Alexandria University

Faculty of Engineering
Chemical Engineering Program
Level 3

CHE341
Corrosion Engineering
Laboratory Notes

Course Instructors:
Prof. Dr. Gomaa Hanafy Sedahmed
Prof. Dr. Mohamed Abbas Elnaggar
Dr. Ahmed Salah Fathalla
Eng. Hala Hossam Mabrouk
 CORROSION ENGINEERING LABORATORY NOTES

Experiment (1)
Measurement of the EMF by the Compensation
method

Introduction:
The electromotive force (EMF) E of a voltage source is the potential difference
between its poles when there is no current flow through the source, that is the
potential difference in an open circuit. Every real voltage source has an internal
resistance Ri which causes an internal voltage loss when current I drifts through the
source. In this case, the measured electromotive force will be reduced by the ohmic
drop.
The Poggendorff Compensation method is a laboratory alternate for measuring
emf while no current flows, and open circuit voltage is maximum.
Objectives:
In the present experiment students should learn:

• To construct a galvanic cell “Daniel Cell”

• The principles of the compensation method
• Use the compensation method to measure the EMF

In this experiment you need the following:

Fully charged car battery: as a source of power Standard cell: Standard cell has
a constant EMF Potentiometric wire: made of a high resistance alloy
Galvanometer: to indicate the current flow direction

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Experimental procedures:
1. Construct a Daniel cell composed of a copper cathode and a zinc anode each

immersed in a solution of its sulfate/chloride salt.

2. Construct the cell as shown in fig.1

Figure 1: scheme of the compensation method

‘Be careful to connect both the positive pole of the battery and the
positive electrode of the galvanic cell to the same end of the
potentiometric wire’

3. Move the slider along the potentiometric wire until the galvanometer

indicates no current flow, record the length Lcell

4. Replace the cell of unknown emf (Daniel cell) by a standard cell for which

the emf is known Est

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5. Move the slider along the potentiometric wire again until the galvanometer

reads no current, record the length Lst

6. Calculate the emf of the cell Ecell where;

Ecell Lcell
= Lst
Est

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Results & Calculations

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Experiment (2)
Determination of Thermodynamic Functions
of an Electrochemical Reaction by
measurement of emf

Introduction:
The tendency for any chemical reaction to go, including the reaction of a metal with
its environment, is measured by the Gibbs free energy change, Δ G. The more
negative the value of Δ G, the greater the tendency for the reaction to go and the less
negative Δ G indicates a less tendency for the reaction to go. However, when Δ G is
positive, it can be stated with certainty that the reaction will not go at all under the
conditions described.
In view of the electrochemical mechanisms of corrosion, the tendency for a metal to
corrode can also be expressed in terms of the electromotive force (emf) of the
corrosion cells that are an integral part of the corrosion process. The relation between
Δ G in joules and emf in volts, E, is defined by:
Δ G = − nFE ...................................... (1)
To obtain Δ G from the above equation the cell emf should be measured while the
cell is working reversibly ‘under zero current’ by using the Compensation method
as mentioned before.
From the second law of thermodynamics, the entropy changes of a reaction ΔS,
and the heat of reaction Δ H, can be related to the cell emf as in Eq.(2):
𝑑∆𝐺 𝑑𝐸
ΔS = - = 𝑛𝐹 ................................(2)
𝑑∆𝑇 𝑑𝑇

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By applying energy balance, the enthalpy change of reaction can be found from
Eq.(3)
Δ H= Δ G + T Δ S ..................................(3)
Finally the enthalpy change is related to the EMF as follows:
𝑑𝐸
Δ H=− nFE + 𝑇𝑛𝐹 ………………………(4)
𝑑𝑇

Objectives:
In this experiment student should learn:
• The relation between different Thermodynamic functions
• The relation between EMF and thermodynamic functions
• Calculate the thermodynamic functions Δ H, Δ G and Δ S for an
electrochemical reaction using EMF measurement

Experimental procedures:
1. Construct a Daniel cell composed of a copper cathode and a zinc anode

each immersed in a solution of its sulfate/chloride salt.

