A

Project Report
On

Effects of Coolants on the Welding Zone of Galvanized Iron Rods In

Corrosive Media
Submitted in the partial fulfilment of the
Requirements for the award of the degree
Of

BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING

AKTU
PROJECT GUIDE: SUBMITTED BY:
Mr. OSAMA LARI MOHIT(1212740121)
(Astt.Professor ME) MULAYAM SINGH YADAV(1212740124)
PANKAJ PRAJAPATI(1212740138)
PRASHANT RANJAN (1212740148)
RAHUL KUMAR (1212740157)

DEPARTMENT OF MECHANICAL ENGINEERING

IIMT ENGINEERING COLLEGE
(Affiliated to AKTU, Lucknow)
MAY, 2016
 Department of MECHANICAL ENGINEERING
IIMT Engineering College

CERTIFICATE

This is to certify that project entitled “Effects of Coolants on the Welding

Zone of Galvanized Iron Rods In Corrosive Media” which is submitted by
(Mohit, Mulayam Singh Yadav, Pankaj Prajapati, Prashant Ranjan and Rahul
Kumar) in partial fulfillment of the requirements for the degree of Bachelor of
Technology in Mechanical Engineering of the APJ Abdul Kalam Technical
University, Lucknow, during the academic year 2015-2016, is a bonafide record
of work carried out under our guidance and supervision. The results embodied
in this report have not been submitted to any other university or institution for
the award of any degree and diploma.

Mr. Osama Lari

(Asst. Proffessor)

(ME Dept)

ii
 ACKNOWLEDGEMENT

It gives us immense pleasure to express our deepest sense of gratitude and

sincere thanks to our highly respected and esteemed guide Mr. Osama
Lari(Astt.Professor in Mechanical Engineering department) for his valuable
guidance, encouragement and help for completing this work. His useful
suggestions for this whole work and co-operative behaviour are sincerely
acknowledged.

We would like to express our sincere thanks to our Head of Department Mr.
Hari Om Sharma for giving us this opportunity to undertake this project. We
are also grateful to our respected faculties of our ME department for their
constant support and guidance.

We also wish to express our indebtedness to our parents as well as our family
members whose blessing and support always helped us to face the challenges
ahead.

MOHIT (1212740121)

MULAYAM SINGH YADAV (1212740124)

PANKAJ PRAJAPATI (1212740138)

PRASHANT RANJAN (1212740148)

RAHUL KUMAR (1212740157)

iii
 DECLARATION

We hereby declare that this submission of work is best of our knowledge and
belief, it contains no material previously published or written by another person
nor material which is to a substantial extent has been accepted for the award of
any other degree or diploma of the university or other institute of higher
learning, except where due acknowledgement has been made in the text.

Date:

MOHIT (1212740121)

MULAYAM SINGH YADAV (1212740124)

PANKAJ PRAJAPATI (1212740138)

PRASHANT RANJAN (1212740148)

RAHUL KUMAR (1212740157)

iv
 CONTENTS

Certificate…………………………………………………….(ii)
Acknowledgement…………………………………………...(iii)
Declaration…………………………………………………..(iv)
Contents……………………………………………………....(v)
Abstract……………………………………………………..(vii)
List of Tables …………………………………………...…(viii)
List of Figures ……………..………………………….….…(ix)
Chapter 1.
1.1 Introduction………......……………………...…10
1.2 Corrosion………………………..………....……11
1.3 Coolants…………………………………........…12
1.3.1 Distilled water………………………...…12
1.3.2 Anti freezer………………………......…..13
1.3.3 Tap water………………………..…....….13
1.3.4 Brine……………………….....…....……15
1.3.5 Deionized water………………….……..16
1.3.6 Palm oil……………………....…………17
1.3.7 Coconut oil…………………….......……18
1.4 Corrosive Media……………………….........…..19
1.4.1 Water…………………….........…………20
1.4.2 Hydrochloric acid……………....………..21
1.4.3 Sulphuric acid…………………......……..22

v
 1.4.4 Nitric acid……………………......………23
1.4.5 Citric acid …………………...………….24
Chapter 2.
2.1 Material……….....……………….....…………..26
Chapter 3.
3.1 Experimental Planning……………………....……34
Chapter 4.
4.1 Result and Discussions……………………......…..36
Chapter 5. Conclusion……………………………........……...50
Chapter 6. Bibliography……………………………......……..51

vi
 ABSTRACT

The study on corrosion rate of welded Galvanized Iron rods in four

corrosive media (water, Hydrochloric acid(HCL), Sulphuric
acid(H2SO4) and Ammonia.) with the effect of local coolants
(Distilled water with anti-freezer, Tap water, Brine, De-ionised water,
palm oil and coconut oil) on the weldments has been studied. The
results showed the trend of corrosion rates of Galvanized Iron in
weldments in water, HCL, H2SO4 , Nitric acid and Citric acid.

vii
 LIST OF TABLES

Table1.1: Water salinity chart

Table2.1: Thickness of the outer zinc coating, of the alloy layer,and of
the total coating on galvanized specimens
Table4.1: Weight loss of specimens immersed in water in respect with
time
Table4.2: Corrosion rates of specimens immersed in water in respect
with time
Table 4.3: Weight loss of specimens immersed in HCL in respect with
time
Table 4.4: Corrosion rates of specimens immersed in HCL in respect
with time
Table 4.5: Weight loss of specimens immersed in Sulphuric acid in
respect with time
Table 4.6: Corrosion rates of specimens immersed in Sulphuric acid
in respect with time
Table 4.7: Weight loss of specimens immersed in Nitric acid in
respect with time
Table 4.8: Corrosion rates of specimens immersed in Nitric acid in
respect with time
Table 4.9: Weight loss of specimens immersed in Citric acid in
respect with time
Table 4.10: Corrosion rates of specimens immersed in Citric acid in
respect with time

viii
 LIST OF FIGURES

Figure 1.1 Distilled Water

Figure 1.2 : Tap water
Figure 1.3: Water- NaCl phase diagram
Figure1.4: Palm oil
Figure1.5: Coconut oil
Figure1.6: Corrosive media
Figure1.7: Water
Figure1.8: HCl
Figure1.9: Sulphuric acid
Figure1.10: Nitric acid
Figure1.11: Citric acid
Figure2.1: GI Rod
Figure2.2: welding of GI Rod
Figure2.3: GMA Welding
Fig3.1: 150mm galvanized iron rod
Fig 3.2: Welding Specimen.
Fig 4.1: Variations of weight loss of specimens immersed in table
water
Fig 4.3: Corrosion rates of specimens immersed in table water
Figure 4.4: Weight loss of specimens immersed in HCL in respect
with time
Fig 4.5: Corrosion rates of specimens immersed in HCL in respect
with time
Fig 4.6: Weight loss of specimens immersed in Sulphuric acid in
respect with time
Fig 4.7: Corrosion rates of specimens immersed in Sulphuric acid in
respect with time
Fig 4.8: Weight loss of specimens immersed in Nitric acid in respect
with time
Fig 4.9: Corrosion rates of specimens immersed in Nitric acid in
respect with time
Fig 4.11: Weight loss of specimens immersed in Citric acid in respect
with time
Fig 4.12: Corrosion rates of specimens immersed in Citric acid in
respect with time

