UNIT – II

Battery Chemistry & Corrosion

Introduction - Classification of batteries- primary, secondary and reserve
batteries with examples. Basic requirements for commercial batteries.
Construction, working and applications of: Zn-air and Lithium ion battery,
Applications of Li-ion battery to electrical vehicles. Fuel Cells- Differences
between battery and a fuel cell, Construction and applications of Methanol
Oxygen fuel cell and Solid oxide fuel cell. Solar cells - Introduction and
applications of Solar cells.
Corrosion: Causes and effects of corrosion – theories of chemical and
electrochemical corrosion – mechanism of electrochemical corrosion, Types of
corrosion: Galvanic, water-line and pitting corrosion. Factors affecting rate of
corrosion, Corrosion control methods- Cathodic protection – Sacrificial anode
and impressed current methods.

Battery Chemistry:
1. What is battery? How the batteries are classified? (KMIT, Jan’24)
Ans: When two or more elecrochemical cells are electrically interconnected, each of which
containing two electrodes and an electrolyte is called ‘Battery’
Classification:
Batteries are classified as follows:
i) Primary cells/batteries: are those in which the cell reaction is not reversible. In this cell
electrical energy is obtained at the expense of chemical reactivity only as long as the active
materials are present.
These are non-rechargeable and are meant for a single use and meant to be discharges after use.
Ex: Lithium cells: These cells having Li anodes, irrespective of the cathode use. Such as Li-MnO 2,
Li-SO2, Li-SOCl2 cells.
Applications: used in electronic devices such as calculators and watches, fully automatic cameras,
in electronic circuit boards, military and space applications.

ii) Secondary Batteries: The cells in which the cell reaction is reversed by passing direct current in
opposite direction. These are rechargeable and are meant for a multi-cycle use. The secondary
batteries can be used through a large number of cycles of discharging and charging.
These batteries have very large capacitance and long periods of low current rate discharge.
Ex: Lead-acid storage cell, Lithium ion battery.
Applications: used to supply current for electric vehicles, gas engine ignition, in telephone
exchanges, electric trains, mines, laboratories, hospitals,automobiles, mobile phones, laptops etc.

iii) Reserve Batteries: A reserve battery, also called stand-by battery, is a primary battery where
part is isolated until the battery needs to be used. When long storage is required, reserve batteries are
often used, since the active chemicals of the cell are segregated until needed, thus reducing self-
discharge.
Reserve batteries effectively eliminate the possibility of self-discharge and minimize chemical
deterioration. Most reserve batteries are used only once and then discarded.
These are a special class of non-rechargeable batteries and can store for long time I.e. greater than
20 years' shelf-life.
A reserve battery is distinguished from a backup battery, in that a reserve battery is inert until it is
activated, while a backup battery is already functional, even if it is not delivering current.

Ex: Zinc-air battery, Silver-Zinc battery, Thermal battery etc.

Applications: These batteries are used in radiosondes (is a battery powered instrument that carried
to atmosphere by weather balloon to measure altitude, temperature etc.), missiles, bomb fuzes, and
various weapon systems.

2. Write about basic requirements for commercial batteries. Or What are the
requirements for commercial batteries?(JNTUH, April’23)

Ans: 1. Capacity: The capacity of a battery determines the amount of energy that can be stored and
delivered over time. The required capacity will depend on the energy consumption of the device.

2.Voltage: The voltage of a battery must match the voltage requirements of the device it is being
used in.

3. Current: The current of a battery must be capable of meeting the current requirements of the
device it is being used in.
4. Size and weight: The size and weight of a battery must be suitable for the device it is being used
in, taking into consideration factors such as physical space constraints and portability.
5. Safety: Batteries must be safe to use, with minimal risk of fire, explosion, or other safety hazards.
This includes considering the materials used in the battery, the construction of the battery, and the
risk of short-circuits.
6. Durability: Batteries must be durable enough to withstand the intended use of the device,
including factors such as vibration, shock, and temperature fluctuations.
7. Cost: The cost of the battery must be within the budget constraints of the device manufacturer or
user.
8. Life span: The life span of a battery is the time it can be expected to deliver useful energy before
it needs to be replaced. The life span requirement will depend on the intended use of the device.
9. Environmental impact: The environmental impact of the battery must be considered, including
factors such as the materials used in the battery, the production process, and the end-of-life disposal
process.
10. Regulatory compliance: Batteries must comply with relevant safety, environmental, and other
regulatory requirements in the markets in which they will be sold.

