Influence of the corrosion products of copper on its atmospheric corrosion kinetics in tropical...
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Corrosion Science 46 (2004) 1189–1200
Influence of the corrosion products ofcopper on its atmospheric corrosion
kinetics in tropical climate
Antonio R. Mendoza a,*, Francisco Corvo a,Ariel G�omez b, Jorge G�omez c
a Corrosion Department, National Centre for Scientific Research, Ave. 25 and 158,
P.O. Box 6412, Cubanacan, Playa, Havana, Cubab Faculty of Physics, University of Havana, San Lazaro and L, 10400, Havana, Cuba
c Oil Research Centre, Washington 169, 12000, Havana, Cuba
Received 23 April 2003; accepted 26 September 2003
Abstract
In the present paper, the identification of the corrosion product phases formed on copper
under different atmospheres of Cuban tropical climate is reported. Cuprite (Cu2O), parat-
acamite (Cu2Cl(OH)3), posnjakite (Cu4SO4(OH)6 Æ 2H2O) and brochantite (Cu4SO4(OH)6)
were the main phases identified by X-ray diffraction (XRD) analysis and Fourier transform
infrared spectroscopy (FTIR).
Copper corrosion products are known to have a protective effect against corrosion.
However, a different behaviour was obtained under sheltered coastal conditions. This can be
due to the corrosion products morphology and degree of crystallisation, rather than their
phase composition. A higher time of wetness and the accumulation of pollutants not washed
away from the metal surface can also play an important role.
� 2003 Elsevier Ltd. All rights reserved.
1. Introduction
Copper is a noble metal, being stable in a part of the stability region of water in
the Pourbaix diagrams [1]. Because of its high electrical conductivity and resistance
* Corresponding author. Present address: Department of Mechanical Engineering, University of
Waterloo, 200 University Avenue West, Waterloo, ON, Canada N2L 3G1.
E-mail address: [email protected] (A.R. Mendoza).
0010-938X/$ - see front matter � 2003 Elsevier Ltd. All rights reserved.
doi:10.1016/j.corsci.2003.09.014
1190 A.R. Mendoza et al. / Corrosion Science 46 (2004) 1189–1200
to the action of the atmosphere, it is widely used in the electrical and electronics
industries. However, the tendency to use smaller electronic components has in-
creased the corrosion risk even indoors where the levels of pollutants and moisture
are very low.
The atmospheric corrosion rate depends mainly on pollutants present in the at-
mosphere and on the time of wetness, i.e., the duration and frequency of wetting towhich metal surface are subjected [2,3], and rate at which dries. The composition,
hygroscopicity and degree of crystallisation of the corrosion products are also
functions of these parameters, and could play an important part on atmospheric
corrosion kinetics. Consequently, the phases present in the copper corrosion prod-
ucts depend on the atmosphere and exposure conditions, so that, their composition
[4] and morphology can be different indoors from outdoors. Most of the studies
about identification of copper corrosion products have been about those formed
outdoors and only a few of them have been focused on those formed indoors.Cuprite is generally the corrosion product first formed regardless of the exposure
conditions, so that it is always present on the copper surface [5–12]. Cuprite reacts
slowly with pollutants such as chloride ions, SO2 and CO2 to form basic copper salts,
provided the pH value of the surface moisture is sufficiently high [11]. In urban,
industrial and rural atmospheres, basic sulphates are the predominating compo-
nents, while in marine atmospheres are basic chlorides [11].
Other patina constituents have been reported, as particulate species, which can
accelerate copper corrosion, especially if they are not washed away from the surface(as when the metal are exposed to sheltered conditions) [11,13].
Hygroscopic corrosion products can diminish the critical relative humidity [6,14],
and influence the sorption of pollutants, so that corrosion is more probable to occur.
Once corrosion products are formed there is a decrease in the level of humidity at
which high rates of adsorption of SO2 may be observed [15]. They could also have a
catalytic effect in the oxidation of SO2, donating reactive species, such as sulphate
ions, which accelerate the corrosion [16,17].
