Cathodic corrosion current

The anode and cathode corrosion currents, fcorr.A and fcorr,B. respectively, are estimated at the intersection of the cathode and anode polarization of uncoupled metals A and B. Conventional electrochemical cells as well as the polarization systems described in Chapter 5 are used to measure electrochemical kinetic parameters in galvanic couples. Galvanic corrosion rates are determined from galvanic currents at the anode. The rates are controlled by electrochemical kinetic parameters like hydrogen evolution exchange current density on the noble and active metal, exchange current density of the corroding metal, Tafel slopes, relative electroactive area, electrolyte composition, and temperature. 

In [2] it is shown that TiN has a high cathodic corrosion current. According to polarization and cyclic voltammetry curves there, between voltages of —0.3 and —1.5V for TIN coated electrode, the cathodic corrosion current is higher or comparable to the one fl om AISI 630 stainless steel. The reaction happening for negative voltages (smaller than —0.3 V) is ... 

The sohd line in Figure 3 represents the potential vs the measured (or the appHed) current density. Measured or appHed current is the current actually measured in an external circuit ie, the amount of external current that must be appHed to the electrode in order to move the potential to each desired point. The corrosion potential and corrosion current density can also be deterrnined from the potential vs measured current behavior, which is referred to as polarization curve rather than an Evans diagram, by extrapolation of either or both the anodic or cathodic portion of the curve. This latter procedure does not require specific knowledge of the equiHbrium potentials, exchange current densities, and Tafel slope values of the specific reactions involved. Thus Evans diagrams, constmcted from information contained in the Hterature, and polarization curves, generated by experimentation, can be used to predict and analyze uniform and other forms of corrosion. Further treatment of these subjects can be found elsewhere (1—3,6,18). 

Asahi also reports an undivided cell process employing a lead alloy cathode, a nickel—steel anode, and an electrolyte composed of an emulsion of 20 wt % of an oil phase and 80 wt % of an aqueous phase (125). The aqueous phase is 10 wt % K HPO, 3 wt % K B O, and 2 wt % (C2H (C4H )2N)2HP04. The oil phase is about 28 wt % acrylonitrile and 50 wt % adiponitrile. The balance of the oil phase consists of by-products and water. The cell operates at a current density of 20 A/dm at 50°C. Circulated across the cathode surface at a superficial velocity of 1.5 m/s is the electrolyte. A 91% selectivity to adiponitrile is claimed at a current efficiency of 90%. The respective anode and cathode corrosion rates are about mg/(Ah). Asahi s improved EHD process is reported to have been commercialized in 1987. 

Corrosion Rate by CBD Somewhat similarly to the Tafel extrapolation method, the corrosion rate is found by intersecting the extrapolation of the linear poi tion of the second cathodic curve with the equihbrium stable corrosion potential. The intersection corrosion current is converted to a corrosion rate (mils penetration per year [mpy], 0.001 in/y) by use of a conversion factor (based upon Faraday s law, the electrochemical equivalent of the metal, its valence and gram atomic weight). For 13 alloys, this conversion factor ranges from 0.42 for nickel to 0.67 for Hastelloy B or C. For a qmck determination, 0.5 is used for most Fe, Cr, Ni, Mo, and Co alloy studies. Generally, the accuracy of the corrosion rate calculation is dependent upon the degree of linearity of the second cathodic curve when it is less than... 

To obtain the corrosion current from Rp, values for the anodic and cathodic slopes must be known or estimated. ASTM G59 provides an experimental procedure for measuring Rp. A discussion or the factors which may lead to errors in the values for Rp, and cases where Rp technique cannot be used, are covered by Mansfeld in Polarization Resistance Measurements—Today s Status, Electrochemical Techniques for Corrosion Engineers (NACE International, 1992). 

To protect steam boilers and their tubes from corrosion, E. Cumberland used cathodic impressed current in America in 1905. Figure 1-10 has been taken from the corresponding German patent [35]. In 1924 several locomotives of the Chicago Railroad Company were provided with cathodic protection to prevent boiler corrosion. Where previously the heating tubes of steam boilers had to be renewed every 9 months, the costs fell sharply after the introduction of the electrolytic... 

The current I is called the total current. In free corrosion, i.e., without the contribution of external currents (see Fig. 2-1), it is always zero, as given by Eq. (2-8). and are known as the anodic and cathodic partial currents. According to Eq. (2-10), generally in electrolytic corrosion anodic total currents and/or cathodic redox reactions are responsible. 