3. Explain construction working and applications of Zinc-air Battery.(JNTUH, April’23),

(KMIT, Jan’24)

Ans: Cathode: Catalyzed carbon which reduce oxygen from the air.
Anode: Gelled mixture of zinc powder and electrolyte.
Electrolyte: Highly conductive solution of KOH in water.
Separator: Materials to prevent migration of solid particles between the electrodes.
Insulating and sealing gasket: Molded nylon.
Exterior battery surface: Nickel is used to resist corrosion and to insure good electrical contact.

Construction: ZABs consists of a Zn electrode as the anode, an open-structured air electrode as the
cathode integrated with a catalyst and gas diffusion layer (GDL) that allows a continuous supply of
oxygen from the external air, and a separator soaked in a metal-ion-conducting electrolyte

Working: During discharge, a mass of zinc particles forms a porous anode, which is saturated with
an electrolyte. Oxygen from the air reacts at the cathode and forms hydroxyl ions which migrate into
the zinc paste and form zincate (Zn(OH)2−4), releasing electrons to travel to the cathode. The zincate
decays into zinc oxide and water returns to the electrolyte. The water and hydroxyl from
the anode are recycled at the cathode, so the water is not consumed. The reactions produce a
theoretical voltage of 1.65 Volts, but is reduced to 1.35–1.4 V in available cells.
The chemical equations for the zinc–air cell are:

Anode:

Fluid:

Cathode:

Overall:
Zinc–air batteries cannot be used in a sealed battery holder since some air must come in; the
oxygen in 1 liter of air is required for every ampere-hour of capacity used.

Applications: zinc–air batteries are as power sources for hearing aids, medical devices, and pagers.

4. Describe construction, working and applications of Lithium - ion batteries with

reactions and diagram. (KMIT, July,2023), (KMIT, April,2023), (JNTUH, Jan’24)

Ans: Lithium -ion battery is a secondary battery. As in lithium cell (primary cell), it does not
contain metallic lithium as anode. The movement of lithium ion are responsible for charging and
discharging.
Lithium-ion cell has the following three components:
A negative electrode(layers of lithium-metal oxide) anode
A positive electrode (layers of porous carbon) cathode
electrolyte (organic solvent) LiPF6 in ethylene carbonate/dimethylene carbonate.

Construction:
The negative electrode is typically made from a layers of chemical compound called LiCoO 2
(lithium cobalt oxide).
The positive electrode is made from layers of porous carbon or graphite.
Both the electrodes are dipped in a polymer gel electrolyte (organic solvent) and separated by
separator, which is a perforated plastic and allows the Li+ ions to pass through.
Working:
The negative electrode half cell reaction is
LiCoO2 ⇌Li1-xCoO2 + xLi+ + xe-
The positive electrode half cell reaction is
xLi+ + xe-+ C ⇌CLix
Net reaction LiCoO2 + C ⇌ Li1-xCoO2 + CLix + 4V
During charging, an external electric power source applies equal or more than 4V, forcing the
current to pass in the reverse direction. The Li+ ions then migrate from positive to the negative
electrode, where they become embedded in the porous electrode material.

Applications:
1. Portable devices: Mobile phones, smart phones, laptops. tablets, digital cameras and flash lights.
2. Electric vehicles: because of light weight lithium ion battery used in electric vehicles, electric
wheel chairs etc.

