A.The gradual destruction of metals by chemical or electrochemical attack by the environment
B.The process of coating a metal with a protective layer
C.The increase in the tensile strength of a metal due to oxidation
D.The purification of metals from their ores
Correct Answer: The gradual destruction of metals by chemical or electrochemical attack by the environment
Explanation:
Corrosion is defined as the gradual destruction or deterioration of metals or alloys by the chemical or electrochemical reaction with their surrounding environment, often returning the metal to its native oxide or sulfide state.
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2According to the Pilling-Bedworth rule, a metal oxide layer is protective if the volume of the oxide is:
A.Equal to or greater than the volume of the metal consumed (but not excessively so)
B.Much smaller than the volume of the metal, causing cracks
C.Zero
D.Less than the volume of the metal consumed
Correct Answer: Equal to or greater than the volume of the metal consumed (but not excessively so)
Explanation:
If the specific volume ratio (Pilling-Bedworth ratio) is , the oxide layer forms a continuous, non-porous covering that protects the underlying metal from further corrosion. If it is , the layer is porous and non-protective.
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3Which mechanism is responsible for dry corrosion?
A.Direct chemical attack by gases like , , or
B.Physical abrasion
C.Microbial activity
D.Electrochemical reaction in an aqueous medium
Correct Answer: Direct chemical attack by gases like , , or
Explanation:
Dry corrosion, or direct chemical corrosion, occurs through the direct chemical attack of atmospheric gases on the metal surface in the absence of moisture/liquid electrolyte.
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4In electrochemical corrosion, the part of the metal undergoing corrosion acts as the:
A.Electrolyte
B.Salt bridge
C.Cathode
D.Anode
Correct Answer: Anode
Explanation:
In electrochemical corrosion, oxidation occurs at the anode, where the metal loses electrons () and dissolves/corrodes.
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5During electrochemical corrosion in an acidic environment, the cathodic reaction results in:
A.The deposition of metal
B.The evolution of hydrogen gas
C.The absorption of oxygen
D.The formation of hydroxide ions
Correct Answer: The evolution of hydrogen gas
Explanation:
In acidic environments containing ions, the cathodic reaction is the evolution of hydrogen: .
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6The formation of rust on iron in a neutral aqueous environment is primarily driven by which cathodic mechanism?
A.Metal deposition
B.Chlorine evolution
C.Oxygen absorption
D.Hydrogen evolution
Correct Answer: Oxygen absorption
Explanation:
In neutral or slightly alkaline solutions containing dissolved oxygen, the cathodic reaction is oxygen absorption: .
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7The chemical formula for rust is generally represented as:
A.
B.
C.
D.
Correct Answer:
Explanation:
Rust is hydrated ferric oxide, chemically represented as .
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8In a Galvanic cell formed by Copper and Zinc, which metal corrodes?
A.Zinc
B.Both corrode equally
C.Neither corrodes
D.Copper
Correct Answer: Zinc
Explanation:
Zinc is higher in the electrochemical series (more anodic/active) than Copper. Therefore, Zinc acts as the anode and corrodes, while Copper acts as the cathode and is protected.
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9Which of the following conditions is necessary for Galvanic corrosion to occur?
A.Two dissimilar metals must be in contact in the presence of an electrolyte
B.A single metal must be exposed to different concentrations of oxygen
C.The metal must be in a vacuum
D.The metal must be subjected to high mechanical stress
Correct Answer: Two dissimilar metals must be in contact in the presence of an electrolyte
Explanation:
Galvanic corrosion occurs when two different metals with different electrode potentials are electrically connected in a corrosive electrolyte.
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10In a concentration cell, corrosion occurs at the part of the metal exposed to:
A.The lower concentration of the electrolyte/oxygen
B.The air-water interface only
C.Direct sunlight
D.The higher concentration of the electrolyte/oxygen
Correct Answer: The lower concentration of the electrolyte/oxygen
Explanation:
In a concentration cell, the area exposed to the lower concentration of metal ions or oxygen acts as the anode and undergoes corrosion.
Correct Answer: Less oxygenated parts act as anodes
Explanation:
According to the principle of differential aeration, the part of the metal which is less aerated (less oxygen) becomes anodic and corrodes, while the more aerated part becomes cathodic.
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12A metal rod is half-immersed in water. Where is the corrosion most likely to occur?
A.In the portion exposed to air
B.At the bottom of the rod
C.Just above the water line
D.Just below the water line
Correct Answer: Just below the water line
Explanation:
This is water-line corrosion. The area just below the meniscus is less aerated compared to the area at the meniscus (water-line), making it anodic and susceptible to corrosion.