Equation (2-38) is valid for every region of the surface. In this case only weight loss corrosion is possible and not localized corrosion. Figure 2-5 shows total and partial current densities of a mixed electrode. In free corrosion 7 = 0. The free corrosion potential lies between the equilibrium potentials of the partial reactions and U Q, and corresponds in this case to the rest potential. Deviations from the rest potential are called polarization voltage or polarization. At the rest potential = ly l, which is the corrosion rate in free corrosion. With anodic polarization resulting from positive total current densities, the potential becomes more positive and the corrosion rate greater. This effect is known as anodic enhancement of corrosion. For a quantitative view, it is unfortunately often overlooked that neither the corrosion rate nor its increase corresponds to anodic total current density unless the cathodic partial current is negligibly small. Quantitative forecasts are possible only if the Jq U) curve is known. 

Even with the superposition of the ac with a cathodic protection current, a large part of the anodic half wave persists for anodic corrosion. This process cannot be detected by the normal method (Section 3.3.2.1) of measuring the pipe/soil potential. The IR-free measurable voltage between an external probe and the reference electrode can be used as evidence of more positive potentials than the protection potential during the anodic phase. Investigations have shown, however, that the corrosion danger is considerably reduced, since only about 0.1 to 0.2% contributes to corrosion. 

Coatings of less noble metals than the substrate metal (e.g., Zn on Fe) are only protective if the corrosion product of the metal coating restricts the corrosion process. At the same time, the formation of aeration cells is hindered by the metal coating. No corrosion occurs at defects. Additional cathodic protection to reduce the corrosion of the metal coating can be advantageous. Favorable polarization properties and low protection current requirements are possible but need to be tested in individual cases. The possibility of damage due to blistering and cathodic corrosion must be heeded. 

Aluminum-sheathed cables should not be connected to other cables because aluminum has the most negative rest potential of all applicable cable sheathing materials. Every defect in the protective sheath is therefore anodically endangered (see Fig. 2-5). The very high surface ratio SJS leads to rapid destruction of the aluminum sheathing according to Eq. (2-44). Aluminum can also suffer cathodic corrosion (see Fig. 2-11). The cathodic protection of aluminum is therefore a problem. Care must be taken that the protection criterion of Eq. (2-48) with the data in Section 2.4 is fulfilled (see also Table 13-1). Aluminum-sheathed cables are used only in exceptional cases. They should not be laid in stray current areas or in soils with a high concentration of salt. 

Further cell currents flow between the wells as a result of electrical connections established between them by the flow lines and of the different free corrosion potentials, thereby allowing them to behave as anode or cathode. The currents can amount to a few amps so that considerable corrosion damage can arise. The action of these cells can be prevented by building in insulators between the drilling and the field cable. 

Before a drainage test is carried out, a so-called zero profile is measured. This involves the indication of corrosion currents, which, according to whether AU values are increasing or decreasing, locate the anodic or cathodic regions (see Fig. 18-3). 

Passivating inhibitors act in two ways. First they can reduce the passivating current density by encouraging passive film formation, and second they raise the cathodic partial current density by their reduction. Inhibitors can have either both or only one of these properties. Passivating inhibitors belong to the group of so-called dangerous inhibitors because with incomplete inhibition, severe local active corrosion occurs. In this case, passivated cathodic surfaces are close to noninhibited anodic surfaces. 

In spite of the possibility of cathodic corrosion discussed in relation to Eq. (2-56), practical experience has shown that carbon steel is a suitable material for impressed current cathodes. Stress corrosion of the cathode material does not have to be considered because of the strong cathodic polarization as shown in Fig. 2-18. 

To avoid galvanic problems, different materials of con-stmction may have to be electrically isolated or at least the electrical resistance between them increased to a level sufficient to reduce the corrosion current to an acceptable value. In some instances it is more practical to paint or otherwise coat the more cathodic of the two parts of the couple. The anodic material should not be coated, since even more rapid penetration would occur at any breaks in the coating. 

When the anodic and cathodic sites are inseparable the corrosion current cannot be determined directly by an ammeter, but it can be evaluated electro-chemically by the linear polarisation technique see Sections 19.1-19.3). 

Although Table 2.16 shows which metal of a couple will be the anode and will thus corrode more rapidly, little information regarding the corrosion current, and hence the corrosion rate, can be obtained from the e.m.f. of the cell. The kinetics of the corrosion reaction will be determined by the rates of the electrode processes and the corrosion rates of the anode of the couple will depend on the rate of reduction of hydrogen ions or dissolved oxygen at the cathode metal (Section 1.4). 