5. Why Lithium ion battery are preferred/used in electric vehicles or explain applications
of Li-ion battery to electric vehicles.
Ans: Currently, the most appropriate energy storage device for powering electric vehicles (EVs) is
lithium-ion batteries (LIBs) because of their interesting characteristics like high power density, high
energy density, long life cycle, lack of memory effect, and high energy efficiency.
Because of these beneficial characteristics, they are lighter and smaller as compared to any other
conventional rechargeable batteries like nickel-metal hydride batteries (Ni–MH), and nickel-
cadmium batteries (Ni-Cd), and lead-acid batteries.
Examples of electric cars using Li-ion batteries: Tesla, Jaguar

6. What is Fuel Cell? Give the differences between battery and fuel cell.
Ans: A fuel cell is a device for producing electricity by converting the chemical energy of a
conventional fuel and oxygen into electrical energy.

Difference between fuel cells and batteries:

S.No Battery Fuel Cell
1 They store energy in the form of chemical They cannot store energy. Fuel cell converts
energy chemical energy to electrical energy.
2 Reactants are inside the cell itself. Reactants for chemical reaction are supplied
continuously.
3 Chemical reaction products remain inside Chemical reaction products are removed from
the cell itself the cell
4 Rechargeable Not rechargeable
5 Less efficiency High efficiency
6 It consists of limited amount of fuel and Needs a continuous supply of fuel and oxygen
oxidant and these reactants diminish with from an external source
 time
7 Supply energy for a limited period of time Supply energy for a long period of time
8 Less expensive They are expensive
9 Example : lithium ion batteries Example : Methyl alcohol-oxygen fuel cell

7. Explain Construction, working, advantages and applications of Methanol - Oxygen fuel

cell.
(JNTUH, Jan’24)
Ans: In this cell CH3OH used as a fuel and O2 as oxidant to generate electrical energy.
Construction: It has two electrodes. The anode consists of porous nickel electrode impregnated
with Pt/Pd catalyst. Porous nickel electrode coated with Ag catalyst constitute a cathode of the cell.
The electrolyte H2SO4 is taken in between the two electrodes. CH 3OH & O2 are sent continuously
into their respective electrodes and electrical energy is produced with the continuous replenishment
of the fuel, CH3OH at the anode.
Working: Methanol is supplied at anode, Oxygen is supplied at cathode. Methanol get absorbed at
anode and reacts with water in electrolyte to form carbon dioxide with liberation of electrons.
Liberated electrons move to cathode through external circuit. At cathode oxygen gets reduced to
form water in presence of H+ ions.
At Anode: CH3OH + H2O → CO2 + 6H+ + 6e-
At Cathode: 3/2 O2 + 6H+ + 6e- → 3H2O
Net Reaction: CH3OH + 3/2O2 → CO2 +2H2O + 1.25V

Advantages:
1. These cells stable at environmental conditions.
2. Easy to transport.
3. These are targeted to portable applications
4. High H2 concentration in CH3OH is an excellent fuel
5. CH3OH posses less risk to living things than gasoline
6. CH3OH has lower inflammability
7. Zero emissions by these cells hence these are eco-friendly.
Applications:
These are power source for electronic equipment, such as notebooks, video cameras, DVD-players,
cell phones, medical devices and electric vehicles.

8. Describe Construction, working of Solid Oxide Fuel Cells(SOFC) and write

advantages, applications of this fuel cell.
Ans: Solid oxide fuel cells use solid electrolyte unlike other fuel cells. They use a solid ceramic
electrolyte such as zirconium oxide stabilized with yttrium oxide. They operate at 800 oC to 1000oC.
A solid fuel cell utilizes the movement of electrons and generates electricity. A fuel such as
hydrogen/ carbon monoxide is fed to the anode and air/oxygen is fed to the cathode.
Construction:
Anode: A porous ceramic material of Ni-ZrO2 or Co-ZrO2 skeleton. Zirconia serves to inhibit
sintering of the metal particles and provides a comparable thermal expansion coefficient.
Cathode: Strontium doped lanthanum manganite, a P-type semiconductor.
Electrolyte: An oxide ion conducting ceramic material as the electrolyte usually Y 2O3 stabilized
ZrO2 (YSZ) thick film is used.
Working:
At anode: H2 + O2- →H2O +2e-1 or CO + O2- → CO2 +2e-
2-
-1
At Cathode: 1/2 O2 + 2e → O 1/2 O2 + 2e-1 → O2-
Over all: H2 + 1/2 O2 → H2O + 0.8 to 1V or CO+1/2 O2 → CO2 + 0.8 to 1V

