Corrosion Tests and Standards - Application and Interpretation

886 Pages·2005·173.852 MB·English

by  Robert Baboian

Corrosion Tests

and Standards:

Application and

Interpretation Second Edition

Robert Baboian, Editor

Section Editors

Robert Baboian
w.
Sheldo n Dea n, Jr.
Harvey P . H ack
Edward L. Hibne r
John R. Sc ully

ASTM Stock Number: MNL20-2nd

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COITOsiontests andstandards :applicationandinterpretationI
Robert Baboian, editor ; section editors, Robert Baboian

[etal.].-2nded.

p.cm.-(ASTMmanualseries;MNL20)

ASTMStockNumber:MNL20-2nd

ISBN0-8031-2098-2

1.Cor rosionandan ti-corrosives-Testing. 1.Baboian,Robert.
n.Series.

TA462.C6662005
620.1'1223- --dc22
2004025972

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PrintedinBaltimore,MD
January2005
THE EDnORS
L.
EDWARD HIBNERisaSen-
ior Metallurgist and Code Manager at S pecial
ROBERT BABOIAN,
Me talsCorporati on,f orrnerJ yIncaAll oys Interna
Editor tional, inHuntingto n,WestV irgin ia. He received
bis B.S. in Chemistry from Marshall University

Robert Baboian is a corrosion consultant with RB and inM et allurgyfrom the University ofCincin
vitpCsuehottrryersysri oiitfcynsra ioolo1 mf9nc T 6hSS4oee.ummrfvHfinisoectt leorkd.y ii HUd nfern p1o ir9vome6esc tr4eRdsiiaovetnycen dtds oisnbsra auil 1slab 9eBsr5eer. 9SqsP e.u aoaednlrneycdtgt hIerhyecai ehrst enitPcnihceh eci.vIDh nUee. sdnmtiiina LGFnoaefa- ltlQJi M o. uCweeH re iretMAt , iwfeiits cmahareodtt he,rA iea oaSl nTfr eAdMAcwi ppiasCpire rodcne,mu ct irtmar hoetiefin to ttnetAlhey, S e TaGVnMA-idleS eTC tF-MhCorea mh naANmciriwAimst aCtaerLEnde.
facu lty appo intm ent to Senior R esearch A ss ocia te in and th e Edito rial Rev iew Chai rman of ASTM
1965. H e joined t he Mate rials and Controls Groupo f Cor nmit tee G-l on Corrosi on of Meta ls. He has
TexasI nstruments,I nc. in 196 6, whereh eestablish ed served as C hair ma n and as T rus tee of t he W est
Virginia Section of NACE International and is
the Electrochemical and Corrosion Laboratory. He
currently serving on the NACE MR0175/ ISO
retired from Texas Instruments in December 1996 as
15156 Maintenance Panel. He has extensive ex
PrincipalFellowandHeadoftheElectrochemicaland
perienceinalloydevelopmentforchemicalproc
CorrosionLaboratory.ThePrincipalFellowpositionat
ess,fluegasdesulfurization.marine, andoilfield
TI is the company's bighest honor for scientific and
applications. He has writtenwide1yonmaterials
technicalacbievement.HeisanASTM HonoraryMem
applications and corrosion topics in these fields
ber,aFellowofASTM,NACE,andSAE,andwasaForo
andhasfourpatentsand60publications.Inaddi
FoundationPostdoctoralFellowin1964.
tiontoASTMIntemational,heisamemberofthe

Dr. Baboia nhasbeend edicate d tothe researchand developmentofcorrosionresistantmate Intemational Desalination Association, the Soci

rials and devices, environmental effects on materials, and the use of e1ectrochemical tech etyforPetroleumEngineers,ASMEIntemational,

niques in corrosiontesting for almost 40years. He holds 15 U.S. patents, is the editorof 13 SAE International, NACE International, and the

