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Cathode Protection

This document discusses different methods of corrosion control, including cathodic protection and protective metal coatings. Cathodic protection works by making the entire metal cathode and stopping corrosion. It can be achieved through sacrificial anodes that act as the anode or through an impressed current. Protective metal coatings involve coating the base metal with a more noble metal to act as a barrier to corrosion. Galvanization coats iron in zinc to provide cathodic protection even if the coating is damaged.

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20 views

Cathode Protection

This document discusses different methods of corrosion control, including cathodic protection and protective metal coatings. Cathodic protection works by making the entire metal cathode and stopping corrosion. It can be achieved through sacrificial anodes that act as the anode or through an impressed current. Protective metal coatings involve coating the base metal with a more noble metal to act as a barrier to corrosion. Galvanization coats iron in zinc to provide cathodic protection even if the coating is damaged.

Uploaded by

Vishal S
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Corrosion control

Module 2
Cathodic Protection
⚫ Cathodic protection is a method of protecting a metal or alloy from corrosion
by converting it completely into cathodic and no part of it is allowed to act as
anode.

⚫ Principle: Metals normally undergo corrosion by electrochemical process


with the formation of anodic and cathodic regions in contact with each other.
The corrosion of metal takes place at the anodic region whereas the metal
remains unaffected at the cathodic region. Therefore corrosion can be
restricted by eliminating the anodic sites and converting the entire metal into
cathodic area.

⚫ By two ways it can be achieved: (a) Sacrificial anode (b) Impressed current.
Cathodic Protection
Sacrificial anode: Sacrificial anode method involves the conversion of the
metal structure (complete metal) into cathode by connecting it into a more
active metal, which acts as an auxiliary anode. The most commonly used
metals as auxiliary anodes are Zn, Mg and aluminium. These metal being more
active, act as anode and undergo preferential corrosion, thus protecting the
metal structure. Since metal used as auxiliary anode are sacrificed to protect
the metal structure, this method is known as sacrificial anode method.
Example: Magnesium block connected to underground pipelines.
Advantages: (a) The method is simple. (b) Low installation cost. (c) Minimum
maintenance cost.
Limitations: (a) Involves recurring expenditure for replacement of consumed
anodes.
Cathodic Protection
Impressed Current Method:

⚫ For larger structures, galvanic anodes can’t economically deliver enough


current to provide complete protection.
⚫ Another method of providing cathodic protection is by applying a direct
current larger than the corrosion current in opposite direction to nullify the
corrosion current. The metal is protected by connecting it to a negative
terminal of the DC source and making it cathodic.
⚫ The anode of the source is connected to an inert electrode.
⚫ To increase electrical contact with itself and the surrounding soil the anode is
buried in back fill (gypsum).
⚫ The metal source being cathode does not undergo corrosion. Anode being
inert is remain intact. Graphite, stainless steel or scrap iron are widely used
as the inert anode in this method which are buried in soil. Silicon-iron alloy,
platinised Ti are also used as anode.
Cathodic Protection
⚫ Example: It is used for protecting marine structures, water storage tanks and
oil pipe lines.
⚫ Advantages: (a) one installation can protect large area of metals. (b) Low
maintenance cost.
⚫ Limitations: (a) Rather expensive, since it requires high current for safe
protection of structure. (b) If the impressed current is not uniform on the
entire surface of the protected structure, localized corrosion may takes place.
Protective Metal Coatings:
Cathodic Coating:
(a) Cathodic coatings are produced by coating a base metal with a more noble metal which is
cathodic. The metals such as copper, tin, nickel is commonly used as cathodic coatings on
steel. These coating metals are less reactive than the base metal and are less susceptible for
corrosion.
(b) The cathodic coating provides protection only when it is undamaged, continuous and non-
porous. When the coating is discontinuous, an intense localized corrosion of the base metal
(small anodic region) occurs due to electrochemical corrosion.
(c) Tinning is a process of coating a base metal with tin. The process is carried out by hot
dipping method and the process involves following steps:
(i) The sheet is first washed with organic solvents to remove grease or oil deposits.
(ii) Then treated with dilute sulphuric acid to remove rust and scale deposits. Finally, it is
washed well with water and air dried.
(iii) The clean and dry sheet is passed through molten zinc chloride flux. The flux helps the
molten metal to adhere on the metal surface.
(iv) It is then passed through a tank that contains molten tin.
(v) Finally passed through series of rollers immersed in palm oil. The rollers wipe out excess
tin deposit and produces a continuous, thin coating on the sheet. The oil prevents the
oxidation of the tin coated surface.
(vi) The tin layer prevent corrosion as long as the layer is continuous and completely
covering the base metal surface.

Anodic Coating:
(a) Anodic coatings are produced by coating a base metal with more active metals (e.g., Zn,
Mg, Al) which are anodic to the base metal.
(b) The coated metal can prevent corrosion of the base metal even if the coated layer is
ruptured. The exposed surface of the base act as a cathode in presence of the remaining metal
layer.
(c) Galvanization note is provided in the Corrosion control notes.
Metal Coating
⚫ Galvanization: Galvanization is a process of putting metallic coating which
are anodic to the base metal. For example, iron is coated with anodic and
more active metals such as zinc, magnesium and aluminium. The one of the
important characteristics of anodic coating is that, even if the coating is
ruptured, the base metal does not undergo corrosion. The exposed metal
surface is cathodic with respect to the coating metal and the coating metal
preferentially undergoes corrosion. It involves following steps:
⚫ The metal surface is washed with organic solvents to remove organic matter
on the surface.
⚫ Rust and other deposits are removed by washing with sulphuric acid.
⚫ Finally the article is well washed with water and air dried.
⚫ The article is then dipped in a bath of molten zinc, maintained at 425-430C
and covered with a flux of ammonium chloride to prevent oxidation of molten
zinc.
Metal Coating
⚫ The excess zinc on the surface is removed by passing through a pair of hot
rollers, which wipes out excess of zinc coating and produces a thin coating.

⚫ Galvanization is used extensively to protect iron from corrosion in the form of


roofing sheets, fencing wire buckets etc. Galvanized steel reinforcements are
used in building construction, where high degree of corrosion resistance is
required.

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