CORROSION TESTING

Reproduci
bility and
Reliability

Corrosion
Tests and
Application
of the
results
Well Planned
and
Executed
Test

Department of Metallurgical Engineering & Materials

1
Science, YTU
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CLASSIFICATION
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Department of Metallurgical Engineering & Materials
n Science, YTU
2
 PUPORSES

Evaluation and selection of Evaluation of new or old Control of corrosion resistance

Study of the corrosion
materials for a specific metals or alloys to determine of materials or corrosiveness
environment or application in which they are suitable of the environment mechanism

•New or modified •Routine test to •Research and

•Selection of
plant, process check the quality of development
•Replaced or materials to be the materials
tested for specific •Huey test •Specialized
expended
application •Salt spray test techniques
materials, less •New materials or •Checking paints and •Precise
contamination, electroplated parts
alloys, concerning measurement
improve safety, possible •Change in
design and aggressiveness of •Very close
applications
fabrication environment control

Department of Metallurgical Engineering & Materials

3
Science, YTU
 MATERIALS AND SPECIMENS

Chemical • Stock and specimen are identified by reference

number
Composition • Sufficient number

• Mill heat number

• Cast or wrought
• Cold drawn wire, large ratio of roll to edge area
Fabrication History • Weld or weld bead
• Size and shape,1/16 to1/4 in thick, 1 in wide, 2
in long

Metallurgical • Heat treatment

• Metallographic
History • Normal structure is desired

Department of Metallurgical Engineering & Materials

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Science, YTU
 MATERIALS AND SPECIMENS

• No. 120 abrasive cloth or paper or its

approximate equivalent.
Surface finishing • Maching, grinding or polishing if necessary
• Avoid contamination of metal surface

• Edges and corners should be beveled or

Removed the severely rounded
cold worked metal • A sharp blade is used to shave or prepare lead
specimen

Chemical treatment • False and misleading results might be obtained,

avoid artificial passivation in service
or passivating • Chemical treatment, decontaminate metal
treatment surfaces
Department of Metallurgical Engineering & Materials
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Science, YTU
 MEASURING AND WEIGHTING

• Carefully measure the surface area

Measuring • Original area is used to calculate the corrosion
rate

• After measuring, specimen is degreased by

washing in suitable solvent acetone
• dried and weight
Weighting • If the material is not corrosion resistant to
atmosphere, exposed to the corrosion
environment immediately
• Store in a desiccators.
Department of Metallurgical Engineering & Materials
6
Science, YTU
 EXPOSURE TECHNIQUES

• Corrosive, easy access to the

specimens
• Supports should not fail during the
Important test
• Specimens, insulated or isolated
considerations electrically contact with another metal
• Specimen, properly positioned
• Plant test, readily accessible as
possible

Department of Metallurgical Engineering & Materials

7
Science, YTU
 DURATIONS
Corrosion rate may increase, decrease or remain constant with time

Semiworks or • Minimum 2 weeks and preferably 1

plant test month

• Atmospheric corrosion or soil

Field test corrosion
• Several years
Department of Metallurgical Engineering & Materials
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Science, YTU
PLANNED-INTERVAL TESTS

Department of Metallurgical Engineering & Materials

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Science, YTU
PLANNED-INTERVAL TESTS

Department of Metallurgical Engineering & Materials

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Science, YTU
 PLANNED-INTERVAL TESTS

• Reduction in concentration of corrosive agents,

depletion of corrosive contaminant, formation
Corrosiveness of of inhibiting products, other metal catalyzed
solution changes in the liquid
• Formation of autocatalytic products,
destruction of corrosion inhibiting substances

• Formation of protective scale, removal of less

resistant surface layer of metals
Corrodibility of • Formation of corrosion accelerating scale ,
metals removal of the more resistant surface layer of
metals

Department of Metallurgical Engineering & Materials

11
Science, YTU
 AERATION

• Acid, neutral and reducing conditions

Attacked • Particular metals, alloys and specific
environments

Better Corrosion • Al and stainless steels

resistance
• Liquid level, completely immersed or semi-
immersion or the atmosphere over the liquid is
air
Aeration • Aeration / Bubbling air through the solution
• Deaeration / Bubbling nitrogen or argon
• Avoid impingement, porous brick should be
used

Department of Metallurgical Engineering & Materials

12
Science, YTU
 CLEANING SPECIMENS AFTER
EXPOSURE
Cause or mechanism of the corrosion involved
•
• Weight change
Observation • Corrosion products
• loose, tight, protective

• Scraping, brushing, scrubbing with abrasives,

Mechanical sandblasting, and rubber stopper cleaning

Chemical • Chemicals and solvents

• Making the specimen the cathode under an

Electrolytic impressed current in a variety of chemical
reagents with or without inhibitors added.

Department of Metallurgical Engineering & Materials

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Science, YTU
 CORROSION RATE EXPRESSION
• Familiar units
• Easy calculation with minimum error
Expression • Ready conversion to life in years
• Penetration
• Whole numbers

Conversion

Weight loss data

Linear polarization

Department of Metallurgical Engineering & Materials

14
Science, YTU