Advantages of SOFC:
1. As all components of SOFC are solid, there is no need for electrolyte maintenance and also
electrode corrosion is eliminated.
2. SOFC since operate at high temperature, expensive catalyst can be avoided.
3. Because of high temperature operation, it has better ability to tolerate the presence of
impurities as a result its life is increased.
4. They release negligible pollutants.
Applications:
1. Used as power systems for trains, ships and vehicles.
2. Used for supplying electric power for residential or industrial utility.

9. What are the Solar cells? And write its types and advantages.
Ans: A solar cell is an electrical device that converts the energy of light directly into electricity by
the photovoltaic effect which is a physical and chemical phenomenon.
Types of Solar cells:
Based on type of crystal used, solar cells can be classified as;
1. Mono-crystalline silicon cells: It is produced from pure silicon (single crystal). As it is pure
and defect free crystal, efficiency of the cell is high.
2. Poly-crystalline silicon cells: In this, liquid silicon is used as raw material. Poly-crystalline
silicon is obtained by solidification process. The material contains various crystalline sizes. Hence
efficiency of this type of cell is less.
3. Amorphous silicon cells: It is obtained by depositing silicon film on the substrate like glass-
plate.
Advantages:
1. It is clean and non-polluting
2. They do not produce noise
3. They require very little maintenance.
4. They are long lasting sources of energy, can be used anywhere.
5. Work on renewable energy
6. They have long life time and no fuel cost.

10. Write construction, working and applications of solar cells.

Ans: Solar cells are fabricated from silicon with increasing efficiency and lowering cost as the
materials range from amorphous (noncrystalline) to poly crystalline to crystalline (single crystal)
silicon forms. Unlike batteries or fuel cells, solar cells do not utilize chemical reactions or require
fuel to produce electric power, and, unlike electric generators, they do not have any moving parts.
Construction: A solar cell is basically a junction diode, although its construction is little bit
different from conventional p-n junction diodes. A very thin layer of n-type semiconductor is grown
on a relatively thicker p-type semiconductor. We then apply a few finer electrodes on the top of the
n-type semiconductor layer.
These electrodes do not obstruct light to reach the thin n-type layer. Just below the n-type layer there
is a n-p junction. We also provide a current collecting electrodes at the top and bottom of the n-type
and p-type layer. We encapsulate the entire assembly by thin glass to protect the solar cell from any
mechanical shock.
Working: When sunlight falls on the cell, photons bombard the upper surface. The photons carry
their energy down through the cell. Then the photons give up their energy to electrons on the lower
p-type layer. The electrons use this energy to jump across the barrier into upper n-type layer and
escape out into the circuit.

Solar cell applications:

1. Powering space vehicles such as satellites, telescopes.
2. In solar power vehicles
3. In telecommunication
4. In domestic lighting system
5. In off shore oil drilling
6. In railway signaling etc.

Corrosion
1. Define corrosion. Write the examples and consequences of corrosion. (JNTUH,
April’23)
Ans: Corrosion is the deterioration of materials by chemical or electrochemical interaction with
their environment on the surface of the metal.

Corrosion E.g.
1) Rusting: Conversion of iron in to its oxide (Fe2O3)
2) Tarnishing: Silver is converted in its sulfide (Ag2S)
3) Conversion of Copper in to its green colored carbonate.

Consequences:
1. Enormous waste of machinery and materials. E.g., 25% of annual production of iron is
wasted.
2.Unpredictable machinery failure leading to dangerous situations such as loss of life.
3.Decrease of efficiency of machine. Replacement of machinery parts is costly.
4.Leakage of inflammable and hazardous gases .
5.Contamination of potable water.