For a long time, it has been claimed the protective action of copper patina withtime, as a result of the cuprite layer [8]. However, an increase in the copper corrosion
rate with time under sheltered coastal conditions was recently found [18]. Several
authors have reported the composition of copper corrosion products formed in
different atmospheres, but very few relate it with the corrosion kinetics. The aim of
this work is to find this relationship based on the results previously reported [18] and
the identification by XRD and FTIR of the corrosion products of copper exposed
to different atmospheres and exposure conditions in Cuban tropical climate.
2. Experimental method
Atmospheric corrosion tests were carried out at three different atmospheres (rural,urban-industrial and coastal), under different exposure conditions (outdoors, shel-
tered and ventilated shed). A detailed description of the test sites and exposure
conditions is given in a previous publication [19]. The average chloride and sulphur
A.R. Mendoza et al. / Corrosion Science 46 (2004) 1189–1200 1191
compound deposition rates, as well as the preparation method [20] of the commercial
pure copper samples (150 mm · 100 mm · 1 mm), are also given.
Duplicate samples were exposed at 45� to the horizontal, facing south, in outdoor
conditions, as well as under sheltered conditions in the rural station. In the coastal
zone, under sheltered and ventilated shed conditions, they were exposed vertically, as
well as in the urban-industrial site under sheltered conditions.The composition of the corrosion products scraped off from the exposed samples
was determined by X-ray diffraction analysis (XRD) and Fourier transform infrared
spectroscopy (FTIR).
The XRD patterns were recorded in HZG4 goniometer (Carl Zeiss, Jena)
equipped with an ENRAFNONIUS Diffractis 582 generator. The patterns were
scanned between 10� and 65� two theta with a 0.05� step and 8 s counting time using
Fe filtered Co-Ka radiation (k ¼ 1:79026 �A). The phases present were identified
using the PCPDFWIN search/match program (Version 1.30) using the PowderDiffraction File (PDF) 1997 Database. The composition of the copper corrosion
products was determined based on the strongest reflection lines in the XRD patterns,
according to the PDF.
Corrosion product samples were also analysed by FTIR. They were examined by
the KBr disk method. A portion of each corrosion product sample was pressed into
pellets, mixed with spectrally pure KBr and subjected to infrared transmission
spectroscopic analysis. Fourier transform transmission spectra in the range of 4000–
400 cm�1 were obtained using a Carl Zeiss (Bruker) spectrophotometer (modelVector 22) equipped with a DTGS detector with KBr window and a KBr beams-
plitter.
IR spectra were recorded in transmittance format at a resolution of 4 cm�1 and
were interpreted taking into account data previously reported in the literature
[5,12,21–28], as well as the XRD results obtained in this work. The characterisation
of the corrosion products has been performed, in most of the cited works, by in-
frared-reflection-absorption spectroscopy (IRAS). However, it is known that IRAS
spectra possibly shift to the high wave number region and give different shapes fromthose obtained by transmission spectra in some cases [4,5,27]. This could be the
reason for the differences in the wavenumber region observed compared with those
reported in the literature.
The remainder of the corrosion products were removed in order to determine the
corrosion rate by weight loss, according to ISO 9226 [29]. The corrosion rate values
have been already reported in a previous work [18].
3. Results
3.1. Analysis of copper corrosion products by X-ray diffraction analysis
The samples exposed in outdoor and sheltered coastal environment are charac-
terised by a surface covered with a loose powdery scale of a light bluish green colour.
However, under ventilated shed conditions the coloration assumed was reddish
1192 A.R. Mendoza et al. / Corrosion Science 46 (2004) 1189–1200
brown with small greenish stains during the first 12 months, being larger after 18
months. In the urban-industrial station, under sheltered conditions, the specimens
developed a golden coloration with some black stains, and in the open air a dark
grey colour. In the case of the rural site the appearance of the outdoor corrosion
products formed was mainly grey-blue, although the inner layer was reddish,
whereas sheltered conditions yielded a brown-reddish appearance. All the coppersamples corroded uniformly, independently of the atmosphere type.