ix
 Chapter 1

1.1 INTRODUCTION

The study on corrosion rate of welded Galvanized Iron rods in four

corrosive media (water, Hydrochloric acid(HCL), Sulphuric
acid(H2SO4), Nitric acid(HNO3) and Citric acid(C6H8O7)) with the
effect of local coolants (Distilled water with anti-freezer, Tap water,
Brine, De-ionised water, palm oil and coconut oil) on the weldments
has been studied. The results showed the trend of corrosion rates of
Galvanized Iron in weldments in water, HCL, H2SO4 , HNO3 and
C6H8O7.

Though, weight loss of specimens was constant in the corrosive

media, this was due to the fact that weight loss increases with increase
in immersion time, and corrosion rate does not follow the same trend
due to concentration of stagnant ions blocking the creation of more
ions and thus reducing Fe2+ activities in the media.

Galvanisation is the process of applying a protective zinc coating

to steel or iron, to prevent rusting. The most common method is hot-
dip galvanizing, in which parts are submerged in a bath of molten
zinc. Galvanizing protects in two ways:
• It forms a coating of corrosion-resistant zinc which prevents
corrosive substances from reaching the more delicate part of the
metal.
• The zinc serves as a sacrificial anode so that even if the coating
is scratched, the exposed steel will still be protected by the
remaining zinc.
• The zinc protects its base metal by corroding before iron, for
better results application of chromates over zinc is also seen as
an industrial trend.

10
1.2 Corrosion

Corrosion is a natural process, which converts a refined metal to a

more stable form, such as its oxide, hydroxide, or sulfide. It is the
gradual destruction of materials (usually metals) by chemical reaction
with their environment. Corrosion is the disintegration of an
engineered material into its constituent atoms due to chemical
reactions with its surroundings. These surroundings, such as water,
salt water, mud water, air etc. are corrosive media (Baroux, 1995).
Some forms of corrosion are: galvanic corrosion, crevice corrosion,
intergranular corrosion, pitting and crevice corrosion etc.

Galvanic corrosion is an electrochemical process in which

one metal corrodes preferentially to another when both metals are in
electrical contact, in the presence of an electrolyte. This same
galvanic reaction is exploited in primary batteries to generate an
electrical voltage. Galvanic corrosion occurs when two different
metals have physical or electrical contact with each other and are
immersed in a common electrolyte, or when the same metal is
exposed to electrolyte with different concentrations. In a galvanic
couple, the more active metal (the anode) corrodes at an accelerated
rate and the more noble metal (the cathode) corrodes at a slower rate.
When immersed separately, each metal corrodes at its own rate. What
type of metal(s) to use is readily determined by following the galvanic
series. For example, zinc is often used as a sacrificial anode for steel
structures. Galvanic corrosion is of major interest to the marine
industry and also anywhere water (containing salts) contacts pipes or
metal structures.

11
1.3 COOLANTS
Coolant is a type of cutting fluid and also a lubricant designed
specifically for metal working and machining processes. A coolant is
a fluid which flows through or around a device to prevent the device
from overheating, transferring the heat produced by the device to
other devices that either use or dissipate it. An ideal coolant has
high thermal capacity, low viscosity, is low-cost, non-toxic,
chemically inert, and neither causes nor promotes corrosion of the
cooling system. Some applications also require the coolant to be an
electrical insulator.
While the term coolant is commonly used in automotive and HVAC
applications, in industrial processing, heattransferfluid is one
technical term more often used, in high temperature as well as low
temperature manufacturing applications. The term also covers cutting
fluids.
The coolant can either keep its phase and stay liquid or gaseous, or
can undergo a phase transition, with the latent heat adding to the
cooling efficiency. The latter, when used to achieve below-ambient
temperature, is more commonly known as refrigerant.
This project is emphasizing on using Distilled water with anti-freezer,
Tap water, Brine, De-ionised water, palm oil and coconut oil.

1.3.1 Distilled water

Distilled water is water that has had many of its impurities removed
through distillation. Distillation involves boiling the water and then
condensing the steam into a clean container.

Pure water, whether from a still, deioniser or reverse osmosis system,

is an excellent solvent and will dissolve carbon dioxide from the
atmosphere to form a very dilute solution of carbonic acid with a pH
below 7.

12
 Fig 1.1: Distilled water

1.3.2 Antifreeze

An antifreeze is an additive which lowers the freezing point of a

water-based liquid. An antifreeze mixture is used to achieve freezing-
point depression for cold environments and also achieves boiling-
point elevation ("anti-boil") to allow higher coolant temperature.
Freezing and boiling points are colligative properties of a solution,
which depend on the concentration of the dissolved substance.
Because water has good properties as a coolant, antifreeze is used
ininternal combustion engines and other heat transfer applications,
such as HVAC chillers and solar water heaters. The purpose of
antifreeze is to prevent a rigid enclosure from bursting due to
expansion when water freezes. Commercially, both the additive (pure
concentrate) and the mixture (diluted solution) are called antifreeze,
depending on the context. Careful selection of an antifreeze can
enable a wide temperature

1.3.3 Tap water

Tap water (running water, city water, municipal water, etc.) is

water supplied to a tap (valve). Its uses include drinking, washing,
cooking, and the flushing of toilets. Indoor tap water is distributed
through "indoor plumbing", which has existed since antiquity but was
13
available to very few people until the second half of the 19th century
when it began to propagate in what are now developed countries. Tap
water became common in many regions during the 20th century, and
is now lacking mainly among people in poverty, especially
in developing countries.

Tap water is often culturally assumed to be drinking water, especially

in developed countries. Usually it is potable, although water quality
problems are not rare. Household water purification methods such
aswater filters, boiling, or distillation can be used when tap water's
potability is doubted.