2. At room temperature measure the cell emf (Ecell ) using the compensation

method

3. Now put the whole cell in a hot water bath, wait a few minutes then use

a thermometer to measure the cell temperature

4. Record the cell emf at this temperature

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5. Repeat the previous 2 steps for 3 times at least and measure E cell at each

temperature using the compensation method

6. Plot Ecell vs. T and determine dE/dT from the slope

7. Substitute in equations (1), (2) and (3) to calculate the thermodynamic

functions of the reaction Δ H, Δ G and Δ S at room temperature

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Results & Calculations

Temperature (◦C) Ecell (volts)

Calculations

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Experiment (3)
Determination of the current efficiency

Introduction:
In many electrochemical reactions the actual amount of product is less than the
theoretical amount obtained by Faraday’s law. The ratio between the actual amount
and the theoretical amount is known as the current efficiency C.E

Objectives:
This experiment is designed to quantify the current efficiency for zinc deposition
cell. In this experiment, student is asked to:

• Construct an electrolytic cell

• Calculate the fraction of current consumed in producing the main product
from the weighed amount of metal deposited.

Experimental procedure:
1. Weigh accurately a clean dry oxide free
steel sheet of known dimensions

2. Connect the steel cathode to the

negative terminal of the DC power

supply and the zinc anode to the

positive pole of the power supply

3. Immerse the electrodes in the zinc

sulfate solution

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4. Fix the cell current to be equivalent to 0.1 A/cm2 current density

5. Area of the cathode = l*w*2

6. After 30 minutes dismantle the cell, wash, dry and reweigh the steel sheet.

7. Calculate the actual mass of zinc deposited on cathode m from the weight
gained measured as follows:
m = m2 − m1
Where,

m1: is the mass before the experiment

m2: is the mass after the experiment

8. Calculate the theoretical amount of product should be obtained from

Faraday’s law:

mtheo=e*I*t
Where,
𝑀𝑤𝑡
e: the electrochemical equivalent of zinc that e= 𝑍𝐹

I: the cell current

t: is the time in seconds
𝑀𝑤𝑡 : Molecular weight of zinc (65 g/mol)
Z: its valency
F: Faraday’s constant (96500 Col/mol of electrons)

1. Calculate the current efficiency:

𝑚
C.E =
𝑚𝑡ℎ𝑒𝑜

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Results and calculations

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Experiment (4)
Measurement of copper ions concentration in
Daniel cell by Nernst equation

Figure1: Schematic representation of Daniel galvanic cell

Introduction:
The Daniel Cell in 1836 was the starting point of modern electrochemistry because,
for the first time, a reliable source of current at a precise voltage was available. It
also was the first practical cell that does not generate a gas when operating. This cell
was used as the first standard to define the unit “Volt”.
Zn(s) → Zn2+(aq) + 2e with (eo)oxd = 0.76 v
Cu (aq) + 2e → Cu(s)
2+
with (eo)red = 0.34 v
0.059 [𝑃𝑟𝑜𝑑𝑢𝑐𝑡]
E=Eo – log
2 [𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡]

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Objectives:
• The purpose of this experiment is to use the Daniel cell to corroborate the
Nernst law (potential vs. concentration).

• It will also be used to find the concentrations (activity) of copper in an

unknown sample of Cu2+.
Experimental procedure:
1. Construct a Daniel cell composed of a copper cathode and a zinc anode each
immersed in a solution of its sulfate salt.

2. Connect the voltmeter to the cell and record the reading Ecell.

Where;

Ecell= eanode+ecathode
3. Substitute at Nernst Equation For anode to calculate eanode.

Where;

0.059 [𝑍𝑛++ ]
Eanode= (eo)oxd. − log ((eo)oxd = 0.76 v)
2 [𝑍𝑛]

4. Calculate the unknown concentration of copper ions from Nernst equation

for cathode.

Where;

0.059 [𝐶𝑢]
Ecathode=(eo)red. − log ((eo)red = 0.34 v)
2 [𝐶𝑢++ ]

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Results and calculations

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Experiment (5)
Determination of the inhibition efficiency of a
corrosion inhibitor

Introduction:
This module covers the method of corrosion prevention and control using surface
coatings, that is, the isolation of the metal from the corrosive environment. Coatings
is one of the most significant method of protection against corrosion. The most
common are organic coatings, which adsorb on the surface of the metal and form a
protective thin film that prevents corrosion, or lower the rate of corrosion, to extend
service lifetime.

Objectives:
In the present work the student should learn:
• The use of organic coatings as corrosion prevention method
• The mechanism of corrosion inhibition by coatings
• The effect of using an organic corrosion inhibitor in decreasing the rate of
metallic corrosion.