Typical diffraction patterns of corrosion products formed in the three atmo-
spheres under different exposure periods and conditions are shown in Figs. 1 and 2.
Table 1 shows the composition of copper corrosion products formed through the
whole test period under different exposure conditions, according to the XRD ana-
lysis.
As can be seen from Table 1, cuprite (Cu2O) was predominant under most of the
exposure conditions and atmospheres. Only in outdoor coastal conditions the copperbehaviour was different where paratacamite (Cu2Cl(OH)3) was the main phase.
Under these conditions posnjakite (Cu4SO4(OH)6 Æ 2H2O) was also detected, while in
industrial (both outdoors and indoors) and rural (outdoors) environments bro-
chantite (Cu4SO4(OH)6) was the basic sulphate found. Gypsum (CaSO4 Æ 2H2O) was
also identified under some of the exposure conditions tested.
It is worth noting from this table the presence of paratacamite in ventilated shed
coastal conditions, even though the chloride deposition rate is very low. Cuprite
and paratacamite were present during the entire exposure period under outdoor andindoor coastal conditions. After 18 months of exposure in the urban-industrial and
Fig. 1. XRD patterns of Cu corrosion products formed on samples exposed in the coastal site.
Fig. 2. XRD patterns of Cu corrosion products formed on samples exposed in the rural and urban-
industrial stations.
Table 1
XRD identification of copper corrosion products formed under different atmospheres during the entire
exposure period
Conditions Atmosphere type
Coastal Industrial Rural
Outdoor Paratacamite Cuprite Cuprite
Cuprite Brochantite Brochantite
Posnjakite Paratacamite Paratacamite
Gypsum
Sheltered Cuprite Cuprite Cuprite
Paratacamite Brochantite Gypsum
Paratacamite
Gypsum
Ventilated shed Cuprite – –
Paratacamite – –
The phases are ordered according to the intensity of their peaks in the XRD pattern.
A.R. Mendoza et al. / Corrosion Science 46 (2004) 1189–1200 1193
rural stations, cuprite continues to be the predominant phase both outdoors and
under sheltered conditions.Atacamite [7,11,22,30–32] and paratacamite [11,30,32,33] are the compounds
commonly reported in the literature as the main constituents of copper patinas
formed in marine atmospheres. However, the former could not be found on any of
the copper samples tested in this work. Paratacamite is said to be an isomorphous
1194 A.R. Mendoza et al. / Corrosion Science 46 (2004) 1189–1200
compound of atacamite to which is transformed with time. Veleva et al. [33] also
found cuprite and paratacamite as the main phases in a marine atmosphere and
noticed that cuprite changes to paratacamite with time.
It should be also noted from Table 1 that under indoor coastal conditions no
crystalline sulphate could be detected.
Brochantite, antlerite and gypsum are the most frequently identified sulphate [23];however, in this study antlerite could not be identified on any of the copper samples.
Some authors have observed that there is a critical SO2 concentration above which
brochantite does not form and existing patinated surfaces will dissolve [34]. Cuprite,
brochantite and antlerite (in a very low proportion) were detected by XRD after 14
years of outdoor exposure in rural and urban-industrial atmospheres [35].
It has been also reported that when the chloride concentration is very high,
brochantite can react with chloride ions to form basic chlorides [28,33]. The stability
of brochantite (Cu4SO4(OH)6) with respect to basic chlorides is represented by thefollowing reaction [28,33]:
Cu4SO4ðOHÞ6 þ 2Cl� () Cu4Cl2ðOHÞ6 þ SO2�4 ð1Þ
Brochantite is stable when [SO2�4 ]/[Cl�]2 P 5.5 [28]. Thus, one possible explanation
of the absence of posnjakite after 18 months could be its transformation in basic
copper chloride, due to the very high chloride deposition rate in the coastal site.
Posnjakite acts as an unstable intermediate phase in the brochantite forming process,
although it also occurs as a naturally formed mineral [22]. Brochantite is more stable
than posnjakite in basic solutions [34].
