference Experimental Values and Calculation Examples for Corrosion Experiments
    1. Reference Experimental Conditions
    2. Ionization Tendency of Metals and How to View Corrosion
    3. Mass Changes When Metals Are Immersed in NaCl Aqueous Solution
    4. Example Calculation of Mass-Loss Percentage
    5. Example Calculation of Corrosion Rate
    6. Comparison of Corrosion Rates Based on Mass Loss
    7. Comparison of Iron Corrosion Under Different Solution Conditions
    8. Example Calculation of Inhibition Efficiency by a Corrosion Inhibitor
    9. Comparison of Corrosion Caused by Contact Between Dissimilar Metals
    10. Example Observation of Displacement Reactions with Metal Ions
    11. Example of How to Write the Results
    12. Points for Connecting the Results to the Discussion
    13. Example Discussion
    14. Summary
  4. Corrosion Is a Redox Reaction
  5. Corrosion of Iron and Formation of Rust
  6. Effects of Water and Oxygen
  7. Effect of Electrolytes
  8. Effect of Chloride Ions
  9. Effect of Acidic Conditions
  10. Ionization Tendency of Metals and Corrosion
  11. Concept of Local Cells
  12. Galvanic Corrosion Caused by Contact Between Dissimilar Metals
  13. Concept of Sacrificial Protection
  14. Difference Between Tin Plating and Zinc Plating
  15. Corrosion Protection by Oxide Films
  16. Corrosion Protection by Painting
  17. Corrosion Protection by Plating
  18. Factors Affecting Corrosion Rate
  19. Evaluation of Corrosion by Mass Change
  20. Causes of Error in Corrosion Experiments
  21. When the Results Can Be Considered Good
  22. Example Discussions When the Experiment Did Not Go Well
  23. How to Write Points for Improvement
    1. Improvements to Metal Samples
    2. Improvements to Solution and Environmental Conditions
    3. Improvements to Observation and Measurement
  24. Difference Between a Superficial Discussion and a Good Discussion
  25. Examples of Expressions That Can Be Used in Reports
  26. Points to Check When Discussing Corrosion Experiments
  27. Summary

What Is a Corrosion Experiment?

A corrosion experiment is an experiment that investigates how metals change under the influence of water, oxygen, acids, salts, other metals, and other environmental factors.
Changes such as discoloration of the metal surface, formation of rust, changes in mass, gas evolution, and changes in solution color are observed to discuss how easily metals are oxidized and under what conditions corrosion can be prevented.
Corrosion is an important phenomenon related to the durability and safety of metallic materials.

In many cases, corrosion occurs through the simultaneous progress of an oxidation reaction in which a metal loses electrons and a reduction reaction in which oxygen or hydrogen ions accept electrons.
In other words, corrosion is a redox reaction and may proceed through the formation of small battery-like reaction sites on the metal surface.
Therefore, corrosion becomes easier to understand when considered from an electrochemical perspective.

Example Discussion:
In a corrosion experiment, oxidation of the metal can be confirmed by observing discoloration and the formation of rust on the metal surface.
Corrosion proceeds not only through the oxidation reaction in which the metal loses electrons but also in combination with reduction reactions in which oxygen or hydrogen ions accept electrons.
Therefore, when discussing corrosion, it is necessary to relate redox reactions to electrochemical reactions occurring on the metal surface.

Main Items to Include in the Results

In the results of a corrosion experiment, organize the type of metal used, type of solution, pH, presence or absence of chloride ions, presence or absence of oxygen, immersion time, temperature, changes in the metal surface, presence or absence of rust or precipitate, mass changes, potential differences, comparison conditions, and other information.
Because corrosion is greatly affected by environmental conditions, it is important to record the conditions specifically.

Main Items to Include in the Results

  • Type of metal sample
  • Pretreatment of the metal surface
  • Type of solution
  • Solution concentration
  • pH conditions
  • Presence or absence of chloride ions
  • Presence or absence of oxygen
  • Temperature
  • Immersion time
  • Discoloration of the metal surface
  • Formation of rust or precipitate
  • Presence or absence of gas evolution
  • Mass change
  • Presence or absence of contact between dissimilar metals
  • Presence or absence of corrosion-protection treatment
  • Degree of corrosion progression
  • Causes of error and points for improvement

Example of How to Write the Results:
Metal samples were immersed for a fixed period under different solution conditions, and discoloration of the surface, formation of rust, gas evolution, and mass changes were compared.
Surface changes were large in sodium chloride aqueous solution, whereas changes were small under dry conditions or in pure water.
From these results, water, oxygen, and electrolytes were considered to affect the progress of corrosion.

Reference Experimental Values and Calculation Examples for Corrosion Experiments

Here, metals are immersed in electrolyte solutions, and mass changes, surface observations, potential differences, and corrosion-protection effects are compared to organize redox reactions, the ionization tendency of metals, and the ease with which corrosion proceeds.

Corrosion is an electrochemical phenomenon that includes the reaction in which a metal is oxidized and becomes metal ions.
The way corrosion progresses changes greatly depending on the type of metal, ions in the solution, oxygen, chloride ions, contact with dissimilar metals, and the presence or absence of corrosion-protection treatment.