The application of technologies (such as water treatment plants)

involved in providing clean water to homes, businesses, and public
buildings is a major subfield of sanitary engineering. Calling a water
supply "tap water" distinguishes it from the other main types of fresh
water which may be available; these include water from rainwater-
collecting cisterns, water from village pumps or town pumps, or water
carried from streams, rivers, or lakes (whose potability may vary).

Figure 1.2 : Tap water

14
1.3.4 Brine

Brine is a solution of salt (usually sodium chloride) in water. In

different contexts, brine may refer to salt solutions ranging from about
3.5% (a typical concentration of seawater, or the lower end of
solutions used for brining foods) up to about 26% (a typical saturated
solution, depending on temperature). Other levels of concentration are
called in different names:

Water salinity based on dissolved salts

Fresh water Brackish water Saline water Brine

< 0.05% 0.05–3% 3–5% > 5%

Table1.1: Water salinity chart

It is held that 0 °F (−17.78 °C) was initially set as the zero point in

the Fahrenheit temperature scale, as it was the coldest temperature

that Daniel G. Fahrenheit could reliably reproduce by freezing brine.

15
 Figure 1.3: Water- NaCl phase diagram.

1.3.5 Deionized water

Deionized water (DI water, DIW or de-ionized water), often

confused with demineralized water / DM water, is water that has
had almost all of its mineral ions removed, such as cations like
sodium, calcium, iron, and copper, and anions such as chloride and
sulphate.

Distilled water has been the most common form of purified water,
but, in recent years, water is more frequently purified by other
processes including capacitive deionization, reverse osmosis, carbon
filtering, microfiltration, ultrafiltration, ultraviolet oxidation
or electrode ionization.

16
Combinations of a number of these processes have come into use to
produce water of such high purity that its trace contaminants are
measured in parts per billion (ppb) or parts per trillion (ppt). Purified
water has many uses, largely in the production of medications, in
science and engineering laboratories and industries, and is produced
in a range of purities. It can be produced on site for immediate use or
purchased in containers.

Purified water in colloquial English can also refer to water which has
been treated ("rendered potable") to neutralize, but not necessarily
remove contaminants considered harmful to humans or animals.

1.3.6 Palm oil

Palm oil (also known as dendê oil, from Portuguese) is an

edible vegetable oil derived from the mesocarp (reddish pulp) of the
fruit of the oil palms, primarily the African oil palm Elaeis
guineensis and to a lesser extent from the American oil palm Elaeis
oleifera and the maripa palm Attalea maripa.
Palm oil is naturally reddish in color because of a high beta-
carotene content. It is not to be confused with palm kernel oil derived
from the kernel of the same fruit, or coconut oil derived from the
kernel of the coconut palm (Cocos nucifera). The differences are in
color (raw palm kernel oil lacks carotenoids and is not red), and in
saturated fat content: Palm mesocarp oil is 41% saturated, while palm
kernel oil and coconut oil are 81% and 86% saturated respectively.
Along with coconut oil, palm oil is one of the few
highly saturated vegetable fats and is semi-solid at room temperature.
Like most plant-based products, palm oil contains very
little cholesterol.
17
Palm oil is a common cooking ingredient in the tropical belt
of Africa, Southeast Asia and parts of Brazil. Its use in the
commercial food industry in other parts of the world is widespread
because of its lower cost and the high oxidative stability (saturation)
of the refined product when used for frying.

Figure1.4: Palm oil

1.3.7 Coconut oil

Coconut oil, or copra oil, is an edible oil extracted from the kernel or
meat of mature coconuts harvested from the coconut palm (Cocos
nucifera). It has various applications. Because of its high saturated
fat content, it is slow to oxidize and, thus, resistant torancidification,
lasting up to six months at 24 °C (75 °F) without spoiling.

Numerous health authorities advise against regular consumption of

coconut oil due to its high levels of saturated fat (similar to that of
animal fat) having potential to increase risk of cardiovascular disease.

18
 Figure1.5: Coconut oil

1.4 CORROSIVE MEDIA

Metallic material constitutes a great and major part of the construction

material element in industries, agricultural equipment, oil and gas and
process and allied industries. In these industries, the metallic materials
as a result of interaction with its environment, losses its integrity over
a period of time such material cannot perform effectively.

A corrosive substance is one that will destroy and damage other

substances with which it comes into contact. It may attack a great
variety of materials, including metals and various organic compounds,
but people are mostly concerned with its effects on living tissue: it
causes chemical burns on contact.
19
In this project, five corrosive media water, Hydrochloric acid(HCL),
Sulphuric acid(H2SO4), Nitric acid(HNO3) and Citric acid(C6H8O7)
has been used and studied.

Figure1.6: Corrosive media

1.4.1 Water

Water: (chemical formula: H2O) is a transparent fluid which forms

the world’s streams, lakes, oceans and rain, and is the major
constituent of the fluids of organisms.As a chemical compound,
a water molecule contains one oxygen and two hydrogen atoms that
are connected by covalent bonds.

Water is a liquid at standard ambient temperature and pressure, but it

often co-exists on Earth with its solid state, ice;
and gaseous state, steam (water vapour). It also exists
as snow, fog, dew and cloud. Corrosion occurs in the presence of
water, water which has a constituent of oxygen and iron reacts with
oxygen to become rust. The involvement of water accounts for the
fact that rusting occurs much more rapidly in moist conditions as
compared with dry environments.

20
 Figure1.7: Water

1.4.2 Hydrochloric acid

Hydrochloric acid is a clear, colorless, highly pungent

solution of hydrogen chloride (HCI) in water. It is a highly corrosive,
strong mineral acid with many industrial uses. Hydrochloric acid is
found naturally in gastric acid. When it reacts with an organic base it
forms a hydro chloride salt.It was historically called acidum
salis, muriatic acid, and spirits of salt because it was produced
from rock salt and green vitriol(by Basilius Valentinus in the 15th
century) and later from the chemically similar common
salt and sulfuric acid (by Johann Rudolph Glauber in the 17th
century). Free hydrochloric acid was first formally described in the
16th century by Libavius. Later, it was used by chemists such
as Glauber, Priestley, and Davy in their scientific research.

21
With major production starting in the Industrial Revolution,
hydrochloric acid is used in the chemical industry as a chemical
reagent in the large-scale production of vinyl chloride for PVC
plastic, and MDI/TDI for polyurethane. It has numerous smaller-scale
applications, including household cleaning, production of gelatin and
other food additives, descaling, and leather processing. About 20
million tonnes of hydrochloric acid are produced worldwide annually.