Odnevall and Leygraf [12,22] reported that in sheltered exposure conditions cu-prite and posnjakite are the main constituents in copper patina formed during rural
and urban exposures. However, they also reported that cuprite was the only iden-
tified crystalline corrosion product after 1 year of sheltered exposure in another test
program, whereas after 2 and 4 years, posnjakite and brochantite were also identi-
fied.
3.2. Analysis of copper corrosion products by IR spectroscopy
Fig. 3 shows representative spectra of copper corrosion products formed in the
coastal station under different exposure conditions and exposure time. As can beseen, significant differences are not observed between the spectra of the corrosion
products formed outdoors and those formed under sheltered conditions. In the
urban-industrial site were obtained similar results, but not in the rural station.
However, whereas strong bands around 3332 and 3440 cm�1 dominate all the spectra
in the coastal station, a band at 1105 and 625 cm�1 dominate the spectra from the
urban-industrial and rural stations, respectively. A band at 623 cm�1 is also pre-
dominant in the spectra from ventilated shed conditions (coastal station).
The bands around 3332 and 3440 cm�1 are assumed to originate from stretchingvibrations of hydroxyl groups of paratacamite, as well as from water [27,36,37]. The
small band at 1630 cm�1 is attributed to OH deformation vibration. Smaller bands
around 940 and 840 cm�1, as well as a shoulder at 985 cm�1, are also assigned to
Fig. 3. IR spectral variations with time and exposure conditions on copper exposed in the coastal site.
A.R. Mendoza et al. / Corrosion Science 46 (2004) 1189–1200 1195
paratacamite [23,25], which, according to XRD results, was the main phase in the
coastal station under outdoor and sheltered conditions. In spite of the fact that the
band characteristic of sulphates (around 1100 cm�1) is observed in all the spectra of
the coastal samples, no crystalline sulphate could be found under sheltered and
ventilated shed conditions by XRD analysis. In contrast, posnjakite (Cu4SO4(OH)6 Æ2H2O) and gypsum (CaSO4 Æ 2H2O) were found outdoors after 12 and 18 months,
respectively. Under sheltered and ventilated shed conditions, sulphates could be
present below XRD detection limits.A band around 1105 cm�1 in the urban-industrial spectra (outdoors) is assigned to
brochantite, as well as those at 608, 878 and 980 cm�1 [23]. However, in the spectra
of the sheltered samples a strong peak around 1140 cm�1, characteristic of gypsum, is
observed after 18 months of exposure, and could influence the mentioned sulphate
bands. The latter is in agreement with XRD data, in that gypsum was detected under
sheltered conditions, but not outdoors. It has been noted that rain exposure delayed
the formation of sulphate-containing corrosion products [38]. Several authors have
reported the basic sulphates as the predominating phase in this type of atmosphere[7,11,22,30–32,39].
In the rural station a peak at 625 cm�1 from cuprite dominates the spectra both
outdoors and indoors, consistent with XRD data. The IR spectra from synthetic
cuprite showed a predominant band at 620 cm�1. Absorption bands at 625 [28], 625–
610 [40], 620–610 [25] and 615 cm�1 [24] have been assigned to cuprite. A strong
1196 A.R. Mendoza et al. / Corrosion Science 46 (2004) 1189–1200
band at 1100 cm�1 is also observed in the spectra from sheltered conditions, although
basic copper sulphate was not found by XRD; however, gypsum was detected after
12 months of exposure under these conditions.
As can be seen from Table 2, bands characteristics of brochantite are also iden-
tified under outdoor rural conditions, mainly after 12 and 18 months. Bands char-
acteristics of basic chlorides are not evident in the spectra, even though paratacamitewas detected by XRD. However, a split approximately at 3440 and 3350 cm�1,
probably due to the presence of this phase, is observed in the spectra.
Some authors have assumed an IRAS peak around 1107 cm�1 to be representative
of a cupric sulphate, whereas splitting of the peak into two peaks at around 1070 and
1120 cm�1 is representative of a basic copper sulphate [22,38], as it was showed
above for outdoor conditions. Odnevall and Leygraf [22] noted that the cuprite
formation is followed by the formation of a noncrystalline copper sulphate phase,
which gradually transforms after short exposure periods into crystalline posnjakite,the hydrate form of brochantite.