Reference Experimental Conditions

Item Details
Metals measured Zinc, iron, copper, aluminum
Test solutions Pure water, 3.5 mass% NaCl aqueous solution, 0.10 mol/L CuSO4 aqueous solution
Immersion time 24 hours
Specimen area 10.0 cm²
Measurement items Mass change, surface observation, natural potential, corrosion rate, corrosion-protection effect
Measurement temperature Room temperature

Ionization Tendency of Metals and How to View Corrosion

In general, metals with greater ionization tendencies more readily release electrons and become positive ions and are therefore considered more easily oxidized.
However, actual corrosion is also affected by oxide films, passive films, solution conditions, oxygen supply, and other factors.

Metal Main Oxidation Reaction View of Ionization Tendency Corrosion Tendency
Zinc Zn → Zn2+ + 2e− Large Easily oxidized and used for sacrificial protection
Aluminum Al → Al3+ + 3e− Large Easily oxidized but readily protected by an oxide film
Iron Fe → Fe2+ + 2e− Moderate Readily corrodes in chloride environments
Copper Cu → Cu2+ + 2e− Small Relatively difficult to oxidize

Mass Changes When Metals Are Immersed in NaCl Aqueous Solution

The following shows an example in which each metal was immersed in a 3.5 mass% NaCl aqueous solution for 24 hours and the masses before and after immersion were measured.
The larger the mass loss, the more the metal is considered to have dissolved and the more corrosion progressed.

Metal Mass Before Immersion Mass After Immersion Mass Loss Surface Observation Evaluation of Corrosion
Zinc 5.238 g 5.201 g 0.037 g White corrosion products observed Corrosion progressed
Iron 6.482 g 6.431 g 0.051 g Clear reddish-brown rust formed Large amount of corrosion
Copper 7.156 g 7.151 g 0.005 g Slight surface discoloration Small amount of corrosion
Aluminum 2.814 g 2.806 g 0.008 g Whitish film observed Corrosion relatively small because of the oxide film

Example Calculation of Mass-Loss Percentage

The mass-loss percentage expresses as a percentage how much mass decreased relative to the mass before immersion.

Mass-loss percentage (%) = Mass loss ÷ Mass before immersion × 100

For example, for iron, the mass before immersion was 6.482 g and the mass loss was 0.051 g, so it can be calculated as follows.

Mass-loss percentage = 0.051 ÷ 6.482 × 100 = 0.79%

In this reference example, the mass-loss percentage of iron was relatively large, indicating that corrosion readily progressed in the NaCl aqueous solution.

Example Calculation of Corrosion Rate

The corrosion rate per unit area and unit time can be calculated from the mass loss.
Here, the corrosion rate is simply expressed using the following equation.

Corrosion rate (mg/cm²·day) = Mass loss (mg) ÷ Specimen area (cm²) ÷ Immersion time (day)

The mass loss of iron is 0.051 g, or 51 mg.
If the specimen area is 10.0 cm² and the immersion time is 1 day, the corrosion rate is calculated as follows.

Corrosion rate = 51 mg ÷ 10.0 cm² ÷ 1 day = 5.1 mg/cm²·day

The larger this value, the more metal was lost over the same area and the same period.

Comparison of Corrosion Rates Based on Mass Loss

Metal Mass Loss Corrosion Rate How to Interpret the Result
Iron 51 mg 5.1 mg/cm²·day Largest amount of corrosion
Zinc 37 mg 3.7 mg/cm²·day Corrosion progressed
Aluminum 8 mg 0.8 mg/cm²·day Corrosion suppressed by the film
Copper 5 mg 0.5 mg/cm²·day Small amount of corrosion

Comparison of Iron Corrosion Under Different Solution Conditions

Corrosion is greatly affected not only by the type of metal but also by the solution conditions.
Here, examples are shown for iron specimens immersed for 24 hours in different solutions.

Solution Condition Mass Before Immersion Mass After Immersion Mass Loss Corrosion Rate Surface Observation
Pure water 6.480 g 6.472 g 0.008 g 0.8 mg/cm²·day Slight discoloration
3.5 mass% NaCl 6.482 g 6.431 g 0.051 g 5.1 mg/cm²·day Reddish-brown rust formed
Acidic aqueous solution 6.479 g 6.405 g 0.074 g 7.4 mg/cm²·day General corrosion observed
NaCl + corrosion inhibitor 6.481 g 6.467 g 0.014 g 1.4 mg/cm²·day Few corrosion products

The mass loss of iron was larger in the NaCl aqueous solution than in pure water.
In addition, corrosion progressed even more readily under acidic conditions, while corrosion was suppressed under conditions where a corrosion inhibitor was added.

Example Calculation of Inhibition Efficiency by a Corrosion Inhibitor

The effect of a corrosion inhibitor can be determined by comparing the corrosion rate without the inhibitor with the corrosion rate in the presence of the inhibitor.

Inhibition efficiency (%) = (Corrosion rate without inhibitor − Corrosion rate with inhibitor) ÷ Corrosion rate without inhibitor × 100

If the corrosion rate of iron in NaCl aqueous solution is 5.1 mg/cm²·day and the corrosion rate in the presence of the corrosion inhibitor is 1.4 mg/cm²·day, the inhibition efficiency is calculated as follows.