books, an dhas auth ored ov er 170tech nic al pub lica tions. He has servedon a num bero fG ov Nava lSubrnarineL eague.
ernmentand Academic Committees and has lectured throughout the world, and hisservices
were d o nat e d b yTI to t he Na tion al Par k S e rviceas a co rro sion con sul tan t on t he S tat ue01 JüH N R. S CUL Ly receivedbisB.S.,
Libe rty restor atio n pro gram o Recent Iy, he has res ea rc hed the si nkingofthe Ti tani c and h as M.S., and Ph.D . in Materials S cience an d E ngi
RCpreaocvpoaognsnae iudzg ehtdh Aefaowrr iaherisds o aancn tdcivoterh rieonsvAioo wlnva emrmdeeconhfta Minn ie strmhit es f trceoacm uhsniAincSgaT lt Mhcoe, rfntahm ieluuArnei S.t Ty,M DrD. uBd aleb yoiAanw harads rfeocr epivuebd l itchae Nnpeuaervsraiu lnigSn gh ifpr boiRms& PDJh o.CDhne., ns theHer oiwnpkoAirnnknse adpU oanltii sv,DerMas viatiyrdy. l TaWnaydhlioilner
tions,theA STMLa Que Aw ardfor out standi ngco ntributi onst ocorro siontes tingand ev aluation, the M arine Cor rosion Br anch. He then join ed
the S pell erAwa rd for outstan din g contributi ons incorrosi on engineeri ng, and the T. J. HuIl San diaNati onalLabora toryafter ate rrnas aVisit
Aw ardfor publicat ions fromNACE ,theSeiencea nd Technolog yAwardofth eSu gaW ea th ering ingSci entistat AT&TBell Labo ra tories .I n 1990,
Techno log yFoundation inJa pan,th eV ittoriod eNo raAwardfro mtheE le ctro chem icalSociety, hej oinedthe fa cultyo fthe Departmento fM ateri
the Francis L. LaQue A w ard fo r con tributio ns to ma rine co rrosi on and prevention f rom the als Scienc e a nd Eng ine erin g at the Un ive rsity of
laQ ue Cen ter Sea Ho rse Ins titut e, and the Na tio nal Mate rials Adva ncem ent Award from the Vir giniaand is afuIlprofesso r and co-directst he
FederationofMaterialsSocieties. HehasservedontheExecutiveCommitteeandtheBoardof CenterforElectroehemicalScienceandEngineer

DirectorsofASTMandNACEandwastheChairmanoftheASTMBoardofDirectorsin1987. ing. Professor Scully received the 1985 A. B.

HealsohaschairedASTMCommitteeG-1 onCorrosionofMetals,theSAEAutomotiveCoITO Campbell Young AuthorAward from NACE. He

sionandProtectionCommittee,andtheNACEResearchCommittee. hasalsobeenselectedasaNationalScienceFoun

dationYoungInvestigator,andhasreceivedtheH.

SECTION EDITORS H.Uhl igAwar dfromNACE an dth eWilliam Blu m
AwardfromtheElectrochemicalSociety.Professor

ScullyhaspublishedoVer1()()technicalpapersand

editedsevera!booksoncorrosion.
P.
SHELDüN W. DEAN, JR. HARVEY HACKDr. Hackisan
is eurrently the Presiden t of Dean C orrosion AdvisoryEngine erfor NorthropG rurnm anCa rp o
Technology,Inc.,aconsultingfinninAllentown, ration, wherehe does materialsselectionandcor

Pennsylvania that provides expert advice on rosioncontrolforunderwatervebiclesandsystems

matters involvingcorrosionofmetals. Heisalso fortheDepartmentofDefense.HereceivedbisB.S.

Editorin ChiefoftheJournalofASTM Interna andM.S.from Carnegie-MellonUniversity,andbis

tional. H e rece ive d b is A.B. fro m Mi ddlebury ph.D . in Metal lurgy from The P ennsylvani a St ate
ColJegeand bis B.S. and Se.D. from the Massa University.HeistherecipientoftheASTMInterna

chusettsInstituteofTechnology.Hehasreceived tionalAwardofMerit,andispastChainnanofthe

theASTMAwardofMerit,theCharlesB.Dudley BoardofDirectorsofASTMInternational.Dr.Hack

Award, the Sam Tour Award, the Francis L. hasreceivedtheDistinguishedServiceAwardfrom

LaQue Memorial Award, the ASTM Committee NACE Intemational,theFrancisL. LaQueMemo

onPublicationsAwardforExcelJence,theASTM rial Award from ASTM Committee G-l onCorro

Committee G-l Certificate of Appreciation, the sion ofMetals, and the Francis L. LaQue Award

NACEFrankNewmanSpellerAward, theNACE fromtheSeaHorseInstitute.HeisaNACECorro

Fellow Honor, and was named a FelJow of the sionSpecialist,CathodicProtectionSpecialist,and