All IR spectra showed peaks approximately below 500 cm�1, which is charac-
teristic of Cu–O bending and could be due to the different phases present in the
corrosion products, and in the region 1500–1380 cm�1, being more or less intense
depending on the exposure conditions. At the present time, it is not possible to assign
the last bands to a particular compound, since other phases may also be present,
even though they were not identified by XRD. Absorption bands in this region have
been reported for basic carbonates [23], nitrates [23,26], and aliphatic compounds[35]. However, it has been stated that the conditions in the atmosphere would not
favour the formation of basic copper carbonate, for the H2CO3 content in the water
film would only be about 10�5 mol/l in equilibrium with the air, although unex-
pectedly it is sometimes found in practice [11].
Table 2
Main absorption bands (cm�1) observed in the IR spectra of the copper corrosion products and phases
assigned
Conditions Atmosphere type
Coastal Industrial Rural
Outdoor Paratacamite (3440, 3332,
940, 840, 985)
Brochantite (1105, 980,
878, 608)
Cuprite (625)
Posnjakite, Gypsum (1110,
604)
Cuprite (625)
Brochantite (1116, 1090,
972, 872, 782)
Cuprite (625)
Sheltered Paratacamite (3440, 3332,
940, 840, 985)
Brochantite (1105, 980,
878, 608)
Cuprite (625)
Cuprite (625) Gypsum (1140)
Gypsum (1140)
Cupric sulphate (1110) Cuprite (625)
Ventilated
shed
Cuprite (623) – –
Paratacamite (3440, 3332,
940, 985)
Cupric sulphate (1110)
A.R. Mendoza et al. / Corrosion Science 46 (2004) 1189–1200 1197
Table 2 shows a resume of the main bands observed in the spectra of copper
corrosion products and the phases identified.
4. Discussion
Previous results showed a generally decrease in the copper corrosion rate in the
rural and urban-industrial stations. This can be due to an improvement of the
protective properties of the corrosion products. However, in the coastal station
under sheltered and ventilated shed conditions the corrosion rate increased with time[18].
The presence of paratacamite under these coastal conditions may explain the
increase in the corrosion rate due to its hygroscopic character. This provokes an
easier wetting of the surface, which results in a decrease of the critical relative hu-
midity, and a larger time of wetness because of the absence of sunlight.
It is well known that the copper corrosion is extremely dependent on the rela-
tive humidity [7]. Several investigators have demonstrated the rate of reaction
dependence of moisture between copper and air pollutants [41]. Cramer and Mc-Donald [3] found that moisture is more readily available on corroded copper sur-
faces from capillary condensation and from the hydrophilic nature of their corrosion
products, than on non corroded surfaces. However, observations of copper roofs
indicate that patina grows preferentially in areas washed by rain and areas that
experience water films thicker than those associate with dew or high relative hu-
midity [34].
It has been also reported that the repeated dissolution–reprecipitation processes
made a slow formation of sulphate containing corrosion products possible due tolong dry and wet periods [22].
The bronze disease is related to the presence of copper chlorides and it is con-
sidered a cyclic and autocatalitic (self-feeding) chemical process [23]. An increase in
the electrolyte film pH promotes oxygen corrosion in the presence of chlorides, to
which copper is susceptible.
It is noteworthy that the difference in the corrosion behaviour between outdoor
and sheltered coastal exposure is observed despite the fact that the corrosion product
composition in both exposure conditions are practically the same.This may indicatea more important role of the morphology and degree of crystallisation of the cor-
rosion products on the corrosion rate than their phase composition, at least during
the exposure period of the test (18 months) and particularly in coastal environments.
This statement is based on the fact that the corrosion products are formed mainly
under the presence or absence of rainfall and sunshine. On the one hand, due to the
absence of rainfall under sheltered conditions, the pollutants are not washed away
from the metal surface, and may act for a longer time. On the other hand, it is
possible that a higher time of wetness could exist due to the absence of sunshine, as itwas proposed previously [18]. According to ISO 9223 [42], the presence of hygro-
scopic salts may increase substantially the time of wetness on marine sheltered
surfaces, where chloride ions are deposited.