Inhibition efficiency = (5.1 − 1.4) ÷ 5.1 × 100 = 72.5%

Therefore, the addition of the corrosion inhibitor was considered to suppress the corrosion of iron by approximately 72.5%.

Comparison of Corrosion Caused by Contact Between Dissimilar Metals

When different metals are electrically connected and placed in an electrolyte solution, galvanic corrosion may occur because of the potential difference.
The metal with the greater ionization tendency and more active potential tends to become the anode and its corrosion is accelerated.

Combination Mainly Corroded Metal Observation after 24 Hours Reason
Iron only Iron Reddish-brown rust formed Iron is oxidized
Iron + Zinc Zinc Little rust on iron and white products on the zinc surface Zinc acts as a sacrificial anode
Iron + Copper Iron Increased rusting of iron Iron becomes the anode and corrosion is accelerated
Iron + Stainless Steel Iron Corrosion is noticeable near the contact area The potential difference makes the iron side more susceptible to corrosion

Example Observation of Displacement Reactions with Metal Ions

One method of confirming the ionization tendency of metals is to place a piece of metal in an aqueous solution containing ions of another metal.
A metal with a greater ionization tendency reduces the metal ions in the solution while itself being oxidized and dissolving.

Combination Observation Concept of the Reaction Judgment
Iron piece + CuSO4 aqueous solution Reddish-brown copper deposits on the iron surface Fe → Fe2+, Cu2+ → Cu Iron has a greater ionization tendency than copper
Zinc piece + CuSO4 aqueous solution Copper deposits on the zinc surface and the blue color becomes lighter Zn → Zn2+, Cu2+ → Cu Zinc has a greater ionization tendency than copper
Copper piece + ZnSO4 aqueous solution No major change Copper does not readily reduce zinc ions Copper has a smaller ionization tendency than zinc
Copper piece + FeSO4 aqueous solution No major change Copper does not readily reduce iron ions Copper has a smaller ionization tendency than iron

Example of How to Write the Results

When each metal was immersed in a 3.5 mass% NaCl aqueous solution for 24 hours, the mass loss of iron was 0.051 g and the corrosion rate was 5.1 mg/cm²·day, which were the largest values among the metals measured in this experiment.
In contrast, the mass loss of copper was 0.005 g and the corrosion rate was 0.5 mg/cm²·day, indicating relatively little corrosion.

When the iron specimens were immersed in different solutions, the corrosion rate was 0.8 mg/cm²·day in pure water, 5.1 mg/cm²·day in 3.5 mass% NaCl aqueous solution, and 7.4 mg/cm²·day in an acidic aqueous solution.
These results confirmed that chloride ions and acidic conditions promote corrosion of iron.

In addition, when a corrosion inhibitor was added to the NaCl aqueous solution, the corrosion rate of iron decreased to 1.4 mg/cm²·day.
The inhibition efficiency compared with the condition without the corrosion inhibitor was 72.5%, so the addition of the corrosion inhibitor was considered to have greatly suppressed corrosion.

Points for Connecting the Results to the Discussion

In a discussion of a corrosion experiment, it is important to relate not only mass changes and appearance but also redox reactions, ionization tendency, solution conditions, and corrosion-protection effects.

  • Can a larger mass loss be explained as indicating greater progress of corrosion?
  • Does the ionization tendency of the metals correspond to the actual corrosion results?
  • Can examples such as aluminum, which has a large ionization tendency but is protected by an oxide film, be explained?
  • Can the reason corrosion progressed more readily in NaCl aqueous solution and acidic aqueous solution be explained?
  • When dissimilar metals are in contact, which metal becomes the anode and is more susceptible to corrosion?
  • Can the concept of sacrificial protection, in which zinc protects iron, be explained?
  • Can corrosion suppression by a corrosion inhibitor be explained using corrosion rate and inhibition efficiency?

Example Discussion

In this experiment, the corrosion behavior of metals was compared in NaCl aqueous solution.
In iron, reddish-brown rust was clearly observed, the mass loss was 0.051 g, and the corrosion rate was 5.1 mg/cm²·day.
In contrast, the mass loss of copper was as small as 0.005 g, and only slight changes were observed on the surface.
This was considered to result from iron being more easily oxidized than copper and therefore more susceptible to corrosion in an aqueous solution containing chloride ions.

Zinc also showed a mass loss, but when iron and zinc were brought into contact, there was little rust on the iron and white corrosion products were observed on the zinc side.
This was considered to result from zinc having a greater ionization tendency than iron and being preferentially oxidized as the anode.
The phenomenon in which zinc corrodes itself and thereby suppresses corrosion of iron can be explained as sacrificial protection.

In addition, when iron and copper were brought into contact, corrosion of iron progressed more readily than when iron was used alone.
This was because a potential difference arose between iron and copper, causing iron, the more active metal, to act as the anode and copper, the more noble metal, to act as the cathode.
As a result, the oxidation reaction of iron was promoted and corrosion was considered to have progressed near the contact area.