Figure1.8: HCl

1.4.3 Sulphuric acid

Sulphuric acid (alternative spelling sulphuric acid) is a highly

corrosive strong mineral acid with the molecular formula
H2SO4 and molecular weight 98.079 g/mol. It is a pungent-ethereal,
colorless to slightly yellow viscous liquid that is soluble in water at all
concentrations . Sometimes, it is dyed dark brown during production
to alert people to its hazards. The historical name of this acid is oil of
vitriol. Sulfuric acid is a diprotic acid and shows different properties
depending upon its concentration. Its corrosiveness on other
materials, like metals, living tissues or even stones, can be mainly
ascribed to its strong acidic nature and, if concentrated, strong
dehydrating and oxidizing properties. Sulfuric acid at a

22
high concentration can cause very serious damage upon contact, since
not only does it cause chemical burns via hydrolysis, but
also secondary thermal burns through dehydration. It can lead
to permanent blindness if splashed onto eyes and irreversible damage
if swallowed. Accordingly, safety precautions should be strictly
observed when handling it. Moreover, it is hygroscopic, readily
absorbing water vapour from the air. In this experiment, Sulphuric
acid is used with a concentration level of 4.

Figure1.9: Sulphuric acid

1.4.4 Nitric acid

Nitric acid (HNO2), also known as aqua fortisand spiritof niter , is a
highly corrosive mineral acid. The pure compound is colorless, but
older samples tend to acquire a yellow cast due to decomposition
into oxides of nitrogen and water. Most commercially available nitric
acid has a concentration of 68% in water. When the solution contains
more than 86% HNO3, it is referred to as fumingnitricacid. Depending
on the amount of nitrogen dioxide present, fuming nitric acid is
further characterized as white fuming nitric acid or red fuming nitric
acid, at concentrations above 95%.Nitric acid is the primary reagent
used for nitration – the addition of a nitro group, typically to
an organic molecule. While some resulting nitro compounds are
23
shock- and thermally sensitive explosive, a few are stable enough to
be used in munitions and demolition, while others are still more stable
and used as pigments in inks and dyes. Nitric acid is also commonly
used as a strong oxidizing agent.

Figure1.10: Nitric acid

1.4.5 Citric acid

Citric acid is a weak organic tri-basics acid. It occurs naturally in

citrus fruits. In biochemistry, it is an intermediate in the citric acid
cycle, which occurs in the metabolism of all aerobic organisms .More
than a million tons of citric acid are manufactured every year. It is
used widely as an acidifier, as a flavoring, and as a chelating agent.

A citrate is a derivative of citric acid; that is, the salts, esters and the
polyatomic anion found in solution. An example of the former, a salt

24
is tri-sodium citrate; an ester is triethyal citrate. When part of a salt,
the formula of the citrate ion is written as C 6H5O73− or
C3H5O(COO)33−.

Citric acid exists in greater than trace amounts in a variety of fruits

and vegetables, most notably citrus fruits. Lemons and limes have
particularly high concentrations of the acid; it can constitute as much
as 8% of the dry weight of these fruits (about 47 g/L in the juices).
The concentrations of citric acid in citrus fruits range from
0.005 mol/L for oranges and grapefruits to 0.30 mol/L in lemons and
limes. Within species, these values vary depending on the cultivar and
the circumstances in which the fruit was grown.

Industrial-scale citric acid production first began in 1890 based on the

Italian citrus fruit industry, where the juice was treated with hydrated
lime (calcium hydroxide) to precipitate calcium citrate, which was
isolated and converted back to the acid using diluted sulfuric acid. In
1893, C. Wehmer discovered Penicillium mold could produce citric
acid from sugar. However, microbial production of citric acid did not
become industrially important until World War I disrupted Italian
citrus exports.

Figure1.11: Citric acid

25
 Chapter 2
2.1 MATERIAL
Galvanization, or galvanisation, (or galvanizing as it is most
commonly called in that industry), is the process of applying a
protective zinc coating to steel or iron, to prevent rusting. The most
common method is hot-dip galvanizing, in which parts are submerged
in a bath of molten zinc.

Zinc is a metal with a relatively low galvanic potential and a small

tendency to corrode. However, the corrosion rate is low in most
environments, since the surface of the coating is quickly covered with
corrosion products, which subsequently protect against further
corrosion. The zinc surface is generally covered with a protective
layer of corrosion products when it is submerged in a liquid.
However, liquids can be acidic or alkaline and can contain dissolved
or solid particles of aggressive substances. The temperature and flow
rate of the liquid are also of significance. All this means that the
protective layer can have a highly varying composition or may not
form at all. Electro-chemical corrosion, which plays a subordinate
role in air, is of greater significance in liquids. The extent of electro-
chemical corrosion depends on the electrical conductivity of the
liquid, which affects the protective influence of the zinc layer over
greater or smaller areas.The pH value of the liquid is of most
significance. The corrosion rate of zinc is normally low and stable in
the pH range of 5,5—12,5, at temperatures between 0 and 20 °C.
Corrosion outside this range is usually more rapid.The corrosion
sequence in water is very complex and is influenced heavily by very
small variations in the composition of the water.

The galvanized and bare steel specimens were 14-in. (35-cm) lengths
of pipe 1.5 in. (3.8 cm) in diameter cut from the same lots of
commercial materials. The nominal weight of the zinc coating on the

26
galvanized specimens was 3.08 oz/ft2.2 The impurities in the spelter
in percent were: Al, 0.008; Fe, 0.07; and Pb, 0.78. The steel, both
galvanized and bare, was AISI No. B1010, with the nominal
composition in percent as follows: C, 0.13 max; Mn, 0.30 to 0.60; P,
0.07 to 0.12; S, 0.06 max. The interior of the specimens was coated
with heavy grease, and the ends were closed in order to prevent
internal corrosion. The zinc specimens were plates having the
dimensions 12 in. (30.5 cm) by 2.3 in. (5.8 cm) by 0.15 in. (0.4 cm).
The impurities determined in the zinc in percent were: Fe, 0.009; Pb,
0.095; Cd, 0.0038.

Figure2.1: GI Rod

27
Distribution of the Coating on the Galvanized Specimens
The distribution of the coating on the galvanized specimens was
measured by a magnetic method. The measurements were made on
one 14-in. (35 cm) length of galvanized pipe selected at random from
the lot of specimens before burial, and on a 6-in. (15 cm) section cut
from a second specimen from the same lot.
A total of 389 measurements of thickness were made on the 14-in.
length of pipe (identified as specimen A), and 162 measurements
were made on the 6-in. section (identified as specimen B). These
curves indicate not only that the specimens differed widely in coating
thickness, but that the distribution of the coating on the individual
specimens was highly variable as well. The variation did not fall in
any particular pattern.