Experimental procedures:
1. Weigh accurately two clean, oxide free sheets of steel and measure their

dimensions

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2. Immerse one of them in 200 cc (1M H2SO4) solution and the other in 200 cc

(1M H2SO4) solution containing 0.1% of suitable organic inhibitor for 30

minutes

3. At the end of the experiment, wash and dry each sheet and reweigh it

4. Calculate the weight loss for each sheet, m

5. Now calculate the rate of corrosion R for both sheets as follows:

=
∗
where,

m: is the loss in weight

a: the sheet wetted area in cm2

t: the experiment time in sec

6. Finally calculate the inhibitor efficiency from the rate of corrosion without

inhibitor R and the rate of corrosion in presence of inhibitor ∗ using the

following equation:

−∗
=

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Results & Calculations

Sheet 1 Sheet 2
Total wetted area, cm2

Mass at the start, g

Mass after 30 min, g

Weight loss m, g

Rate of corrosion R,
g/cm2.s

Efficiency of inhibitor

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Experiment (6)
Protection of steel against corrosion by cathodic
protection

Introduction:
The corrosion engineer applies scientific knowledge to control corrosion and reduce
capital losses. Cathodic protection is accomplished by supplying an external current
to the corroding metal that is to be protected; current leaves the auxiliary anode -the
more noble one- passes through the electrolyte, enters the metal that is to be
protected. The corroding metal is now fully protected and the corrosion rate is zero.

Objectives:
This experiments studies the effect of steel zinc coupling on the rate of steel
corrosion. Student will learn to:

• Measure the rate of corrosion of steel in presence of a more active zinc sheet
in contact
• Calculate the degree of protection obtained by cathodic protection

Experimental procedures:
1. Weigh accurately two clean, oxide free steel sheets of known dimensions

2. Immerse one of them in a corrosive ammonium chloride (NH4Cl) solution

for 45 minutes

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3. At the same time couple the other steel sheet with a zinc sheet of similar

dimensions and immerse the couple in a similar electrolyte for 45 minutes

4. At the end of the experiment wash, dry and reweigh the steel sheets

5. Now calculate the rate of corrosion R for both sheets as follows:

=
∗
where,

m: is the loss in weight

a: the sheet area in cm2

t: the experiment time in sec

6. Finally calculate the degree of protection from the rate of corrosion of the
uncoupled sheet R and the rate of corrosion in presence of coupling ∗ using

the following equation:

−∗
=

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Results & Calculations

Sheet 1 Sheet 2
Total wetted area, cm2

Mass at the start, g

Mass after 45 min, g

Weight loss m, g

Rate of corrosion R,
g/cm2.s

Degree of Protection,

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Experiment (7)
Corrosion inhibition of steel by passivation

Introduction:
Prevention of metal corrosion by passivation refers to treatment of the metal surface
to reduce its activity. This passivation of the metal surface helps increases its
corrosion resistance and life time.

Objectives:
This experiment is designed to study another method of metal protection against
corrosion. In this experiment corrosion prevention by passivation of the metal
surface is studied. Student is asked to:

• Passivate one steel sheet surface using oxidizing chromate solution

• Calculate its rate of corrosion in a corrosive ammonium chloride solution
compared with another unpassivated steel sheet of similar dimensions

Experimental procedure:
1. Weigh two clean oxide free steel sheets of known dimensions

2. Passivate one sheet in 200 cc of sodium chromate 227 oxidizing solution in

presence of sodium hydroxide for 15 min at room temperature

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3. After passivating one sheet, simultaneously place each sheet in a separate

container containing saturated ammonium chloride 4 corrosive solution for 45

minutes

4. At the end of time, wash, dry and reweigh each steel sheet to determine its

weight loss m

5. Calculate the rate of corrosion R for both sheets as follows:

=
∗

where,
m: is the loss in weight
a: the sheet area in cm2
t: the experiment time in sec

6. Finally calculate the degree of protection from the rate of corrosion of the

unpassivated sheet R and the rate of corrosion of the passivated sheet Rp using

the following equation:

−
=

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Results & Calculations

Sheet 1 Sheet 2
Total wetted area, cm2

Mass at the start, g

Mass after 45 min, g

Weight loss m, g

Rate of corrosion R,
g/cm2.s

Degree of Protection,

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