Regarding the solution conditions, the corrosion rate of iron was larger in NaCl aqueous solution and acidic aqueous solution than in pure water.
In NaCl aqueous solution, chloride ions may have readily destroyed the surface film and promoted localized corrosion.
In addition, under acidic conditions, hydrogen ions readily participate in the reduction reaction, making the oxidation reaction of the metal more likely to proceed.

Under conditions where a corrosion inhibitor was added, the corrosion rate of iron decreased from 5.1 mg/cm²·day to 1.4 mg/cm²·day, and the inhibition efficiency was 72.5%.
This was considered to result from the corrosion inhibitor adsorbing onto the metal surface and forming a protective film or suppressing the anodic or cathodic reaction.
Therefore, to suppress corrosion, it is important to appropriately select the combination of metals, solution conditions, and corrosion-protection treatment.

Summary

In corrosion experiments, the ease with which corrosion progresses can be specifically evaluated by comparing metal mass changes, surface observations, contact between dissimilar metals, solution conditions, and the presence or absence of corrosion inhibitors.

In this reference example, corrosion of iron progressed greatly in NaCl aqueous solution, while corrosion of copper was relatively small.
In addition, zinc acted as sacrificial protection for iron, and the addition of a corrosion inhibitor reduced the corrosion rate of iron.
In a report, it is useful to discuss redox reactions, ionization tendency, galvanic corrosion, and corrosion-protection effects in relation to one another.

Corrosion Is a Redox Reaction

In metal corrosion, an oxidation reaction occurs in which metal atoms lose electrons and become metal ions.
For example, in iron, Fe loses electrons and becomes Fe2+.
These electrons are consumed in reduction reactions involving oxygen, hydrogen ions, or other species.
In other words, metal corrosion is a phenomenon in which oxidation and reduction reactions occur simultaneously.

For corrosion to proceed, there must be a location where the metal releases electrons and a location where a reaction that accepts those electrons occurs.
If there are nonuniform areas on the metal surface, local anodic and cathodic regions may form and the reaction may proceed like a small battery.
This can be explained using the concept of a local cell.

Oxidation of a metal: M → Mn+ + ne-

Oxidation of iron: Fe → Fe2+ + 2e-

Example Discussion:
Corrosion is an oxidation reaction in which a metal loses electrons and becomes metal ions.
However, because the electrons produced by oxidation are consumed by reduction reactions involving oxygen or hydrogen ions, corrosion can be understood as an electrochemical reaction combining oxidation and reduction reactions.
In the case of iron, the oxidation reaction in which Fe becomes Fe2+ is the starting point of corrosion.

Corrosion of Iron and Formation of Rust

During corrosion of iron, Fe is oxidized to Fe2+ and subsequently undergoes further oxidation and hydroxide formation to become hydrated iron oxides known as rust.
Rust is not a single substance but is treated as a complex mixture of oxides and hydroxides including Fe2O3·nH2O and FeOOH.

Iron rust generally appears reddish brown, and corrosion may progress from the surface into the interior.
Unlike a dense and protective film such as the oxide film on aluminum, iron rust is porous and allows water and oxygen to pass through, so it does not easily stop corrosion completely.
Therefore, corrosion-protection treatment is important for iron.

Fe → Fe2+ + 2e-

O2 + 2H2O + 4e- → 4OH-

Fe2+ + 2OH- → Fe(OH)2

Example Discussion:
The reddish-brown rust formed on the iron surface was considered to result from oxidation of iron to Fe2+, followed by reactions with oxygen and water to form hydroxides and oxides.
Iron rust is porous and allows water and oxygen to pass through, so even after rust forms, corrosion of the underlying metal cannot be completely prevented.
Therefore, to prevent corrosion of iron, corrosion-protection treatments that reduce contact with oxygen and water are important.

Effects of Water and Oxygen

Water and oxygen are strongly involved in the corrosion of many metals, including iron.
Water assists ion movement and provides an environment in which electrochemical reactions can proceed.
Oxygen acts as a reactant in the reduction reaction and accepts electrons released by the metal.
Therefore, corrosion progresses readily under conditions where both water and oxygen are present.

Corrosion progresses less readily in dry air because little moisture is present.
In addition, in water from which oxygen has been removed, the oxygen-reduction reaction is less likely to occur, so corrosion may be suppressed.
When comparing experimental conditions, it is important to discuss that the coexistence of water and oxygen, rather than water or oxygen alone, is important for corrosion.

Example Discussion:
Because corrosion of iron progressed under conditions where water and oxygen were present, corrosion was considered to require not only oxidation of the metal but also the reduction of oxygen and water that assists ion movement.
Water dissolves electrolytes and creates an environment in which ions can move, while oxygen acts in the reduction reaction by accepting electrons.
Therefore, corrosion may be suppressed under dry conditions or conditions where oxygen has been removed.

Effect of Electrolytes

Corrosion progresses more readily in environments containing electrolytes such as sodium chloride aqueous solution.
When an electrolyte is present, the conductivity of the solution increases and the movement of electrons and ions associated with reactions on the metal surface becomes easier.
This allows the reactions at the anodic and cathodic regions to continue more readily.