American Institute of Chemical Engineers and Coatings Inspector, a FelJow of NACE Interna

theMaterialsTechnologyInstitute.Hehasserved tional,ASTMInternational,lheWashingtonAcad

as chairman ofASTM Committee G-l fur four ernyofSciences,and theInstituteofCorrosionin

years. He alsoservedonand chaired theASTM the United Kingdom, and is a Registered profes

ComrnitteeonPublicationsandtheASTMBoard sionalEngineerinMaryland.Dr.HackistheAsso

ofDirectors, and chairedthe Finance andAudit ciate Editor for the Materials Perfonnance and

Committee. He has also served on and chaired Characterization section of the Journal ofASTM

theBoardofDirectorsoftheMaterialsTechnol InternationaI (JAlJ. is on the Materials Advisory

ogyInstitute.Hehas12U.S.patents,96publica Boardforthe NationalAirandSpace Museumof

tions.andhasco-editedeightbooks. theSmithsonianInstitution,andisapastPresident

oftheCouncilofEngineeringandScientificSpecialty

Boards.Dr.Hackhasapproximate1y70publications

andistheauthor,editor,ormajorcon-tributartofive

books.Heistheauthorofaregularcolurnnoncorro

sioninUnderwaterMagazine.

iii
Reviewers

DineshAgarwal JimGossett SankaraPapavinasam
VinodA garwala Ric hardGra nata Frederic kPettit
HiraA hluwalia HarveyH ack Bopinder Phull
Paul Aimone William Hart t RobertPu year
Geor geAnde rsen Gardner Hayn es DavidR eiser
FrankA nsuini GeorgeH ays Pierre Rober ge
PeterA ult Edward Hib ner PaulR othman
Denis eAy lor Stanley Hiroza wa Ken Sto John
Robert Babo ian F. Galen Hodge Albe rto Sagu es
BrianB aker Al fredH opkins StuartS aunder s
Milan Barto s William Jarosin ski JohnS chemel
NealB erke JamesJe nkins Geor geSchick
Thom asBr itton Denny Jones JohnSc ully
C. Sean Brossia Russell Jones K. An thony Selby
Ru dolph G. Buc hheit Robert Kain Da vidShifle r
Kenneth Bu dinski MikeK atche r Tetyan aShmy reva
JamesBu shman Robe rtKelly DavidSi lverman
PaulB rewer Gerhar dusK och J. Dou glasSinda ir
Julie Brown SimeonKr umbei n R ayrnund Singleto n
Kirk Bundy PaulLab ine JosephSlu sser
Gust avoCra gnolino Herb ertLaw son Gaylor dSmith
LeeCrai g JasonLe e JohnSn odgras s
She ldonD ean Daom ingL i Dona ldSnyder
TerryDe Bold BrendaL ittl e NarasiS ridhar
Steph enDexte r DarylL ittle Sridha rSriniva san
George D iBari Frank Lutze Anthony Stavros
JeffreyD idas Floria nMans feld T.J. Sum merson
Charles Dillo n Charles Marsh W il liamTillis
Marcia Domac k JamesM artin Herbert Town send
George Downs PeterM ayer HectorV idela
DaveDu quette Josep hMenk e YashV irmani
K. Da nielEfird Jean-M arc Mey er Georg eWaid
Na thanEi singe r HaroldMic hels RobertW ei
PeterEl liott TomM ills PaulW hitcr aft
David Enos Jame sMor an JanW right
EdEsc alant e Patrick Morri s Geo rgeYou ng
Joh nFitzgera ld MaxMo skal Waltery oung
Anna Fraker JimM yers
Gerald Frank el Jam esNoe l

iv
Foreword

THEREVISEDPUBLICATION,Corrosion Tests andStandards:ApplicationandInterpretation,
is sp onsored by ASTM Co mmittee G1 o n Co rrosion of Metals an d edi ted by Robert
Ba boian, RB Co rrosion Service. S ect ion editors in clu de Rob ert B aboian , S heldon
W. Dean, Dea nCorrosio nTechno logy, Har veyP. H ack, No rthrupG rumman Corpora
tion , Edw ard H ibner, Spe cial Metals C orpora tio n, and John R. Scully, Uni versity of
Virgi nia.This isthese conded itionof Manual20in theA STM M anualse ries.

