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GALVANIC CORROSION OF ZINC ANODE AND COPPER CATHODE CELL

Article · January 2018

DOI: 10.31127/tuje.330672

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Nurettin Çek
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 Turkish Journal of Engineering

Turkish Journal of Engineering (TUJE)

Vol. 2, Issue 1, pp. 22-26, January 2018
ISSN 2587-1366, Turkey
DOI

GALVANIC CORROSION OF ZINC ANODE AND COPPER CATHODE CELL

Nurettin Çek *1
1
Fırat University, Faculty of Engineering, Department of Metallurgical and Materials Engineering, Elazığ, Turkey
ORCID ID 0000-0001-6120-9228
[email protected]

* Corresponding Author
Received: 24/07/2017 Accepted: 22/09/2017

ABSTRACT
Detection and control of galvanic corrosion is a critical aspect of engineering for the chemical processes used in the
fabrication of metals, alloys and materials industry. Galvanic corrosion can occur when two metals having different status
in the electrochemical ambient are configured in mutual interaction within the galvanic cell structure and are exposed to
the ion conducting electrolyte. In this study, ion-containing water was used as an electrolyte, the zinc as the anode electrode,
copper as the cathode was used as an electrode, and a galvanic cell was fabricated. The formation of corrosion products
with time on zinc anode reduced the voltage and current in galvanic cell considerable and anode film layer of considerable
increase. Time-dependent experiments have provided good sources of information about the performance of the zinc anode
electrode and the copper cathode electrode in the galvanic cell.

Keywords: Zinc, Copper, Electrode, Galvanic Cell, Corrosion

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 Turkish Journal of Engineering (TUJE)
Vol. 2, Issue 1, pp. 22-26, January 2018

1. INTRODUCTION length, 0.75 cm diameter. Digital multimeter (UNI-T:

UT61C) was used to make for direct current and voltage
Corrosion is the chemical and physical properties of measurements. Resistance, 980 ohm (Ω). Digital pH
metal and metal-like materials event change. The meter (616.0.001, ISOLAB). Sensitive Scale (PKS 360-3,
extensive use of metal in the process of daily life and the KERN). Plastic box shaped like a truncated cone (4 cm
resulting metal corrosion has caused challenging bottom diameter, 7 cm ceiling diameter, 8 cm diameter)
problems. Corrosion of metals are a terrible waste both of and the empty volume of the plastic box chamber was
economic and natural resources. Metals are suffering 191.68 cm3 (191.68 milliliter (mL)). Water is pH value
corrosion because they want to return to their natural about at 7.65 and it content includes sodium (Na),
oxide form (Ammal et al., 2017). There are many factors potassium (K), magnesium (Mg), calcium (Ca) cations
that affect corrosion. For example; with biofilm and fluorine (F), chlorine (Cl), sulphate (SO4) anion.
formation, corrosion is occurring (Cordas et al., 2008).
Various methods have been applied to prevent inhibit 2.2. Method
corrosion. These methods typically include: Use of alloys
in place of pure metal, improvement of metal plating Weight (gram (g)) measurements are made with the
(organic or inorganic), improvement of metal design precision weighing instrument (Sensitive Scale). Weight
(avoiding excessive stress, minimizing indentation), measurements were made before and after use of the
electrochemical protection (anodic protection, reduced electrodes of the galvanic cell. The total surface area
temperature, reduced speed liquid, removing oxygen (191.68 cm3) of the plastic box has about at 191.68 mL
from the environment, reduced the concentration of the water intake capacity. After, zinc as anode electrode and
solution, use of corrosion inhibitors) etc. applications copper as cathode electrode was used in the plastic box.
(Çek, 2014, Cicek, 2017). Corrosion applications are Therefore, galvanic cell was designed.
galvanic cell of one example. The type of corrosion that The galvanic cell was subjected to daily electrical
occurs in the galvanic cell is called as galvanic corrosion. measurements according to resistance-dependent and
The galvanic cell basically consists of the anode electrode, non-resistance-related conditions. In addition, oxide layer
cathode electrode and an electrolyte (water, moisture, in manufactured galvanic cell, the time-dependent states
ionic liquid etc.). Galvanic corrosion is perceptible in heat of the anode and cathode electrodes, corrosion etc. factors
exchangers, pipelines, cooling towers, and in each status have been detected. Discussions were held in regard to
in which two different metals materials come in contact the formation, development and effects of these factors
in the presence of water or moisture (Shi et al., 2012; on the system. In this study, galvanic cell model is shown
Hasan, 2014, Cicek, 2017). Example; in the study in Fig. 1.
conducted by Çek (2014), corrosion of copper in the
aqueous medium was prevented by using vaseline.
Therefore, galvanic corrosion in copper is inhibited.
Vaseline is an organic material obtained from petroleum
and is often used to heal wound (Çek, 2014; Bhupinder
and Manju, 2015).
In the galvanic cell, voltage and current generated
values by anode and cathode electrodes are an important
parameter affecting corrosion. The use of materials with
minimum potential (voltage) differences would minimize
corrosion in a galvanic cell. In addition, low current
(ampere) production in the galvanic cell reduces usually
corrosion (Taher and Al Jabab, 2003). Galvanic corrosion
is one of the major problems to the use of zinc materials
in the industry. During the galvanic corrosion process of
zinc's, the zinc ions react and precipitate in the form of
oxides or hydroxides (Song et al., 2004). Therefore, Fig. 1. Galvanic cell model of in this study
detailed information about the time-dependent galvanic
corrosion of the zinc materials should be obtained. In this 3. RESULTS AND DISCUSSION
study for this purpose, the zinc as anode electrode the
copper as the cathode electrode and ionic conductive As the zinc plate (-) load electrode and as the copper
water as the electrolyte was used. The corrosion effect of cylinder rod (+) load electrode the worked. This situation
the anode and cathode electrodes was studied based on was detected by the multimeter. Without external load
time dependent voltage and current measurements on the (resistance) on galvanic cells are open-circuit voltage
galvanic cell. (VOC) and short-circuit current (ISC) values measured by
the multimeter. Volt (VR) and current (IR) values were
2. MATERIALS AND METHOD measured by multimeter while the galvanic cells were
connected to the external load (resistance). Resistance is
2.1. Materials not constantly connected to the galvanic cell; it is only
connected during measurements. Time-dependent
Materials and apparatus properties were as follows. electrical generation values of galvanic cells are in shown
Zinc (Zn) plate electrodes; 99.9% purity, 3.060 grams, in Table 1.
each electrode has 4 cm length and 4.5 cm wide. Copper
cylinder rod electrodes; 99.9% purity, 3 grams, 8 cm