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13Which type of corrosion is characterized by the formation of deep, localized holes or cavities?
A.Intergranular corrosion
B.Galvanic corrosion
C.Pitting corrosion
D.Uniform corrosion
Correct Answer: Pitting corrosion
Explanation:
Pitting corrosion is a localized form of corrosion that leads to the creation of small holes or pits in the metal.
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14Why is pitting corrosion considered more dangerous than uniform corrosion?
A.It causes sudden structural failure with little weight loss
B.It is easily detectable
C.It only occurs in noble metals
D.It consumes more metal mass
Correct Answer: It causes sudden structural failure with little weight loss
Explanation:
Pitting is insidious; it causes intense localized damage that can penetrate a pipe or vessel wall while the total metal loss is small and often difficult to detect visually.
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15Intergranular corrosion typically occurs at:
A.Random locations
B.The grain boundaries
C.The surface of the metal only
D.The center of the grains
Correct Answer: The grain boundaries
Explanation:
Intergranular corrosion is a localized attack along the grain boundaries of a metal or alloy, often due to precipitation of impurities or specific phases (like chromium carbide in stainless steel).
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16Weld decay in stainless steel is a specific form of:
A.Intergranular corrosion
B.Stress corrosion
C.Pitting corrosion
D.Erosion corrosion
Correct Answer: Intergranular corrosion
Explanation:
Weld decay occurs in the heat-affected zone of welds in stainless steel due to the precipitation of chromium carbide at grain boundaries, which depletes chromium and facilitates intergranular corrosion.
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17Soil corrosion is primarily influenced by which property of the soil?
A.The altitude of the ground
B.Color of the soil
C.pH and moisture content
D.Presence of macroscopic rocks
Correct Answer: pH and moisture content
Explanation:
Soil corrosion depends heavily on soil resistivity, which is dictated by moisture, pH, dissolved salts, and aeration of the soil.
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18Which factor regarding the nature of the metal tends to increase the rate of corrosion?
A.High purity of the metal
B.Formation of a non-porous oxide film
C.Presence of impurities with higher electrode potential
D.Passive character of the metal
Correct Answer: Presence of impurities with higher electrode potential
Explanation:
Impurities that act as cathodes (higher potential) relative to the base metal create microscopic galvanic cells, thereby increasing the rate of corrosion of the anodic base metal.
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19What happens when the anodic area is much smaller than the cathodic area?
A.Corrosion stops completely
B.The cathode begins to corrode
C.Corrosion is rapid and intense at the anode
D.Corrosion is slow and uniform
Correct Answer: Corrosion is rapid and intense at the anode
Explanation:
A small anode/large cathode ratio results in a high current density at the anode, leading to rapid, severe, and localized corrosion (e.g., pitting).
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20How does an increase in temperature generally affect the rate of corrosion?
A.No effect
B.Stops corrosion
C.Increases the rate
D.Decreases the rate
Correct Answer: Increases the rate
Explanation:
Higher temperatures generally increase the rate of chemical reactions and diffusion, thereby increasing the rate of corrosion.
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21If the corrosion product (oxide layer) is volatile (e.g., ), the corrosion:
A.Stops immediately
B.Slows down significantly
C.Becomes continuous and rapid
D.Is unaffected
Correct Answer: Becomes continuous and rapid
Explanation:
If the oxide layer is volatile, it evaporates as soon as it forms, leaving fresh metal surface exposed for further attack, resulting in continuous and rapid corrosion.
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22Passivity refers to the phenomenon where a metal:
A.Corrodes very quickly
B.Dissolves completely in water
C.Exhibits much higher corrosion resistance than expected due to a thin protective film
D.Becomes magnetic
Correct Answer: Exhibits much higher corrosion resistance than expected due to a thin protective film
Explanation:
Passivity is the loss of chemical reactivity exhibited by certain metals (like Al, Cr, Ti) due to the formation of a highly protective, thin, and invisible surface film.
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23Which of the following is an example of cathodic protection?
A.Ceramic coating
B.Anodizing
C.Sacrificial anodic protection
D.Phosphating
Correct Answer: Sacrificial anodic protection
Explanation:
Sacrificial anodic protection involves connecting the metal to be protected to a more active metal (sacrificial anode), which corrodes instead of the protected metal.
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24In sacrificial anodic protection of an underground iron pipeline, which metal is commonly used as the anode?
A.Magnesium or Zinc
B.Silver
C.Gold
D.Copper
Correct Answer: Magnesium or Zinc
Explanation:
Magnesium and Zinc are more anodic (active) than iron in the electrochemical series, so they are used as sacrificial anodes.