2. What is dry corrosion. Explain in detail about different types of dry corrosion. Or
explain about chemical corrosion with suitable reactions.
Ans: It explains Dry corrosion or Chemical corrosion or Atmospheric corrosion:
This type of corrosion occurs mainly through the direct chemical action of environment /
atmospheric gases such as O 2, halogens, H2S, SO2 etc., or anhydrous inorganic liquid with
metal surface.
The chemical corrosion is generally of three types.
a) Oxidation corrosion
b)Corrosion by other gases
c)Liquid metal corrosion.

a)Oxidation corrosion:
Oxidation corrosion is brought about the direct action of oxygen at low or high temperature on
metals, usually in the absence of moisture. Alkali and Alkaline earth metals are rapidly oxidized at
low temperature. Chemical reactions:
M → Mn+ + ne- loss of electrons
1/2O2 + 2e- → O2- gain of electrons
n+ 2-
M + O → MO Metal Oxide.
eg. Rusting of Iron in presence of atmospheric oxygen.
Pilling –Bedworth Rule:
The protective or non-protective nature of oxide layer is determined by the ratio of the volume of
metal oxide layer to the volume of the metal consumed. This ratio is known as Pilling-Bedworth
ratio.
Pilling-Bedworth ratio= [Vol. of metal oxide formed ] / Vol. of metal consumed.

According to this, an oxide layer is protective if it is non-porous. The volume of the oxide layer is
great as the volume of the metal from which it is formed.
An extremely tightly adhering non-porous layer is formed.
E.g., 4 Al + 3O2 → 2 Al2O3
An oxide layer is non-protective if it is porous. The volume of the oxide is less than the volume of
the metal from which it is formed. So O 2 reacts with the metal and rapid continuous corrosion takes
place.
eg. Alkali and Alkaline earth metals Li, Na, K, Mg.

b) Corrosion by other gases: Corrosion due to other gases like SO 2, CO2, F2, Cl2, H2S, etc.,
depends on: The chemical affinity between the metal and the gas involved. These gases react with
the metal and form of protective or non-protective film on the metal surface.
Eg: 1) AgCl a protective layer formed on the surface of Ag.
2Ag + Cl2 → 2 AgCl Further corrosion is prevented.
Eg: 2) SnCl2 a volatile layer formed on the surface of Sn.
Sn + Cl2 → SnCl2
This causes rapid, continuous corrosion, leading to excessive corrosion.

(c) Liquid – metal corrosion: This type of corrosion is due to chemical action of flowing liquid
metal at high temperature on solid metal or alloy.
Corrosion reaction involves: Dissolution of a solid metal by a liquid metal and internal penetration
of the liquid metal into the solid metal. Both these methods weaken the solid metal.
E.g.: 1. Liquid metal mercury dissolves most metals by forming Amalgams thereby corroding them.
2. Coolant in nuclear reactor is liquid sodium metal which leads to corrosion of cadmium rods.

3. Explain about wet corrosion by hydrogen evolution and oxygen absorption. Or Write
the mechanism of elctrochemical corrosion with suitable examples. (KMIT, April,2023),
(KMIT, May,2022, Jan’24), (JNTUH, Jan’24)
Ans: This corrosion occurs when the Conducting liquids is in contact with metal (or)
When two dissimilar metals or alloys are immersed or dipped partially in a solution.
Mechanism:
Due to the existence of separate anodic‘ and cathodic‘ areas/parts between which current flows
through the conducting solution.
Oxidation takes place at anodic area – metal ions are formed.
Reduction takes place at cathodic area – OH- or O2- ions are formed.
Metals ions and non-metal ions diffuse towards each other through the conducting medium.
Corrosion product is formed somewhere between the anodic & cathodic areas.
At cathodic area electrons are accepted by-

Oxygen absorption:
This type of acceptance takes in the presence of dissolved oxygen in the medium. This type of
reaction takes place in neutral or weak alkaline medium.
Ex: Electrolytes like NaCl soln.
Hydrogen Evolution:
It occurs in acidic environment.
At Anode: Fe → Fe2+ + 2e- (Oxidation)
At cathode: 2 H+ + 2e- → H2 (Reduction)
Net reaction: Fe + 2 H+ → Fe2+ + H2↑

All metals above hydrogen in the electrochemical series have a tendency to get dissolved in acidic
medium with the evolution of H2.

