A study of corrosion on a rotating iron disk electrode

Corrosion of iron in slightly acidified sodium sulphate solutions (mainly pH 4.5) in the open air was studied with a rotating disk electrode method at room temperature.Microscopic observations of corroded iron disk surfaces in the pH 4.5 solution revealed that iron initially corrodes locally with the formation of round pits of 10–30 μm in diameter and of(0.6–1.3) × 10³ in number per apparent square centimetre followed by the U-shaped brown protective wall formation of precipitates (rust) outside the pits. Each protective wall is formed along the lines of flow of the solution adjacent to the iron surface and each pit is located near the upstream end of the wall. Steady state of corrosion sets in when the parts of surface area surrounded by the wall are completely covered with a microscopically non-porous rust film.The amount of iron in the rust film and the total amount of corrosion of iron including that in the film increase parabolically with the increase in the time of immersion. The amount of iron in the film increases in proportion to the total amount of corrosion independently of the speed of rotation of the disk electrode even in the steady state.The fraction of area of iron surface not covered with the film decreases with time and reaches a certain fixed value in the steady state: the value is smaller at higher rotational speed. The corrosion rate is proportional to the uncovered area, as the corrosion is near the steady state. The pH of the bulk solution increases as corrosion progresses.The corrosion rate of iron can be well interpreted by assuming that the rate is controlled by the diffusion of oxygen from the bulk solution to the surface of iron and that the rust film on iron impedes the diffusion of oxygen.