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25The method of Impressed Current Cathodic Protection involves:
A.Connecting the structure to the negative terminal of an external DC source
B.Coating the metal with paint
C.Heating the metal to high temperatures
D.Connecting the structure to the positive terminal of an external DC source
Correct Answer: Connecting the structure to the negative terminal of an external DC source
Explanation:
In impressed current protection, an external DC current is applied to force the metal structure to become the cathode (negative), preventing it from losing electrons.
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26Anodic inhibitors work by:
A.Retarding the anodic reaction by forming a precipitate on the anode
B.Increasing the hydrogen overvoltage
C.Eliminating oxygen from the medium
D.Reducing the pH of the solution
Correct Answer: Retarding the anodic reaction by forming a precipitate on the anode
Explanation:
Anodic inhibitors (e.g., chromates, phosphates) react with ions at the anode to form insoluble precipitates that block the anodic sites.
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27Which of the following is a Ceramic coating?
A.Galvanizing
B.Enameling
C.Tinning
D.Cladding
Correct Answer: Enameling
Explanation:
Enamels are ceramic coatings (glass-like) applied to metals and fused at high temperatures to provide heat and corrosion resistance.
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28The primary advantage of ceramic coatings is their ability to withstand:
A.Mechanical bending
B.High electrical conductivity
C.High ductility
D.High temperatures
Correct Answer: High temperatures
Explanation:
Ceramic coatings are chemically inert and refractory, making them excellent for protecting metals at high temperatures where organic coatings would fail.
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29Electroplating is the process of:
A.Spraying metal powder
B.Dipping metal into molten zinc
C.Melting two metals together
D.Depositing a layer of metal on an object using electric current
Correct Answer: Depositing a layer of metal on an object using electric current
Explanation:
Electroplating uses electrolysis to deposit a thin, protective layer of a superior metal onto a base metal.
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30In the electroplating process, the article to be plated is made the:
A.Salt bridge
B.Electrolyte
C.Cathode
D.Anode
Correct Answer: Cathode
Explanation:
The object to be coated receives metal ions (reduction), so it must be the cathode (negative electrode).
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31The electrolyte used in electroplating must contain:
A.Ions of the coating metal
B.No ions
C.Ions of the base metal
D.Only distilled water
Correct Answer: Ions of the coating metal
Explanation:
The electrolyte must contain a soluble salt of the metal that is to be deposited (the coating metal).
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32What is Galvanization?
A.Coating Iron with Copper
B.Coating Iron with Zinc
C.Coating Iron with Tin
D.Coating Iron with Aluminum
Correct Answer: Coating Iron with Zinc
Explanation:
Galvanization is the specific process of applying a protective zinc coating to steel or iron.
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33What is Tinning?
A.Coating Copper with Iron
B.Coating Iron with Tin
C.Coating Aluminum with Nickel
D.Coating Iron with Zinc
Correct Answer: Coating Iron with Tin
Explanation:
Tinning is the process of coating a base metal (usually iron or steel) with a layer of tin, often used for food containers.
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34Why is Tinning preferred for food containers over Galvanizing?
A.Zinc dissolves in food instantly
B.Zinc salts are toxic, while Tin is non-toxic
C.Tin is cheaper than Zinc
D.Tin is harder than Zinc
Correct Answer: Zinc salts are toxic, while Tin is non-toxic
Explanation:
Zinc compounds are toxic, making galvanized ware unsuitable for food storage. Tin is non-toxic and resists organic acids in food.
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35In a tinned iron container, if the coating is scratched, the iron corrodes rapidly because:
A.Iron is anodic to Tin
B.Iron becomes passive
C.Tin acts as a catalyst
D.Tin is anodic to Iron
Correct Answer: Iron is anodic to Tin
Explanation:
Tin is cathodic (more noble) relative to iron. If the coating breaks, a large cathode (Tin) and small anode (exposed Iron) form, causing rapid pitting of the iron.
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36Caustic embrittlement is a type of corrosion primarily found in:
A.Underground pipes
B.High-pressure boilers
C.Concrete structures
D.Car engines
Correct Answer: High-pressure boilers
Explanation:
Caustic embrittlement is a form of stress corrosion cracking occurring in steel boilers due to the presence of highly alkaline water (NaOH) at points of stress.
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37The phenomenon where a metal cracks under the combined action of tensile stress and a corrosive environment is called:
A.Stress corrosion cracking
B.Erosion corrosion
C.Pitting
D.Fatigue corrosion
Correct Answer: Stress corrosion cracking
Explanation:
Stress corrosion cracking (SCC) is the failure of metals due to the simultaneous presence of a corrosive medium and tensile stress.