4. Write a note on different types of wet corrosion or Explain about various types of
electrochemical corrosion with suitable reactions and diagram.
Ans: Types of wet corrosion:
1. Galvanic or Two-metal corrosion
2. Pitting corrosion
3. Differential aeration corrosion /waterline corrosion.

1. GALVANIC or TWO METAL CORROSION: (KMIT, April,2023),(JNTUH, April’23)

When two dissimilar metals are joined together and exposed, the more active of the two metals
corrode faster and the other metal is protected. This excess corrosion is due to the galvanic current
generated at the junction.

Three conditions must exist for galvanic corrosion to occur:

1. The Electrochemically dissimilar metals must be present.
2. The metals must be in electrical contact.
3. The metals must be exposed to an electrolyte.
Prevention of galvanic corrosion:
1.Select in the metals/alloy as close together as possible in the galvanic series.
2.Avoid unfavorable area effect of a small anode and large cathode.
3.Insulate dissimilar metals whenever practical.
4.Paint the cathode (or both) and keep the coatings in good repair on the anode.
5.Avoid threaded joints for materials or far apart in the galvanic series.

2. PITTING CORROSION: (JNTUH, April’23)

A form of extremely localized attack causing holes in the metal due to breakdown of a protective
layer or uneven deposition of dirt on the metal surface, Most destructive form and Auto catalytic
nature.
At anode: Fe → Fe2+ + 2e−
At cathode: H2O + ½ O2 + 2e−→ 2 OH−
Fe2+ + 2OH− → Fe(OH)2 →Fe(OH)3

Prevention of pitting corrosion :

(1) Provide a uniform surface through proper cleaning, heat treating and surface finishing.
(2) Make the surface of the specimen smooth and shiny and do not allow any impurities to deposit
on the surface.
(3) Control pH, chloride concentration and temperature.
(4) Cathodic protection and / or Anodic protection.

3. DIFFERENTIAL AERATION CORROSION OR WATER LINE CORROSION : (KMIT,

July,2023)
This type of corrosion occurs when a metal is exposed to different concentrations of Oxygen.
The part of metal which is more exposed to air act as cathode and unaffected. The other part of the
metal, which is less, exposed to air act as anode and undergoes corrosion.
Example: Water line corrosion
It is differential aeration type of corrosion observed in water storage tanks, ships, etc.
During water line corrosion, the part of the Metal below waterline is exposed to less Oxygen
concentration act as anode and undergoes corrosion than the other part which is
more exposed to atmospheric Oxygen which act as cathode.
At anode: Fe → Fe++ + 2e_
At cathode: 2Fe++ + 4OH - → 2Fe(OH)2
Net Reaction: 2Fe(OH)2+ O2 + 2H2O → 2(Fe2O3. 3H2O) rust.
5. State the Differences between Dry and Wet corrosion.

6. Explain various factors affecting rate of corrosion on the basis nature of the metal and
corroding environment. (KMIT, Sep,2021)(KMIT, Oct,2021 & Jan’24), (JNTUH, Jan,24),