Thickness of the Outer Zinc Coating and of the Alloy Layer

The thickness of the outer zinc coating and of the alloy layer was
measured by modifications of the electrolytic stripping methods
described by Britton and by Anderson and Manuel.
The electrolytic cell consisted of a 4-oz (120-ml) plastic bottle from
which the bottom had been removed. The cathode was a strip of zinc
1.5 in.(38 mm) in width formed so as to fit tightly around the inner
periphery of the bottle. Contact with the coating was made by means
of a hole 0.19 in. (5 mm) in diameter in a No. 8 rubber stopper. A
larger hole bored partly through one end of the stopper permitted the
stopper to be placed over the mouth of the bottle. The electrolyte was
a solution containing 20 g of NaCl, 10 g of ZnSO4, and 100 g of
H2O. In operation, the bottle was inverted and the test piece placed in
contact with the hole in the stopper with sufficient pressure to prevent
leakage of the electrolyte.
By means of a 6-v storage battery shunted by a variable voltage
divider, an initial current of 25 mA was passed through the cell with
the test piece as the anode, the current being read on a recording

28
milliammeter. As the outer zinc coating was removed by electrolysis
and different phases of zinc-iron alloy and finally steel were exposed,
the changes in potential associated with each phase produced
corresponding changes in the recorded current. The minimum
thickness of the zinc layer is measured by the horizontal part of the
curve at point A. On exposure of an alloy layer locally, the counter
emf increases, and the current proportionally decreases until the zinc
is completely removed and a uniform layer of the first phase of the
alloy layer is exposed (point B). The current then remains unchanged
until a second phase of the alloy layer is exposed and so on through
the various phases until the underlying steel is completely exposed.
The minimum thickness of the alloy layer, including the intermediate
phases, is represented by the distance BC, and the maximum thickness
by the distance AD. The reported thicknesses were computed from the
areas under the curve. For the present investigation the thickness of
the zinc coating was taken as the maximum thickness, that is, to point
B, and the thickness of the alloy layer was taken as being represented
by the distance BD. The maximum thickness of the outer zinc coating
and of the alloy layer at several points on two specimens are recorded
in table 2.1. These data indicate that a large part of the zinc applied to
the steel pipe was converted to alloy layer.

TABLE2. 1. Thickness of the outer zinc coating, of the alloy layer,

and of the total coating on galvanized specimens
In mtls.

Specimen Zn layer Alloy Layer Total coating

A……… 1.8 2.3 4.1

A……… .9 2.4 4.3

A……….. 2.0 2.3 4.3

A……… 2.0 3.0 5.0

B………. 2.7 3.2 5.9

B………. 2.8 3.2 6.0

29
Welding of Galvanized Products

Welding of galvanized steel is done almost exactly the same way as

welding of the bare steel of the same composition; the same welding
processes, volts, amps, travel speed, etc. can be used with little
modification when the switch is made from uncoated steel to
galvanized steel -- unless the zinc coating is unusually
thick.Galvanized steels are welded easily and satisfactorily by all
commonly practised welding techniques. Closer control of welding
conditions than for uncoated steel is usually necessary but procedures
are simple and well established.

The difference between welding galvanized steel and welding

uncoated steel is a result of the low vaporization temperature of the
zinc coating. Zinc melts at about 900˚F and vaporizes at about
1650˚F. Since steel melts at approximately 2,750˚F and the welding
arc temperature is 15,000 to 20,000˚F, the zinc that is near the weld
does not stand a chance -- it's vaporized! By the time the weld pool
freezes, the zinc is gone. This has two immediate consequences:
• The vaporized zinc increases the volume of welding smoke and
fumes.
• The zinc at and near any welds is actually burned off by the heat of
the arc, removing the protective zinc coating.

GMA (gas metal arc) welding, also known as CO2 - or MIG/MAG

welding, is a versatile semi-automatic welding process which is
convenient and easy to use. It is particularly suited to the welding of
thinner materials.

30
Welding galvanized steel vaporizes the zinc near the arc (zinc boils
before steel melts). The zinc oxidises in the air to a fine white powder.
Prolonged breathing

of these fumes can cause side effects which lasts about 24 hours. As
with all welding proper ventilation and fume exhaust is of first
priority.

In the GMA welding of galvanized steel the presence of the zinc

coating has no effect on weld properties although some weld spatter is
produced as discussed below under ‘Appearance of GMA welds in
galvanized steel’. Arc stability is excellent and is not affected by the
galvanized coating.

Figure2.2: welding of GI Rod

31
The GMA welding process

The weld takes place in a protective gas shield. A small diameter

consumable wire electrode of 0.8mm to 1.6mm is fed automatically to
the weld torch. The high current density resulting from the small
diameter of the wire is in the region of 200 amperes per square
millimetre.

The constant voltage type power sources employed offer

instantaneous self adjustment of the arc so that the arc length remains
constant even when the operator varies the distance between the
electrode and the work piece – power sources are designed to increase
welding current as the arc length shortens and the wire burns off at a
higher rate to maintain the original arc length. When the arc is
lengthened, current is reduced and the wire is consumed at a lower
rate, again maintaining the original pre-set arc length.

Welding parameters provide for two different types of metal transfer

in GMA welding:
1. Spray transfer, in which globules of metal are detached
magnetically from the wire and propelled across the arc. This is the
high current/high voltage form of the process which is used in the flat
position on plate thick enough to prevent burn-through.
2. Short circuiting transfer sometimes known as ‘dip transfer’, in
which lower currents and voltages are used. The end of the wire dips
into the molten weld pool while a globule of metal is being
transferred. Short circuiting transfer occurs about 100 times per
second producing a characteristic buzzing sound. The process is used
for welding thin sheet and for positional welding of all thicknesses.

32
Figure2.3: GMA Welding

33
 Chapter 3
3.1 EXPERIMENTAL PLANNING

Materials and specimen procurement and preparation:

The 16mm diameter Galvanised iron rod procured was prepared into a
150mm length as shown in figure3.1 which are to be cut into 20
pieces by a hack saw.

16mm

150mm
Fig3.1: 150mm galvanized iron rod

0.5mm

40mm
40mm 40mm
40mm
110mm 110mm
110mm

Fig 3.2: Welding Specimen.