Preface

CORROSIONCONTINUES to be a problem ofworldwide importance. The second edition
ofthis man ual has bee n pre pa redand pub lishedto a ddress this f orm ofdegra dation.
Co rros ion is a fien negle cted, but it se riously im pa cts our econ omy, jeo pardizes hu
man healt h a nd sa fety, and im ped es technolog ical pro gres s. The mos timportant fac
tors in addr essi ng corr osio n and its control are: ( 1) recogn izing and understan ding
the me chanisms, (2) develo ping sol utions t o th e p roblems, and (3) implementing
tho se solutions. C orro siontests a ndstanda rds are verysignifi cant ina ddressingeach
ofthe se factors. Therefore , this ma nual inclu des guide lines for re co gnizing typ es of
co rrosio n as wel las fundam enta ls oftes ting andp rovides the too ls required for ma k
ingcalcul ati ons, i nte rpretations, a nd correla tions . Itserve s as a sou rce book ofp roce
dur es, equipmen t, andstandards use d intesting.
The editor and sect ion editor s hav e c oordin ated the revision and update of this
books othat most recentt echnolo gies a reincludedi nea chsection . In mostca ses ,the
origin al auth ors of chap ters have ma de the revis ion s. In sorne c ase s, ne w auth ors
neededt obecho sen , orthe e ditors perfo rmed thattask. Us ers of thema nual willfind
that it is a n invaluab le and instruc tive tool, as wel l as a sour ce b ook on how to con
duct co rr osi ontests, int erpr etresults, a ndus es tanda rd s.
Th eseconde dition ofthem anuali s the res ultofa ma ssiveeffortofplanning, writ
ing, re viewing , editin g, prod uction, an d m arketi ng . It would not h ave been pos sible
with out the ou tstandin g efforts of the A STM staff an d the v alua ble a nd co mpetent
work of the editors and over 40 0 e xpe rts in t he fie ld th at d onated th eir time as au
thors an d r eviewers . Th ey rep rese nt indus tr ial, educa tiona l, and go vernm ent org ani
zation s,a ndtheirco ntribu tionsareg reatlyappr eciated.

RobertBaboian
Editor

v
Contents

Introduction 1

1:GENERALINFORMATION-R.Baboían, SectionEditor

UnifiedNumberingSystemforMetalsandAlloys 4
Exampl esofComm onNam eso fSelec tedU NSAl loys 5
Standard Ter minology Relatin g toCorros ionan dCor rosionTesting 7
Glossary ofCorrosion-R elatedA cr onyms 12
Standard A bbreviationsandU nitSymbol s 14
Intematio nalSystemof Unit s (SI ) 17
GeneralConv ersionF ac tors 18
Condens edMetricP racticeG uideforCorrosion 20
Multiplicat ionFac tors (SIP refixe s) 22
CorrosionRate Conver sion Factors 22
Corrosion Rate Calculation (fromM ass Loss) 23
Corrosion Rate Conversion Factor s 24
DensitieslK Fac torsforAllo ys 25
Overvoltage Values 26
ReferencePo tential sand ConversionTable 27
Equivalen tWeightV alue sforMetals andA lloys 28
ConstantsU sedin Faraday 'sE quatio n 30
PhysicalP roper tie sofGases andLiqui ds 31
Physical Properties of Eleme nts 32
Densities ofMetals an dAlloys 33
Densityo fM aterial s 35
Therma lE xpansion CoefficientsforAlloys 36
Physical Properties ofWater 37
DewPoi ntofMoist Ai r 38
Chem icalC le aning Proc eduresforRemovalofCorrosionProducts 43
Electrolyt icCleanin gProcedur esfo rRemov al ofCorrosio nproduc ts 46

11:TESTINGAND EVALUATION-R.Baboian, SectionEditor

Chapter l-PlanningandDesignofTests 49
StephenD . Cra merand Ba rnieP . Iones

Chapter2-TypesofData 59
David C. Silver man

Chapter3-MetallographicAnaIysis 66
RichardL. Colwe ll

vü
vili CORROS/ONTESTSANDSTANDARDS MANUAL

Chapter4-SurlaceAnmys~ 76
AlfredG. Hopkins

Chapter5-StatisticmTreatmentofData,DataInterpretation,andReliability 83
FredH. Ha ynie

Chapter6--ComputerBasedDataOrganizationandComputerApplications 89
PierreR. R oberge

III:TYPES OFTESTS-H. P. Hack, SectionEditor

Chapter7-ElectrochemicmTests 107
John R. Scully

Chapter8-CabinetTests 131
Cynthia L. Mea de

Chapter9-lmmersionTesting 139
RichardA. C orbett

Chapter 10-High-TemperatureandHigh-PressureCorrosionTesting 147
RussellD. Kane

Chapter ll-Atmospheric 159
Sheldon W. De an, Jr.