The general form of the anodic polarisation curve of the stainless steels in acid solutions as determined potentiostaticaiiy or potentiodynamically is shown in Fig. 3.14, curve ABCDE. If the cathodic curve of the system PQ intersects this curve at P between B and C only, the steel is passive and the film should heal even if damaged. This, then, represents a condition in which the steel can be used with safety. If, however, the cathodic curve P Q also intersects ED the passivity is unstable and any break in the film would lead to rapid metal solution, since the potential is now in the active region and the intersection at Q gives the stable corrosion potential and corrosion current. 

It should be noted that it is extremely difficult to predict service lives of buried pipelines from the results of controlled trials with small specimens, whether in the laboratory or in the field. For example a study on the comparative corrosion resistances of ductile and grey iron pipes carried out jointly by European pipemakers in 1964-1973 indicated a mean pitting rate of 0 -35 mm/y for uncoated ductile iron pipe exposed in a typical heavy Essex clay of 500-900 ohm cm resistivity for 9 years. This is clearly at odds with the rate of 1 mm/y normally found on a corroded service pipe from such a soil. The discrepancy appears to be due to the use of specimens that were only a third of a pipe length each and were buried separately. It may reflect the contribution of the total surface area of the pipe as a cathode to the corrosion current at the anodic area at the pitting site. 

Fig. 10.6 Polarisation diagram showing the limited role hydrogen evolution plays at the corrosion potential of steel in aerated neutral solution, the larger role in determining cathodic protection currents and the dominant role in contributing to current requirements at very negative potenitals. The dotted line shows the total cathodic current due to oxygen reduction and...

In practice the cathodic protection current will be carried in the corrosive environment by more mobile ions, e.g. OH, Na, etc. 

The proof of protection is more difficult to establish in this case for two reasons. First, the object is to restore passivity to the rebar and not to render it virtually immune to corrosion. Second, it is difficult to measure the true electrode potential of rebars under these conditions. This is because the cathodic-protection current flowing through the concrete produces a voltage error in the measurements made (see below). For this reason it has been found convenient to use a potential decay technique to assess protection rather than a direct potential measurement. Thus a 100 mV decay of polarisation in 4 h once current has been interrupted has been adopted as the criterion for adequate protection. It will be seen that this proposal does not differ substantially from the decay criterion included in Table 10.3 and recommended by NACE for assessing the full protection of steel in other environments. Of course, in this case the cathodic polarisation is intended to inhibit pit growth and restore passivity, not to establish effective immunity. 

It was indicated earlier that the cathodic current was a poor indicator of adequate protection. Whilst, to a first approximation the protection potential is a function of the metal, the current required for protection is a function of the environment and, more particularly, of the cathodic kinetics it entails. From Fig. 10.4 it is apparent that any circumstance that causes the cathodic kinetics to increase will cause both the corrosion rate and the current required for full (/") or partial (1/ — /, ) protection to rise. For example, an increase in the limiting current in Fig. 10.5 produced by an increase in environmental oxygen concentration or in fluid flow rate will increase the corrosion rate and the cathodic protection current. Similarly, if the environment is made more acid the hydrogen evolution reaction is more likely to be involved in the corrosion reaction and it also becomes easier and faster this too produces an increased corrosion rate and cathodic current demand. 

At the start the cathode is invariably a metal different from that to be deposited. Frequently, the aim is to coat a base metal with a more noble one, but it may not be possible to do this in one step. When a metal is immersed in a plating bath it will corrode unless its potential is sufficiently low to suppress its ionisation. Fortunately, a low rate of corrosion is tolerable for a brief initial period. There are cases where even when a cathode is being plated at a high cathodic (nett) current density, the substrate continues to corrode rapidly because the potential (determined by the metal deposited) is too high. No satisfactory coating forms if the substrate dissolves at a high rate concurrently with electrodeposition. This problem can be overcome by one or more of the following procedures ... 

Fig. 12.4 Corrosion diagram for a zinc diecasting in a nickel plating bath, pH 2-2. There are two possible cathodic reactions, hydrogen evolution (H) and nickel ion reduction (AO. The corrosion current is the sum of the partial cathode currents. Even with live entry the potential is still too high to suppress corrosion, though the rate is reduced to...

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