34
 Corroding media preparation: The corrosive media such as water,
Hydrochloric acid(HCL), Sulphuric acid(H2SO4), Nitric acid(HNO3)
and Citric acid(C6H8O7) will be got and procured from nearby
environment in equal volume of 75cl. The initial weight of the
prepared and locally welded and cooled specimen will be taken before
immersed completely into its corrosive media maintained at room
temperature.
Experimentation: After cooling of specimen will be performed (first
five specimen was cooled by Distilled water with anti-freezer, then
another five by Tap water, then another five by Brine, another five
specimens was cooled by De-ionised water, then another five by palm
oil and last five specimens was cooled by coconut oil), then placing
the specimens each in a corrosive media (one specimen cooled by
Distilled water with anti-freezer, Tap water, Brine, De-ionised water,
palm oil and coconut oil is placed in each corrosive medium) prior to
that the initial weights has been taken and hence complete immersion
of the specimen in its corrosive solutions. Weighing has done every
120hours for 720hours. At every 120hours interval, the specimens
will be removed from the solution and descaled with an emery paper
and cleaned and then returned back to its solution, after the weight
loss has been taken. Specimens from the water will be washed
thoroughly under running tap and dried, then reweighed. This helped
to remove all deposits from the rod and allow freshly new surface for
corrosion. Each specimen should be subsequently weighed on a
sensitive weighing balance to determine its weight loss. The corrosion
rate given will be used to determine its corrosion rate using the
formula written by (Krishner, 2011).
CR (mm/yr.) = 876w ……. (Equation 1)
pAt
CR is corrosion rate in mm/yr.
w is weight loss, g
p is density of specimen g/cm3
A is total surface area, cm2
t is time of immersion in corrosive medium, hr

35
 Chapter 4
4.1 RESULT AND DISCUSSIONS

The effect of local coolants used (Distilled water with anti-freezer,

Tap water, Brine, De-ionised water, palm oil and coconut oil.) in the
different welded galvanised iron rods which were immersed in five
corrosive media (water, Hydrochloric acid(HCL), Sulphuric
acid(H2SO4), Nitric acid(HNO3) and Citric acid(C6H8O7)) has been
studied.

Table 4.1 showed the actual weight loss of specimens immersed in

water. Weight loss of specimen cooled by brine was the highest
(3.49g), followed by tap water (3.00g), then De ionized water,
coconut oil, distilled water with antifreeze and specimen cooled by
palm oil (1.35g). However, the graphical representations of these
variations are shown below in figure 4.1 as the graph of weight loss
was plotted against exposure time immersed in its corrosive media.

Table 4.1: Weight loss of specimens immersed in water in respect with time

Coolants Weight Loss(g)

used/Time
0hours 120hours 240 360 480 hours 600 720
Taken
hours hours hours hours
Distilled water 0 1.30 1.42 1.49 1.50 1.50 1.50
+antifreeze
Tap water 0 2.30 2.90 3.40 3.40 3.40 3.40

Brine 0 3.10 3.27 3.45 3.49 3.49 3.49

De ionised 0 1.70 1.91 1.97 2.10 2.15 2.15

water
Palm oil 0 0.90 0.90 1.20 1.35 1.35 1.35

Coconut oil 0 0.47 0.98 1.47 1.73 1.90 1.90

36
37
 Fig 4.1: Variations of weight loss of specimens
immersed in table water
4

3.5

Distilled water +antifreeze

2.5
Weight loss (g)

Tap water

2 Brine
De ionised water
1.5 Palm oil
Coconut oil
1

0.5

0
0 hrs 120 hrs 240 hrs 360 hrs 480 hrs 600 hrs 720 hrs

Figure4.2 corrosion in GI rod through water

37
Table 4.2 showed the corrosion rates in water and figure 4.3 showed the
corrosive rates against time in water. Corrosion rate of specimen cooled by
distilled water with antifreeze had the highest corrosive rate of 3.69mm/yr,
followed by brine at 3.25mm/yr till the last one specimen cooled by palm oil was
least in water at 0.44mm/yr.
Table 4.2: Corrosion rates of specimens immersed in water in respect with time

Coolants used/Time Corrosion rates(mm/yr)

Taken
120hours 240 hours 360 hours 480 hours 600 hours 720 hours
Distilled water 3.20 3.37 3.62 3.69 3.69 3.69
+antifreeze
Tap water 4.60 2.75 2.13 1.60 1.27 1.06

Brine 2.90 3.10 3.21 3.25 3.25 3.25

De ionised water 1.97 2.13 2.29 2.30 2.30 2.30

Palm oil 1.83 0.90 0.75 0.67 0.53 0.44

Coconut oil 0.90 0.90 0.90 0.80 0.72 0.60

Fig 4.3: Corrosion rates of specimens immersed

in table water
5

4.5

4
corrosion rates (mm/yr)

3.5
Distilled water +antifreeze
3 Tap water

2.5 Brine
De ionised water
2
Palm oil
1.5
Coconut oil
1

0.5

0
120 hrs 240 hrs 360 hrs 480 hrs 600 hrs 720 hrs

38
Table 4.3 givesthe weight difference of the specimens immersed in HCL.
Specimen cooled by Tap water has the highest weight loss of 3.91g, then
specimen cooled by brine (3.54g) followed by specimen cooled by palm oil
(2.63g) then specimen cooled by coconut oil to be 2.22g,
then specimen cooled by distilled water with antifreezer to be 1.92g, with de
ionized water cooled specimen having the least weight loss of 1.33g.
Figure 4.4 gave a variation of the specimens plotted by weight loss against time,
gotten from table 4.3.

Table 4.3: Weight loss of specimens immersed in HCL in respect with time

Coolants used/Time Weight Loss(g)

Taken
0hours 120hours 240 hours 360 hours 480 hours 600 hours 720 hours
Distilled water 0 1.52 1.67 1.83 1.92 1.92 1.92
+antifreeze
Tap water 0 3.20 3.45 3.91 3.91 3.91 3.91

Brine 0 3.21 3.49 3.52 3.54 3.54 3.54

De ionised water 0 1.25 1.27 1.32 1.33 1.33 1.33

Palm oil 0 2.45 2.52 2.57 2.63 2.63 2.63

Coconut oil 0 1.92 2.10 2.21 2.22 2.22 2.22

39
 Figure 4.4: Weight loss of specimens immersed in
HCL in respect with time

4.5

3.5
Distilled water +antifreeze
3
Weight Loss(g)

Tap water
2.5
Brine
2
De ionised water
1.5 Palm oil

1 Coconut oil

0.5

0
0 hrs 120 hrs 240 hrs 360 hrs 480 hrs 600 hrs 720 hrs

From table 4.4, specimen cooled by Distilled water with antifreezer was most
corroded in this HCL at 1.52 mm/yr followed by specimen cooled by coconut oil
at 4.02mm/yr, then palm oil and brine are almost equally gets corroded at the
required studied time(3.85mm/yr), then specimen cooled by Tap water at
2.78mm/yr, then de ionized water at 2.75mm/yr, distilled water with antifreeze
cooled was least corroded specimen at 1.52mm/yr, with its respective figure 4.5,
showing its graphical representation of corrosion rate of specimen immersed in
HCL.