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38Season cracking of brass is caused by:
A.Exposure to Oxygen
B.Exposure to Ammonia
C.Exposure to Chlorine
D.Exposure to Water
Correct Answer: Exposure to Ammonia
Explanation:
Season cracking is a specific form of stress corrosion cracking in brass primarily caused by exposure to traces of ammonia.
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39Which of the following creates a crevice corrosion site?
A.A hanging wire
B.The gap between a bolt and a nut
C.A flat metal sheet
D.A smooth, polished surface
Correct Answer: The gap between a bolt and a nut
Explanation:
Crevice corrosion occurs in confined spaces (crevices) where the stagnant solution allows for differential aeration or concentration cells to form, such as under gaskets, bolt heads, or lap joints.
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40To prevent galvanic corrosion in a design using dissimilar metals, one should:
A.Increase the conductivity of the medium
B.Use an insulating washer between the metals
C.Make the anode area very small
D.Use metals far apart in the galvanic series
Correct Answer: Use an insulating washer between the metals
Explanation:
Insulating the two metals electrically prevents the flow of electrons between them, thereby breaking the galvanic circuit.
Sulphate-reducing bacteria (SRB) operate in anaerobic conditions, reducing sulphates to sulphides and depolarizing the cathode, accelerating corrosion.
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42Corrosion fatigue is the failure of metal due to:
A.Cyclic/Alternating stress and corrosion
B.High pressure and corrosion
C.High temperature and corrosion
D.Static stress and corrosion
Correct Answer: Cyclic/Alternating stress and corrosion
Explanation:
Corrosion fatigue is caused by the combined action of alternating (cyclic) stresses and a corrosive environment.
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43Which cleaning process typically precedes electroplating to remove grease and oil?
A.Polishing
B.Annealing
C.Solvent cleaning or degreasing
D.Pickling
Correct Answer: Solvent cleaning or degreasing
Explanation:
Solvent cleaning is used to remove organic contaminants like oil and grease before the metal undergoes pickling (acid treatment) and plating.
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44What is the function of Pickling in metal finishing?
A.To deposit the metal
B.To remove grease
C.To polish the surface
D.To remove oxide scales and rust
Correct Answer: To remove oxide scales and rust
Explanation:
Pickling involves dipping the metal in acid (like ) to remove surface oxide scales and rust to ensure good adhesion of the coating.
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45In the context of the Pilling-Bedworth rule, if the ratio is significantly greater than 2, what happens?
A.The metal becomes harder
B.The coating becomes transparent
C.The coating buckles and flakes off
D.The coating is perfect
Correct Answer: The coating buckles and flakes off
Explanation:
If the oxide volume is much larger than the metal volume (high PB ratio), massive internal compressive stresses develop, causing the coating to buckle and flake off (e.g., Tungsten).
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46Which metal is typically used as a coating in anodizing?
A.Aluminum
B.Copper
C.Iron
D.Silver
Correct Answer: Aluminum
Explanation:
Anodizing is an electrolytic passivation process used to increase the thickness of the natural oxide layer on the surface of metal parts, most commonly Aluminum.
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47The tendency of a metal to undergo corrosion can be predicted by:
A.The periodic table group
B.The melting point
C.The Electrochemical (EMF) Series
D.The density of the metal
Correct Answer: The Electrochemical (EMF) Series
Explanation:
The EMF series arranges metals by their standard electrode potentials. Metals high in the series (more negative potential) are more anodic and prone to corrosion.
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48In Water-line corrosion, the cathodic reaction occurs at:
A.Deep in the water (low oxygen)
B.The water meniscus (high oxygen)
C.The center of the rod
D.The metal bottom
Correct Answer: The water meniscus (high oxygen)
Explanation:
The area at the water line (meniscus) has high oxygen concentration and acts as the cathode ( absorption), driving the corrosion at the anodic area just below it.
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49Which of the following represents a proper design to minimize corrosion?
A.Using dissimilar metals in direct contact
B.Providing crevices for water retention
C.Providing drainage for liquids
D.Designing with sharp corners
Correct Answer: Providing drainage for liquids
Explanation:
Proper design involves avoiding traps for water/moisture. Providing drainage ensures electrolytes do not accumulate and cause corrosion.
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50During Differential Aeration Corrosion, the electron flow in the metal is from:
A.No electron flow occurs
B.Aerated part to non-aerated part
C.Non-aerated part (Anode) to Aerated part (Cathode)
D.Solution to metal
Correct Answer: Non-aerated part (Anode) to Aerated part (Cathode)
Explanation:
Electrons flow from the site of oxidation (Anode/Non-aerated part) through the metal to the site of reduction (Cathode/Aerated part).