Ans: The important factors, which affect on the rate of corrosion, are
a) Nature of the metal and b) Nature of the environment
NATURE OF THE METAL:
1. Position of metal in galvanic series: When two metals or alloys are in electrical contact in
presence of an electrolyte the more active metal having higher position in the galvanic series
undergoes corrosion. The greater is the difference in position, the faster is the corrosion.
2. Nature of Corrosion Product: If the corrosion product is soluble in the corroding medium,
the corrosion rate will be faster. Similarly, if the corrosion product is volatile like MoO3 on Mo
surface, the corrosion rate will be faster.
3. Nature of surface/oxide film: Nature of the oxide film, formed on the metal surface, decides
the extent of corrosion which can be decided by Pilling-Bedworth Rule.
4. Purity of metal: Lesser is the percentage purity of a metal, faster is the rate of corrosion. The
impurities present in a metal cause heterogeneity and form a local galvanic cell (metal anode,
impurity cathode) and results corrosion of metal. Thus corrosion resistance of metal can be
improved by increasing its purity and pure metals are generally corrosion resistant.
5. Physical state of metal: Physical state of a metal means orientation of crystals, grain size,
stress etc., the larger the grain size of metal/alloy, the smaller will be its solubility and hence the
lesser will be the corrosion. Area under stress tends to undergo corrosion as it behaves as anode.
6. Anodic to cathodic areas: If a metal has small anodic and large cathodic area the
rate of corrosion increases and vice versa. This is because when anode is small the electrons
liberated during oxidation are completely consumed on large cathodic surface for the
reduction reactions and rate of corrosion increases.

NATURE OF THE ENVIRONMENT:

1.Temperature: Increases in temperature results in an increase in the conductance of the
aqueous medium and rate of corrosion also increases and vice versa.
2. PH: In general at lower P H value the rate of corrosion is more at higher pH value (more
than PH = 10) the rate of corrosion ceases due to the formation of protective coating of
hydrous oxides on the metal. Corrosion rate is maximum between P H 3 and 10 in presence of oxygen
.
3. Presence of impurities in atmosphere, humidity of air, conductance of the corrosion medium also
influences the rate of corrosion.
4. Formation of Oxygen concentration cell: Oxygen is one of the important elements responsible for
corrosion. Due to differential aeration, oxygen concentration cell sets up and anodic part having less
oxygen concentration suffers corrosion.
e.g., Crevice, waterline corrosion.
5. Humidity: Moisture in the atmosphere dissolves gases and makes electrolyte. Humidity increases
rate of corrosion also increases.

7. What is the principle of cathodic protection? Explain cathodic protection using

sacrificial anode method. And write its advantages and applications. (KMIT, July,2023)

Ans: Principle: The principle involved in cathodic protection is forcing the metal to behave like
cathode.
Sacrificial Anodic protection:
In this method the more active metals like Zn, Mg, and Al etc are attached to base metal.
The anodic metals being more reactive undergoes corrosion but base metal remains
unaffected .
The sacrificial anodes have to be replaced from time to time after complete corrosion.

Advantages:
1. No external power required.
2. It is easy to install.
3. Installation can be inexpensive, if installed at the time of construction.
4. Anodes can be readily added.
5. Minimum of cathodic interference problems.
6. Minimum maintenance required.

Applications: 1. Protection of underground cables & pipelines from soil corrosion periodically.
2. Insertion of Mg sheets or rods into domestic water boilers or tanks to prevent rusty water.
3. Used for protecting ship or boat hulls, steel rods in RCC columns.

7. Write an account on impressed current cathodic protection and give its advantages,
limitations and applications. (KMIT, April,2023)

Ans: Impressed current cathodic protection: In this method the base metal is connected to
negative terminal of the D.C source and made it cathode, an inert anode is graphite rod/
carbon connected to positive terminal of the D.C source. The protected base metal does not
undergo corrosion.
Current from an external source is applied in the opposite direction to nullify the corrosion current.
The corroding metal is converted from Anode to Cathode and is protected. Anode is an inert
material or one which deteriorates and is replaced periodically.
Examples of Anodic materials: Graphite, carbon, platinum(Inert materials), stainless steel, scrap
iron, High silica iron. These are replaced periodically.
Advantages:
1. Large structures can be protected for long term operations.
2. It can be designed for a wide range of voltage and current.
3. It can be applied in high resistivity environment.
4. Effective in protecting non-coated and poorly coated structures.
Limitations:
1. Require periodic maintenance
2. Require external power, resulting in monthly power costs.
3. Over protection can cause coating damage.
Applications: used for protection of large structures such as underground cables, buried pipe lines,
submarines etc.