Chapter12-Seawater 170
James F. J enkins

Chapter13-Freshwater 175
WalterT. Yo ungandPhilippaFairer

Chapter 14-Soils 181
Edwa rdEscalante

Chapter 15-lndustrlmApplications 187
AllanPerk ins

Chapter 16--High-Temperature 194
GaylordD. Smith

IV:TESTINGFORCORROSIONTYPE~.R. Scully, SectionEditor

Chapter17-UniformCorrosion 205
JamesA. EllorandJo hn Repp

Chapter 18-Pitting 211
Robert G. Kelly

Chapter19-CreviceCorrosion 221
Narasi S ridhar, Dar rellS. Dunn, C. S. Brossia, GustavoA. Cragnolino, andJefferyR. Kearns

Chapter20-Gmvanic 233
HarveyP. Hack

Chapter21-Intergranular 244
MichaelA. Stre icher
CONTENTS ix

Chapter22-Exfoliation 266
DonaldO. Sp rowls;revisedbyKevin R. Cooper

Chapter23-Erosion, Cavitation, and Fretting 273
W. A. Gla eser

Chapter24--Dealloying 278
AnnChidest erVan Orden

Chapter25-EnvironmentalCracking-StressCorrosion 289
W. BanyLisagor

Chapter26-EnvironmentalCracking-CorrosionFatigue 302
RichardP. Gang loff

Chapter27-HydrogenDamage 322
C. G. Interr anteand L. Raymond

V:TESTlNGINENVIRONMENTS-H. P. Hcu:k, SectionEditor

Chapter28-outdoorAtmospheres 343
HerbertH . Lawson

Chapter29-IndoorAtmospheres 349
J. D. Sin clair

Chapter3O-Seawater 362
DavidA. S hiflerandDeniseM. Aylor

Chapter31-Freshwater 380
WalterT. Yo ungandPhilippaFairer

Chapter32-Soils 387
Lucie nVeleva

Chapter33-Concrete 405
NealS. Be rke

Chapter34--IndustrlalWaters 413
A. S. Krish er

Chapter35-IndustrlalChemicals 418
RobertB. P uyear

Chapter36--Petroleum 425
K. DanielE fird

Chapter37-High-TemperatureGases 434
GaylordD. Smithan dBria nA. Baker

Chapter38-0rganicLiquids 448
C. S. Bro ssiaand D. A. Shifler

Chapter39-MoltenSalts 457
F. S. Pe ttit

Chapter40-LiquidMetals 465
ChrisB agnall, PeterF. Tortorelli, StevenJ. Pawel, Jack H. DeVan, andStevenL. Schrock
x CORROSIONTESTSANDSTANDARDS MANUAL

Chapter41-CorrosionInhibitors 480
RudolfH. Hausler

Chapter42-CorrosionTestinginInVivo Environments 500
K. l. Bundy

Chapter43-MicrobiologicalEffects 509
Stephen C. Dexter

VI: MATERIALSTESTING-E. L. Hibner, SectionEditor
Chapter44-Zinc 525
Fran kE. GoodwinandSafaal. Alhassan

Chapter45-Lead(andAlloys) 531
Safaa l. Al hassana ndFrankE. Goodwin

Chapter46-Magnesium(andAlloys) 537
lamesE. Hil lis

Chapter47-Aluminum(andAlloys) 547
BernardW. Lifka

Chapter48-Steels 558
M. E. Komp, D. L.lordan, andR. Baboian

Chapter49-Copper(andAlloys) 565
ArthurC ohen

Chapter5O-Nickel(andAlloys) 580
Edwar dL. H ibner

Chapter51-StainlessSteels 585
lames W. Martin

Chapter52-Cobalt-BaseAlloys 591
P. Crook

Chapter53-Titanium 598
RonaldW. Schutz

Chapter54-ZirconiumandHafnium 613
Te-Un Yau

Chapter55-TantalumandNiobiumAlloys 617
E. B. Hinsh awa ndK. D. M oser

Chapter56-MetallicCoatingsonSteel 620
T. C. Sim psonand H. E . Tow nsend

Chapter57-NonmetallicCoatings 632
RichardD. G ranata

Chapter58-Metal-MatrixComposites 637
L. H. Hihara

Chapter59-Electrodeposits 656
T. P. Moffat