40
Table 4.4: Corrosion rates of specimens immersed in HCL in respect with time

Coolants used/Time Corrosion rates(mm/yr)

Taken
120hours 240 hours 360 hours 480 hours 600 hours 720 hours
Distilled water 4.49 2.10 1.92 1.87 1.72 1.52
+antifreeze
Tap water 6.67 3.24 2.96 2.79 2.78 2.78

Brine 4.42 4.13 4.02 3.92 3.85 3.85

De ionised water 3.27 3.10 2.82 2.75 2.75 2.75

Palm oil 4.12 4.04 3.92 3.87 3.85 3.85

Coconut oil 4.52 4.42 4.36 4.23 4.04 4.02

Fig 4.5: Corrosion rates of specimens immersed

in HCL in respect with time
8

6
corrosion rates (mm/yr)

Distilled water +antifreeze

5
Tap water

4 Brine
De ionised water
3
Palm oil

2 Coconut oil

0
120 hrs 240 hrs 360 hrs 480 hrs 600 hrs 720 hrs

41
Table 4.5 gives the data of weight loss as weight loss by bine is highest as
compared with all other coolants (3.74g) and by tap water is lowest (2.98).
Figure 4.6 shows the graph between weight loss of specimen when dipped in
respective coolants with sulphuric acid.
Table 4.5: Weight loss of specimens immersed in Sulphuric acid in respect with time

Coolants used/Time Weight Loss(g)

Taken
0hours 120hours 240 hours 360 hours 480 hours 600 hours 720 hours
Distilled water 0 1.85 1.93 2.15 2.37 3.40 3.40
+antifreeze
Tap water 0 2.30 2.47 2.68 2.82 2.95 2.98

Brine 0 3.13 3.42 3.59 3.68 3.73 3.74

De ionised water 0 3.40 3.47 3.53 3.58 3.60 3.60

Palm oil 0 2.87 2.98 3.15 3.29 3.30 3.30

Coconut oil 0 3.10 3.29 3.30 3.42 3.45 3.45

Fig 4.6: Weight loss of specimens immersed in

Sulphuric acid in respect with time
4

3.5

Distilled water +antifreeze

2.5
Weight loss (g)

Tap water

2 Brine
De ionised water
1.5 Palm oil
Coconut oil
1

0.5

0
0 hrs 120 hrs 240 hrs 360 hrs 480 hrs 600 hrs 720 hrs

42
Table 4.6: Corrosion rates of specimens immersed in Sulphuric acid in respect with time

Coolants used/Time Corrosion rates(mm/yr)

Taken
120hours 240 hours 360 hours 480 hours 600 hours 720 hours
Distilled water 4.32 4.10 3.96 3.82 3.75 3.74
+antifreeze
Tap water 3.20 3.12 2.98 2.82 2.73 2.70

Brine 4.52 4.41 4.25 4.16 4.05 4.02

De ionised water 4.93 4.81 4.75 4.63 4.60 4.59

Palm oil 3.82 3.76 3.77 3.63 3.55 3.54

Coconut oil 3.76 3.62 3.55 3.43 3.42 3.42

Fig 4.7: Corrosion rates of specimens immersed in

Sulphuric acid in respect with time
6

5
corrosion rates (mm/yr)

4 Distilled water +antifreeze

Tap water

3 Brine
De ionised water

2 Palm oil
Coconut oil

0
120 hrs 240 hrs 360 hrs 480 hrs 600 hrs 720 hrs

43
From table 4.6, specimen cooled by de ionised water was most corroded in
Sulophuric acid at 4.59mm/yr followed by specimen cooled by Brine at
4.02mm/yr. then specimen cooled by Distilled water with antifreeze at
3.74mm/yr, Palm oil at 3.54mm/yr, coconut oil 3.42mm/yr, Tap water cooled
with least corrosion specimen at 2.70mm/yr, with respective figure 4.7, showing
its graphical representation of corrosion rate of specimen immersed in Sulphuric
acid.

Table 4.7: Weight loss of specimens immersed in Nitric acid in respect with time

Coolants used/Time Weight Loss(g)

Taken
0hours 120hours 240 hours 360 hours 480 hours 600 hours 720 hours
Distilled water 0 1.57 1.63 1.72 1.81 1.85 1.87
+antifreeze
Tap water 0 1.62 1.69 1.77 1.83 1.85 1.85

Brine 0 2.10 2.23 2.39 2.46 2.53 2.55

De ionised water 0 2.13 3.27 3.47 3.55 3.62 3.62

Palm oil 0 4.13 4.21 4.29 4.32 4.37 4.37

4.37 0 2.92 3.12 3.31 3.39 3.42 3.43

Table 4.7 gives the weight difference of the specimens immersed in Nitric acid.
Specimen cooled by palm oil has the highest weight loss of 4.37g, then
specimen cooled by ground nut oil (4.00g) followed by specimen cooled by de
ionized water (3.62g) then specimen cooled by coconut oil to be 3.43g, then by
Brine with 2.55g, then distilled water with anti freeze 1.87, with Tap water
cooled specimen having the least weight loss of 1.85g. Figure 4.8 gave a
variation of the specimens plotted by weight loss against time, gotten from table
8.

44
 Fig 4.8: Weight loss of specimens immersed in Nitric
acid in respect with time
5

4.5

3.5
Distilled water +antifreeze
Weight loss (g)

3 Tap water

2.5 Brine
De ionised water
2
Palm oil
1.5 Coconut oil

0.5

0
0 hrs 120 hrs 240 hrs 360 hrs 480 hrs 600 hrs 720 hrs

From table 4.8, specimen cooled by Brine was most corroded in this Nitric acid
at 3.83mm/yr followed by specimen cooled by Distilled water with anti freeze at
3.75mm/yr then specimen cooled by Coconut oil and tap water at 3.70mm/y,
then by de ionised water at 2.83mm/yr,palm oil cooled was least corroded
specimen at 2.78mm/yr, with its respective figure 4.9, showing its graphical
representation of corrosion rate of specimen immersed in Nitric acid.