1198 A.R. Mendoza et al. / Corrosion Science 46 (2004) 1189–1200
Nairn et al. [43] also concluded that the corrosion rates for copper alloys can be
very dependent on the morphology of the corrosion products on the copper surface.
They confirmed that corrosion products of the same composition (Cu2O) could give
higher corrosion rates when they do not dry out than when they do. These rapid
corrosion rates have been associated with corrosion products in the form of a gel
rather than an oxide [42]. It has been reported that the amorphous ferric oxyhy-droxide acts as a protective rust against atmospheric corrosion of steels [43].
The abovementioned could be also the reasons for the higher corrosion rates
under ventilated shed conditions than outdoors after 12 months of coastal exposure.
It must be recalled that under these conditions the corrosion products are mostly
constituted by cuprite, which is very different from outdoors. Cuprite is an electri-
cally conducting compound and is known to play a decisive role in the protectiveness
of corrosion layers on copper [44,45]. The electrolyte film on the surface is then
considered to be in contact with cuprite (no copper substrate) and further oxidationoccurs via the following reaction [34]:
Cu2Oþ 2Hþ ! 2Cu2þ þH2Oþ 2e� ð2Þ
Precipitation of brochantite from the electrolyte resulted from an increase in pH,which it is attributed to both the anodic oxidation of cuprite (increase in cupric ion
concentrations) and the cathodic reduction of oxygen to produce OH� ions via the
following reaction [34]:
O2 þ 2H2Oþ 4e� ! 4OH� ð3Þ
Another detail noted in this work was the higher corrosion rate in the rural stationunder sheltered conditions, than in the urban-industrial atmosphere during the entire
exposure period. Odnevall and Leygraf [12] noticed that cuprite formation is much
faster in the rural than in the urban site, mainly due to the higher relative humidity
and despite lower concentrations of SO2 and NO2 in the rural site. This evidencesthat initial weathering conditions have a significant influence on atmospheric cor-
rosion rates of copper. It is well known that high relative humidities and tempera-
tures enhance the copper corrosion in rural atmospheres [9]. These authors
concluded that the fast formation rate of cuprite retards the formation of posnjakite
and could retard the subsequent formation of brochantite [12]. Fitzgerald et al. [34]
found that cuprite oxidation is the rate-controlling step for brochantite or posnjakite
precipitation within the aqueous layer.
5. Conclusions
The main phases present in copper corrosion products formed in Cuban tropical
climate were: cuprite (Cu2O), paratacamite (Cu2Cl(OH)3), posnjakite (Cu4SO4(OH)6 Æ2H2O) and brochantite (Cu4SO4(OH)6), depending on the atmosphere type and ex-posure conditions. In the coastal site outdoors and under sheltered conditions, pa-
ratacamite was the main phase, whereas under ventilated shed conditions cuprite was
predominant. In the urban-industrial, both outdoors and under sheltered conditions,
A.R. Mendoza et al. / Corrosion Science 46 (2004) 1189–1200 1199
brochantite was predominant, as well as in the rural station outdoors. Under sheltered
rural conditions cuprite was the predominating phase. Gypsum (CaSO4 Æ 2H2O) was
also identified among the corrosion products, mainly under sheltered conditions.
At very high concentrations of chloride ions, the transformation of basic copper
sulphates in basic chlorides is possible to occur, as a result of their chemical reaction.
The highest corrosion rate values observed in the coastal site under sheltered andventilated shed conditions, as well as their increase with exposure time, could indi-
cate a major role of the corrosion products morphology and degree of crystallisation
than their phase composition. A longer action of pollutants and a higher time of
wetness under these conditions, as well as the hygroscopicity of some copper com-
pounds can also influence the corrosion rate.
Acknowledgements
The authors want to thank to Dr. Carmen Haces for her help in the interpretation
of IR spectra and XRD data, and for numerous stimulating discussions.
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