Iron and steel corrode readily in seawater because water, oxygen, and salts are all present.
If corrosion progresses more readily in salt water than in pure water, one possible cause is that the electrolyte makes corrosion current flow more readily.
The presence or absence of electrolytes greatly affects the corrosion rate.

Example Discussion:
Corrosion of the metal progressed more readily in salt water because NaCl acted as an electrolyte and increased the conductivity of the solution.
In a highly conductive environment, electrochemical reactions between the anodic and cathodic regions on the metal surface proceed more readily.
Therefore, corrosion was considered to have been accelerated more in salt water than in pure water.

Effect of Chloride Ions

Chloride ions, Cl-, are representative ions that promote metal corrosion.
Cl- may destroy protective films on metal surfaces and promote localized corrosion.
In particular, in metals such as stainless steel and aluminum that are protected by surface oxide films, chloride ions may destroy the films and cause pitting corrosion.

Corrosion progresses readily in salt water and seawater not only because their conductivity is increased by electrolytes but also because Cl- destabilizes protective films.
If corrosion is large only under experimental conditions containing chloride ions, the effect of Cl- should be discussed.

Example Discussion:
Corrosion progressed in the solution containing chloride ions because Cl- was considered to have destroyed the protective film on the metal surface and promoted localized corrosion.
In addition, NaCl aqueous solution increases conductivity, making the electrochemical reactions associated with corrosion proceed more readily.
Therefore, metal corrosion is considered particularly likely to occur in environments containing chloride ions.

Effect of Acidic Conditions

Under acidic conditions, a large amount of H+ is present, so corrosion of metals may be promoted.
The metal is oxidized and releases electrons, and H+ accepts those electrons to produce H2.
Reactions in which metals such as zinc and iron dissolve in acids and evolve gas can be explained by this concept.

Under acidic conditions, protective oxide or hydroxide films may also dissolve more readily.
Therefore, even metals whose corrosion is suppressed by protective surface films may corrode more readily in acidic solutions.
If bubbles are observed in an experiment, they can be discussed as corrosion reactions accompanied by hydrogen evolution.

Zn → Zn2+ + 2e-

2H+ + 2e- → H2

Zn + 2H+ → Zn2+ + H2

Example Discussion:
If bubbles were generated from the metal surface in an acidic solution, the metal was considered to have been oxidized and released electrons, which were accepted by H+ to produce H2.
Under acidic conditions, the H+ concentration is high, so the reduction reaction proceeds readily and dissolution of the metal is promoted.
Therefore, metal corrosion is considered to progress readily in acidic environments.

Ionization Tendency of Metals and Corrosion

The ionization tendency of metals is a concept that represents the order in which metals readily lose electrons and become positive ions.
Metals with greater ionization tendencies tend to be more easily oxidized and more susceptible to corrosion.
For example, zinc and iron ionize more readily than copper and silver and may corrode more readily depending on the conditions.

However, actual susceptibility to corrosion is not completely determined by ionization tendency alone.
Some metals, such as aluminum, have a large ionization tendency but form a dense oxide film on the surface that suppresses corrosion.
Therefore, both ionization tendency and surface films must be considered.

Example Discussion:
Metals with greater ionization tendencies lose electrons and become positive ions more readily and therefore tend to corrode more easily.
For example, zinc and iron are more easily oxidized than copper and may show greater changes in corrosion experiments.
However, metals such as aluminum form dense oxide films on the surface, so corrosion may be suppressed even though their ionization tendency is large.

Concept of Local Cells

Metal surfaces are not completely uniform and contain differences such as scratches, dirt, crystal structure, and oxygen concentration.
Therefore, even on the same metal surface, one area may act as an anode while another area acts as a cathode.
Such a state resembling a small battery is called a local cell.

When a local cell forms, the metal is oxidized and dissolves at the anodic region, while reactions such as oxygen reduction occur at the cathodic region.
As a result, localized corrosion may occur in which only part of the metal surface corrodes.
The reason scratches and surface nonuniformity promote corrosion can be explained by the formation of local cells.

Example Discussion:
When scratches or dirt are present on a metal surface, differences in surface condition can cause local anodic and cathodic regions to form.
At the anodic region, the metal is oxidized and dissolves, while at the cathodic region, oxygen reduction proceeds, so corrosion is promoted by the local cell.
Therefore, if corrosion was particularly strong in a scratched sample, formation of a local cell can be considered as a possible cause.

Galvanic Corrosion Caused by Contact Between Dissimilar Metals

When different types of metals are in contact in an electrolyte solution, a battery may be formed because of the potential difference and corrosion of one of the metals may be accelerated.
This is called galvanic corrosion or dissimilar-metal contact corrosion.
The metal with the greater ionization tendency tends to become the anode and is preferentially oxidized.

For example, when iron and copper are brought into contact and placed in salt water, iron may become the anode and become more susceptible to corrosion.
On the other hand, when zinc is brought into contact with iron, zinc is more easily oxidized than iron, so the zinc corrodes first and the iron may be protected.
This leads to the concept of sacrificial protection.

Example Discussion:
Corrosion progressed under conditions where different metals were in contact because a battery was considered to have formed as a result of the potential difference between the metals.
The metal with the greater ionization tendency becomes the anode and more readily loses electrons and dissolves.
Therefore, when iron and copper are brought into contact, iron may be preferentially corroded.