45
Table 4.8: Corrosion rates of specimens immersed in Nitric acid in respect with time

Coolants used/Time Corrosion rates(mm/yr)

Taken
120hours 240 hours 360 hours 480 hours 600 hours 720 hours
Distilled water 4.13 4.05 3.91 3.83 3.79 3.75
+antifreeze
Tap water 3.19 3.05 2.82 2.76 2.71 2.70

Brine 4.52 4.35 4.10 3.91 3.85 3.83

De ionised water 3.16 3.10 2.92 2.87 2.85 2.83

Palm oil 2.96 2.92 2.85 2.81 2.78 2.78

Coconut oil 3.10 3.05 2.96 2.89 2.82 2.70

Fig 4.9: Corrosion rates of specimens immersed in

Nitric acid in respect with time
5

4.5

3.5
corrosion rates (mm/yr)

Distilled water +antifreeze

3
Tap water

2.5 Brine
De ionised water
2
Palm oil

1.5 Coconut oil

0.5

0
120 hrs 240 hrs 360 hrs 480 hrs 600 hrs 720 hrs

46
Table 4.9 gives the weight difference of the specimens immersed in Citric acid.
Specimen cooled by Brine has the highest weight loss of 4.60g, then specimen
cooled by Distilled water with anti freeze (4.45g) followed by specimen cooled
by Palm oil (4.42g) then specimen cooled by Tap water to be 4.39g, then by
coconut oil by 4.25g with De ionized water cooled specimen having the least
weight loss of 3.24g. Figure 4.11 gave a variation of the specimens plotted by
weight loss against time, gotten from table 4.9.
Table 4.9: Weight loss of specimens immersed in Citric acid in respect with time

Coolants used/Time Weight Loss(g)

Taken
0hours 120hours 240 hours 360 hours 480 hours 600 hours 720 hours
Distilled water 0 4.27 4.29 4.35 4.39 4.42 4.45
+antifreeze
Tap water 0 3.96 4.05 4.19 4.23 4.35 4.39

Brine 0 4.19 4.23 4.41 4.53 4.59 4.60

De ionised water 0 3.16 3.19 3.23 3.23 3.24 3.24

Palm oil 0 4.05 4.18 4.29 4.35 4.39 4.12

Coconut oil 0 3.92 3.98 4.12 4.19 4.23 4.25

Figure4.10: Corrosion through Citric acid

47
 Fig 4.11: Weight loss of specimens immersed in Citric
acid in respect with time
5

4.5

3.5
Distilled water +antifreeze
Weight loss (g)

3 Tap water

2.5 Brine
De ionised water
2
Palm oil
1.5 Coconut oil
1

0.5

0
0 hrs 120 hrs 240 hrs 360 hrs 480 hrs 600 hrs 720 hrs

From table 4.10, specimen cooled by Brine was most corroded in this Citric acid
at 3.85mm/yr followed by specimen cooled by De ionized water at 3.25mm/yr,
then by coconut oil at 3.13mm/yr then specimen cooled by Tap water at
3.07mm/y, then by distilled water with anti freeze by 2.87mm/yr, Palm oil
cooled was least corroded specimen at 2.63mm/yr, with its respective figure
4.12, showing its graphical representation of corrosion rate of specimen
immersed in Citric acid.

48
Table 4.10: Corrosion rates of specimens immersed in Citric acid in respect with time

Coolants used/Time Corrosion rates(mm/yr)

Taken
120hours 240 hours 360 hours 480 hours 600 hours 720 hours
Distilled water 3.12 3.10 3.09 2.95 2.92 2.87
+antifreeze
Tap water 3.19 3.17 3.16 3.11 3.08 3.07

Brine 4.29 4.17 4.11 4.02 3.93 3.85

De ionised water 4.17 3.85 3.60 3.42 3.29 3.25

Palm oil 3.19 3.02 2.95 2.82 2.73 2.63

Coconut oil 3.93 3.82 3.63 3.52 3.32 3.13

Fig 4.12: Corrosion rates of specimens immersed in

Citric acid in respect with time
5

4.5

3.5
corrosion rates (mm/yr)

Distilled water +antifreeze

3
Tap water

2.5 Brine
De ionised water
2
Palm oil
1.5 Coconut oil

0.5

0
120 hrs 240 hrs 360 hrs 480 hrs 600 hrs 720 hrs

49
 Chapter 5
CONCLUSION
This project work has been able to evaluate the trend of corrosion rates
of Galvanised iron rod weldments in five different corrosive media
namely water, hydrochloric acid, sulphuric acid, nitric acid and citric
acid.This report contains the results of measurementsof corrosion made
on specimens of galvanized iron rod.The galvanized specimens were
especiallyresistant to corrosion in alkaline soils that were
highlycorrosive to bare steel or other materials.Though weight loss
increases with increase in immersion time, corrosion rate does not
follow the same trend due to stagnant ions blocking the creation of more
ions and thus reducing Fe2+ activities in the solution. The high corrosion
resistanceshown by most of the galvanized specimens after theouter zinc
coating had been virtually removed bycorrosion is tentatively attributed
to a film or coating,probably silicious in nature, that was
depositedcathodically by galvanic action between the outerzinc coating
and the alloy layer or the underlyingsteel.The findings of this research
work showed that Brine water-quenched weldments (specimen cooled
by Brine water) have the fastest rate of corrosion in all the corrosive
media; while Tap water quenched weldments displayed the least
corrosion rates. Hence, Brine water- quenching in industries is not
recommended. Also, Tap water cooling of weldments cause downtime in
production as compared with other coolants; hence, Tap water cooling is
also not recommended. Coconut oil- quenched weldments is not
recommended for any usage at all because it has relatively higher
corrosion rates. Distilled water may be preferred more as compared with
Palm oil due to comparatively less corrosion rate. De ionized water
quenched weldments is recommended for uses due to lowest corrosion
rate.

50
 Chapter 6

BIBLIOGRAPHY

References:-
 Baroux, B (1995); Corrosion mechanism in theory and practices,
Marcel Dekker press.
 Callister, W.D., (1992) Materials science and Engineering, 4th ed.
John Wiley, New York.
 Holleman, A. F., Wiberg E. (2001) “Inorganic Chemistry”
Academic press, San Diego. ISBN 0-12-352651-5.
 S. C. Britton, J. Inst. Metals 58, 211 (1936).
 Stanley Anderson and R. W. Manuel, Trans. Electrochem.
o Soc. 78, 373 (1940).
 Wikipedia (https://www.wikipedia.org)
 Krishner, A.S., Technical Information Regarding Coupon Testing
in Metal Samples Corrosion Monitoring Systems, retrieved from
www.aispi.com/cpntst.html
 “Materials Science and Engineering: An Introduction” by William
D.Callister
 Hollenman and Wiberg, 2001.

51