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 Turkish Journal of Engineering (TUJE)
Vol. 2, Issue 1, pp. 22-26, January 2018

Table 1. Electrical measurements of first type galvanic

cell

Time VOC ISC VR IR

(Day) (mV) (µA) (mV) (µA)
1 360 33 2 3
2 180 14 1 1
3 181 1 0.5 0.5
4 152 0.5 0.2 0.3
5 67 0.3 0.2 0.2
6 60 0.2 0.1 0.1

According to Table 1, the zinc anode initially

experienced a very rapid galvanic corrosion process. The
rate of galvanic corrosion decreased with time in the zinc
anode. Therefore, electrical (VOC, ISC, VR and IR) values
decreased. The change in electrical values is evidence of
galvanic corrosion. According to Table 1, the current
values increase as the voltage values increased. In
addition, the corrosion of the anode zinc electrode occurs
whether or not it is resistance. But, the corrosion state is Fig. 3. The zinc anode status in the second 6 days (total
different when there is resistance and when there is no 12 days)
resistance. After 6 days, the colorless water was red
colored and a red precipitate was observed under the The electrodes on the galvanic cell and the
plastic box (Fig. 4.). Due to galvanic corrosion of zinc appearance of red colored water (electrolyte) are shown
anode, white rust first film layer formed and then red rust in Fig 4.
film layer formed. The zinc anode electrode image in the
first 6 days is shown in Fig. 2.

Fig. 2. The zinc anode state in the first 6 days Fig. 4. The electrodes and electrolyte on the galvanic cell

Upon this, the water in the plastic box was drained, The oxide layer dominates more area in Fig. 3 than
the plastic container was cleaned with clean water, and Fig. 2.
the plastic container was re-filled with clean water. Weight loss is the proof of corrosion and corrosion
Electrical measurements were made again and the results rate (CR) is measuring to the formula in Equation (1)
similar to the results (±10 mV of VOC, ±10 µA of ISC, (Ammal et al., 2017; Tribak et al.,2017)
±0.05 mV of VR, ±0.05 µA of IR) in Table 1 were obtained.
Observations made the additional 6 days more the first 6 𝐖
CR=𝐀.𝐭 (1)
days showed that the area covered by the oxide film layer
increased and that red precipitate accumulated at the
Where, W is the difference between starting weight
plastic box.
(Wstart) and end weight (Wfinish), A is the surface area of
At the end of all these 12 days, the zinc anode
immersed anode metal and t is time (hours) of application.
electrode was removed from the galvanic cell, it was In this study; Wstart is 3.060 grams, Wfinish is 3.030 grams,
washed with clean water and dried in the environment (1
Wchange is 0.030 g (30 mg), A is 18 cm2, t is 288 hours (12
hour) and weigh measurement was made. At the end of days). The corrosion rate (CR) in this study is calculated
12 days, zinc anode electrode weight (Wfinish) was
in Equation (2).
measured as 3.030 gr.