Concept of Sacrificial Protection

Sacrificial protection is a method in which a metal that ionizes more readily than the metal to be protected is brought into contact with it, allowing that metal to corrode first and thereby protecting the target metal.
A representative example is the use of zinc to protect iron.
Zinc ionizes more readily than iron, so zinc becomes the anode and is oxidized, while iron is protected as the cathode.

Galvanized steel is iron plated with zinc, and even if the surface is scratched, zinc may corrode sacrificially and protect the iron.
This property is a corrosion-protection method that applies the concepts of the ionization tendency of metals and contact between dissimilar metals.

Zn → Zn2+ + 2e-

Example Discussion:
If corrosion of iron was suppressed under conditions where zinc was in contact with the iron, sacrificial protection by zinc was considered to have occurred.
Zinc ionizes more readily than iron, so zinc becomes the anode and is preferentially oxidized.
As a result, iron becomes the cathodic side and is less easily oxidized, so corrosion is suppressed.

Difference Between Tin Plating and Zinc Plating

In corrosion protection of iron, the difference between zinc plating and tin plating is important.
Zinc ionizes more readily than iron, so even if the iron is scratched, the zinc may corrode sacrificially and protect the iron.
In contrast, tin ionizes less readily than iron, so it can protect the iron while the surface remains completely covered, but if the coating is scratched and iron is exposed, the iron becomes more likely to corrode preferentially.

This difference can be explained by the relationship between the ionization tendencies of metals and galvanic corrosion caused by contact between dissimilar metals.
Corrosion protection that merely covers the surface behaves differently when damaged from corrosion protection that also acts sacrificially.
When discussing plating for corrosion protection in a report, attention should be paid to the type of plating metal.

Example Discussion:
In zinc plating, zinc ionizes more readily than iron, so even if the surface is scratched, zinc is oxidized first and protects the iron.
On the other hand, in tin plating, tin ionizes less readily than iron, so if iron is exposed through a scratch, the iron becomes the anode and is more susceptible to corrosion.
This difference can be explained by the ionization tendencies of the metals and whether sacrificial protection occurs.

Corrosion Protection by Oxide Films

Aluminum and stainless steel suppress corrosion by forming dense oxide films on their surfaces.
Aluminum is a metal with a large ionization tendency, but a thin Al2O3 oxide film forms on its surface, making corrosion less likely to progress into the interior.
Protection by such a film may be called passivation.

However, if the oxide film is destroyed by chloride ions, strong acids, or strong bases, corrosion may progress.
If aluminum normally shows little change but corrodes in a specific solution during an experiment, destruction of the oxide film should be considered.

Example Discussion:
Although aluminum has a large ionization tendency, corrosion may progress only slightly in ordinary water.
This is because a dense Al2O3 film forms on the surface and protects the underlying metal.
However, if the film is destroyed by chloride ions, acids, or bases, corrosion may become more likely to progress.

Corrosion Protection by Painting

Painting is a corrosion-protection method in which the metal surface is covered with a resin or paint to block contact with water, oxygen, and electrolytes.
Because water, oxygen, and ion movement are necessary for corrosion to proceed, corrosion can be suppressed by keeping these away from the metal surface.
Painting is commonly used to protect steel materials from corrosion.

However, if scratches or pinholes are present in the coating, water and oxygen can enter through those areas and localized corrosion may progress.
The effectiveness of corrosion protection by painting greatly depends on adhesion, coating thickness, and the presence or absence of defects.
Comparing corrosion at coated and scratched areas in an experiment makes it possible to discuss the role of the protective coating.

Example Discussion:
Corrosion was suppressed in the painted metal because the coating covered the metal surface and blocked contact with water, oxygen, and electrolytes.
On the other hand, in areas where the coating was scratched, water and oxygen could enter through the damaged region and localized corrosion could progress.
Therefore, preventing defects in the coating is important for corrosion protection by painting.

Corrosion Protection by Plating

Corrosion protection by plating includes methods that cover the metal surface to prevent contact with the environment and methods that act as sacrificial protection.
In cases such as tin plating, where water and oxygen are blocked by covering the metal surface, it is important that the plating layer remain undamaged.
If the coating is scratched, the underlying metal may be exposed and corrosion may progress.

On the other hand, in zinc plating, zinc ionizes more readily than iron, so even when scratches are present, zinc may be oxidized first and protect the iron.
The corrosion-protection effect of plating changes depending on the type of plating metal, film thickness, adhesion, and presence or absence of scratches.

Example Discussion:
Corrosion protection by plating has the effect of covering the metal surface and preventing contact with water and oxygen.
Furthermore, in the case of zinc plating, zinc ionizes more readily than iron, so zinc corrodes sacrificially and protects the iron.
Therefore, when discussing the corrosion-protection effect, it is necessary to consider not only the presence or absence of the plating film but also the ionization tendency of the plating metal.

Factors Affecting Corrosion Rate

Corrosion rate changes depending on the type of metal, solution pH, chloride-ion concentration, oxygen concentration, temperature, surface condition, and presence or absence of contact with dissimilar metals.
In general, when the temperature increases, reaction rates increase and corrosion may progress more readily.
In addition, scratches or dirt on the surface make local cells more likely to form.

The higher the conductivity of the solution, the more easily corrosion current flows and the more readily corrosion progresses.
Therefore, corrosion may be greater in salt water than in pure water and in strongly acidic solutions than in weakly acidic solutions.
When comparing corrosion rates, it is important to change and consider one condition at a time.

Example Discussion:
Corrosion rate is affected not only by the type of metal but also by pH, chloride-ion concentration, oxygen concentration, temperature, and surface condition.
If corrosion progressed rapidly in salt water, the solution was considered to have high conductivity and electrochemical reactions to proceed readily.
In addition, in metals with scratches on the surface, local cells may have formed and promoted localized corrosion.

Evaluation of Corrosion by Mass Change

The progress of corrosion may be evaluated from changes in the mass of a metal sample.
When the metal dissolves into the solution, its mass decreases.
On the other hand, if rust or oxides remain attached to the surface, the apparent mass may increase because oxygen and water have been added.
Therefore, care is required when interpreting mass changes.

Measuring the decrease in the metal itself after removing corrosion products has a different meaning from measuring the mass including the corrosion products.
In a report, it should be clearly stated what the measured mass represents.
If surface rust is not sufficiently removed, errors arise in the evaluation of corrosion amount.

Example Discussion:
When a metal dissolves into the solution because of corrosion, the mass of the metal sample decreases.
However, if oxides and hydroxides such as iron rust remain attached to the surface during weighing, the mass of corrosion products containing oxygen and water is added and the apparent mass may increase.
Therefore, when evaluating the amount of corrosion from mass change, it is necessary to distinguish whether the corrosion products were included in the measurement or removed before measurement.

Causes of Error in Corrosion Experiments

Causes of error in corrosion experiments include differences in pretreatment of metal surfaces, presence or absence of scratches and dirt, differences in sample area, errors in solution concentration, changes in pH, temperature differences, differences in immersion time, differences in oxygen supply, solution stirring conditions, mass-measurement errors, and insufficient removal of corrosion products.
Because corrosion is sensitive to surface condition, even small differences among samples can greatly affect the results.

Causes of apparently large corrosion include scratches on the surface, high chloride-ion concentration, acidic conditions, contact between dissimilar metals, and increased temperature.
Causes of apparently small corrosion include formation of oxide films, insufficient dissolved oxygen, insufficient immersion time, and corrosion products acting like protective films.
Organizing the causes according to the experimental conditions makes the discussion more specific.

Example Discussion:
Possible causes of error in the corrosion experiment include differences in polishing condition or contamination of the metal surfaces, differences in sample area, deviations in solution concentration or pH, and differences in immersion time.
If scratches are present on the metal surface, local cells form more readily and the amount of corrosion may appear excessively large.
In addition, if corrosion products are not sufficiently removed before mass measurement, the amount of corrosion of the metal itself cannot be evaluated accurately.

When the Results Can Be Considered Good

A corrosion experiment can be considered to have produced good results when clear differences in the degree of corrosion are observed depending on the type of metal and solution conditions and those differences can be explained by redox reactions, ionization tendency, the effect of electrolytes, and the presence or absence of corrosion-protection treatment.
For example, if corrosion progresses in salt water and is small under dry conditions, the results clearly demonstrate the effects of water and electrolytes.

In addition, if corrosion of iron is suppressed when it is in contact with zinc, it can be explained as sacrificial protection, while if corrosion of iron progresses when it is in contact with copper, it can be explained as galvanic corrosion caused by contact between dissimilar metals.
If the observations correspond to theory, the experimental results can be considered reasonable.

Example Discussion:
In this experiment, corrosion of iron was large in salt water, whereas almost no corrosion was observed under dry conditions.
This result is consistent with the idea that the presence of water and electrolytes makes electrochemical reactions proceed more readily and promotes corrosion.
In addition, because corrosion was suppressed in iron brought into contact with zinc, zinc was considered to have acted as a sacrificial anode.

Example Discussions When the Experiment Did Not Go Well

When a corrosion experiment does not go well, possible causes should be considered from results such as difficulty observing differences in corrosion, a metal different from that expected corroding, unnatural mass changes, variation in surface changes, or only small differences from the control experiment.
Organizing the causes according to the metal surface, solution conditions, immersion time, oxygen supply, measurement method, and sample area makes the discussion easier.

Example Discussion:
In this experiment, the differences in corrosion among the conditions were smaller than expected.
Possible causes include insufficient immersion time for corrosion to progress adequately, oxide films remaining on the metal surfaces, and insufficient oxygen supply in the solution.
In addition, if the polishing condition or surface area of the samples was not consistent, variation in corrosion progression may have occurred, making differences among the conditions difficult to observe.

How to Write Points for Improvement

In a discussion of a corrosion experiment, writing not only the causes of error but also points for improvement makes the report easier to organize.
Points for improvement can be organized according to pretreatment of the metal samples, solution conditions, immersion conditions, observation and measurement methods, and corrosion-protection conditions.