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 Turkish Journal of Engineering (TUJE)
Vol. 2, Issue 1, pp. 22-26, January 2018

𝟑𝟎
CR= =0.005 mg/cm2h (2)
𝟏𝟖.𝟐𝟖𝟖

Table 4. In this study corrosion rate (CR) scenario of year

Another issue to be taken into account in corrosion
rate calculations is current density. Current density is
Time CR (mm/year) CR (mm/year)
shown in Equation (3).
(Day) (not resistance) (Resistance connect)
𝐀𝐦𝐩𝐞𝐫𝐞 (𝐀) 1 0.02742 0.00248
Current density= (3)
𝐀𝐧𝐨𝐝𝐞 𝐬𝐮𝐫𝐟𝐚𝐜𝐞 𝐚𝐫𝐞𝐚 (𝐜𝐦𝟐 ) 2 0.01162 0.00082
3 0.00082 0.00040
In this study, current density is shown in Table 2. 4 0.00040 0.00023
5 0.00023 0.00016
Table 2. In this study current density 6 0.00016 0.00007
Time Current density Current density
According to the table 4, the corrosion rate is
(Day) (not resistance) (Resistance connect)
reducing daily. If the galvanic cell was regularly
1 18.33x10-7 1.66x10-7
maintained at the initial current intensities, the annual
2 7.77x10-7 0.55x10-7 corrosion rate (CR) obtained would be 0.02742 mm/year
3 0.55x10-7 0.27x10-7 without resistance and 0.00248 mm/year with resistance.
4 0.27x10-7 0.16x10-7 The lowest corrosion rate was achieved on the 6 th day. If
5 0.16x10-7 0.11x10-7 the galvanic cell was regularly maintained at the 6 th day
6 0.11x10-7 0.05x10-7 current intensities, the annual corrosion rate (CR)
obtained would be 0.00248 mm/year without resistance
According to literature as the current density and 0.00007 mm/year with resistance.
increases, the corrosion rate (CR) increases (Bardal,
2007). The corrosion rate due to current density is 5. CONCLUSION
calculated as in Equation (4).
The zinc anode electrode is not a material that can
𝐈.𝐌 withstand long-term corrosion. The cathode electrode is
CR= 𝐳.𝐅.𝐩 cm/s (Bardal, 2007) (4)
protected until the anode electrode is depleted. During
this time the copper cathode electrode is not affected
Where, I is current density (µA/cm2), M is mol mass corrosion by values measurable.
of the anode (65.38 g/mol atom of Zn), z is number of The formation of the oxide film (rust) on the surface
electrons in the reaction equation for the anodic reaction of the zinc anode electrode has been increased with the
(dissolution reaction) (per atom of the dissolving metal) decrease of voltage and current values at the galvanic cell.
(2e- of Zn), F is Faraday constant (96485 C/mol e-), p is After 6 days the electrolyte (water) of the galvanic cell
density of anode (7.14 g/cm3 of Zn), Using the equation was renewed. The materials precipitate under the plastic
(4), the data in Table 3 was obtained. box and the rust in the face of the anode were cleaned
away with clean water. However, current and voltage
Table 3. Corrosion rate (CR) due to current density values approaching to their first state. But, the current and
voltage values are reducing again due to rust formation
Time CR (cm/s) CR (cm/s) on the zinc anode electrode surface. This shows that the
(Day) (not resistance) (resistance connect) oxide film (rust) layer reduces the corrosion rate.
1 8.69x10-11 7.88x10-11 One of the important findings obtained in this study
2 3.68x10-11 2.63x10-11 is that the current increases as the voltage increases and
3 2.63x10-11 1.28x10-11 the current decreases as the voltage decreases. The
4 1.28x10-11 0.75x10-11 corrosion rate increases as the current and current density
5 0.75x10-11 0.52x10-11 increase (Bardal, 2007). In addition to this, in this study,
6 0.52x10-11 0.27x10-11 it has been determined that the voltage values and the
corrosion rate (CR) are directly proportional.
A constant corrosion rate is desirable for the Adding on the galvanic cell of electrical resistance
calculations to be the healthy and long term. However, as has also reduced and slowed down the corrosion as it
shown in Table 3, the corrosion rate in this work is not reduces voltage and current. This is a positive finding.
constant. Use of electrical resistance to reduce the negative effects
The annual corrosion rate is calculated using of corrosion on places such as galvanic cells will be a
Equation (5). useful application.
𝐈.𝐌
CR=3268
𝐳.𝐩
mm/year (Bardal, 2007) (5) ACKNOWLEDGEMENTS

Since the corrosion current and the current density are Koç Holding and Arçelik thanks for the experimental
not constant, an annual corrosion rate (CR) scenario is instruments. I thank Prof. Dr. Mustafa Aksoy for his
established for each current and current density obtained. scientific supports.
The annual corrosion rates of the different electrical
values according to different days are given in Table 4.

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 Turkish Journal of Engineering (TUJE)
Vol. 2, Issue 1, pp. 22-26, January 2018

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