Improvements to Metal Samples

  • Polish the metal surfaces under the same conditions
  • Remove oil and contamination
  • Keep the sample areas consistent
  • Check for the presence or absence of scratches
  • Keep electrical-contact and contact conditions constant
  • Do not touch the samples with bare hands

Improvements to Solution and Environmental Conditions

  • Prepare the solution concentrations accurately
  • Measure or adjust the pH
  • Keep the chloride-ion concentration consistent
  • Keep the temperature constant
  • Keep the immersion time exactly the same
  • Keep the oxygen-supply conditions constant

Improvements to Observation and Measurement

  • Take photographs before and after corrosion
  • Record the color and degree of rust using consistent levels
  • Standardize drying conditions before weighing
  • Standardize the method for removing corrosion products
  • Perform multiple measurements and calculate the average
  • Prepare a control experiment

Example of How to Write Points for Improvement:
To improve the reproducibility of corrosion experiments, the metal surfaces must be polished under the same conditions and oil and contamination removed before the experiment.
In addition, it is important to keep the solution concentration, pH, temperature, and immersion time constant so that the corrosion conditions are standardized.
When measuring mass changes, the handling of corrosion products and drying conditions should be standardized, and multiple measurements should be performed to confirm variation.

Difference Between a Superficial Discussion and a Good Discussion

In a discussion of a corrosion experiment, simply writing that “it rusted” or “it changed color” results in a superficial discussion.
A good discussion relates redox reactions, the ionization tendency of metals, the roles of water, oxygen, and electrolytes, local cells, and corrosion-protection methods.

Superficial Discussion Good Discussion
The iron rusted. Iron was oxidized to Fe2+ and then reacted with oxygen and water to form oxides and hydroxides, so reddish-brown rust was considered to have been observed.
It corroded in salt water. Salt water has high conductivity, and Cl- may also destroy protective films, so electrochemical corrosion reactions were considered to have proceeded more readily.
Zinc protected the iron. Because zinc ionizes more readily than iron, zinc was preferentially oxidized as the anode, while iron became the cathodic side and its corrosion was suppressed.
It did not corrode. Possible reasons for the small amount of corrosion include insufficient oxygen or water, low electrolyte concentration, protection by a surface oxide film, and insufficient immersion time.

Examples of Expressions That Can Be Used in Reports

The following expressions can be used when writing the results and discussion of corrosion experiments.
Adjust the necessary parts according to your own experimental results.

  • Corrosion is a reaction in which a metal loses electrons and is oxidized.
  • In corrosion, the oxidation reaction of the metal and reduction reactions of oxygen or hydrogen ions proceed simultaneously.
  • Water assists ion movement and provides an environment in which corrosion reactions can proceed.
  • Oxygen participates in a reduction reaction that accepts electrons and is a factor that promotes corrosion.
  • When an electrolyte is present, the conductivity of the solution increases and corrosion becomes more likely to proceed.
  • Chloride ions may destroy protective films and promote localized corrosion.
  • Metals with greater ionization tendencies tend to be more easily oxidized.
  • When dissimilar metals are in contact, the potential difference may promote corrosion of one of the metals.
  • In sacrificial protection, a metal that ionizes more readily than the metal to be protected is corroded first.
  • Painting and plating suppress corrosion by preventing contact with water and oxygen.

Points to Check When Discussing Corrosion Experiments

Checking the following points before writing the report makes the discussion easier to write.

  • Is corrosion explained as a redox reaction?
  • Is it stated that the metal is oxidized and becomes metal ions?
  • Are reduction reactions involving oxygen or H+ considered?
  • Are the effects of water and oxygen explained?
  • Are the effects of electrolytes and chloride ions considered?
  • Is the ionization tendency of metals related to corrosion susceptibility?
  • Is the concept of local cells used?
  • Is galvanic corrosion caused by contact between dissimilar metals explained?
  • Is the mechanism of sacrificial protection explained?
  • Are corrosion-protection methods using oxide films, painting, and plating considered?
  • Is the meaning of mass change interpreted correctly?
  • Do the points for improvement correspond to the causes of error?

Summary

A corrosion experiment is an experiment that investigates the phenomenon in which a metal reacts with its surrounding environment and becomes oxidized.
Corrosion proceeds through a combination of an oxidation reaction in which the metal loses electrons and reduction reactions in which oxygen or hydrogen ions accept electrons.
Water, oxygen, electrolytes, chloride ions, and acidic conditions are important factors that promote corrosion.

The susceptibility of metals to corrosion is related to their ionization tendencies.
However, in practice, the presence or absence of oxide films, surface condition, contact with dissimilar metals, pH, chloride-ion concentration, and other factors also have an effect.
Sacrificial protection using zinc, painting, plating, and oxide films are representative methods for preventing corrosion.

In a report, rather than simply writing that “it rusted” or “it corroded,” organize and discuss redox reactions, the ionization tendency of metals, local cells, galvanic corrosion caused by contact between dissimilar metals, sacrificial protection, the effects of water, oxygen, and electrolytes, causes of error, and points for improvement.
Corrosion experiments are important experiments for understanding the relationship between the properties of metallic materials and electrochemical reactions.