[ Corrosion Testing ]

Corrosion testing techniques and

evaluation practices used in industry
There are endless options for surface finishes and conditions for metal products. Chemical
coatings, films and paints are commonly applied to metal parts. The many surface preparation
and coating options range from; blasting and polishing, to pickling, passivation and plating.
But remember, application of any type of coating adds another level of complexity to the
finishing process. So how do you know if your coating, plating or application is going to hold
up over time and exposure to the elements before going into production? Environmental
simulation, and/or accelerated corrosion testing, is the perfect technique to determine
durability of your products.

By Michael Porfiliio, Director, of Quality, Stainless Foundry & Engineering, Inc., USA

Corrosion costs a savings of 15% to 35% of the cost of performance reducing costs and offering
The products of corrosion that are at corrosion could be realized; between sustainability.
times an aesthetic annoyance cannot be $375 to $875 billion USD annually on a on
compared to the potential catastrophic a global basis could be saved 1. See Salt spray and humidity testing
failure to many corrosion modes. There table 1.0 below. Tests such as neutral salt spray testing
are numerous hidden costs of corrosion The coatings industry is experiencing (NSS) and humidity testing can help a
to structures, equipment, bridges, pressure from environmentalist groups, manufacturer or end user determine
proactive coatings, specialty materials, corporate sustainability programs the effectiveness and reliability of their
cathodes, anodes, or other manufactured and individuals to produce “greener” coating/finishing process. By examining
parts are just some of the items that suffer products. These greener offerings in the test specimens throughout the duration
the effects of corrosion. long run will in general will be the future of the test, obviously surface effects are
The price of corrosion damage is of coating processing but at what cost noticeable sometimes within a single
staggering. A 2016 global study by if they don’t perform. Environmentally day or two, preventing expensive and
NACE International puts the global cost friendlier coatings generally have less time consuming rework and recalls. The
of corrosion is estimated to be $2.5 USD corrosion resistance over the lifetime comparison to an unfinished or control
trillion, which is equivalent to 3.4% of the of the coating or finish. This has left the specimens will help to determine the
global Gross Domestic Product (GDP) industry, in some situations, struggling to best surface finish for the intended
in 2013 1. By using available corrosion come up with new alternative friendlier application. At times no surface finish
control practices, it is estimated that counterparts that have long term will be acceptable and a new material

Table 1.0 Cost of Corrosion Figures

Global Cost of Corrosion (CoC) by Sector (Billion USD) – NACE Impact Study1

Agriculture CoC Industry COC Services COC Total COC Total GDP USD
Economic Regions COC % GDP
USD billion USD billion USD billion USD billion billion

United States 2.0 303.2 146.0 451.3 16,720 2.7%

India 17.7 20.3 32.3 70.3 1,670 4.2%

European Region 3.5 401 297 701.5 18,331 3.8%

Arab World 13.3 34.2 92.6 140.1 2,789 5.0%

China 56.2 192.5 146.2 394.9 9,330 4.2%

Russia 5.4 37.2 41.9 84.5 2,113 4.0%

Japan 0.6 45.9 5.1 51.6 5,002 1.0%

Four Asian Tigers + Macau 1.5 29.9 27.3 58.6 2,302 2.5%

Rest of the World 52.4 382.5 117.6 552.5 16,057 3.4%

Global 152.7 1446.7 906.0 2505.4 74,314 3.4%

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[ Corrosion Testing ]
selection may be the only remedy. iron detection tests. Free iron testing to zinc/cadmium/chrome plating
There are many specifications and is an excellent predictor of corrosion providers, and everyone in between.
standards written to direct how testing, resistance properties and surface finish The ultimate goal in applying a coating or
and equally important, to evaluate the success. Locations on a casting or perform surface treatments is to protect
results of your tests. The most common finished part, which are rich in free iron, surfaces providing the highest quality
specifications for performing a NSS test can become epicenters for corrosion product with the least amount of overhead
are ASTM B117 and ISO 9227, which while in service or inventory. In most in order to yield maximum profit.
outline the test conditions required cases, free iron tests can be done via salt
for the neutral salt spray testing. spray testing in about two hours or in a Accelerated corrosion testing
These specifications unify the testing humidity chamber in about 24 hours. concepts
parameters across the globe in the efforts These different combinations of test Accelerated corrosion testing allows
to evaluate the effectiveness of paints, media and hours of exposure have base material verification prior to final
coatings and finishes. led to a host of different conclusions application of surface treatments such as
These specifications unify the test for manufacturers and end users. The plating or polishing. Unwanted corrosion
parameters worldwide in order to most important element is the cost in stainless steels and other related alloys
evaluate the effectiveness of paints, effectiveness of coating and surface is of significant concern and consideration
coatings and finishes. In this test, an finishes vs. corrosion resistance. in their engineering and function. Rough
atmosphere of 5% solution of Sodium In addition to these two cabinet surface finish, elevated temperatures and
Chloride is atomized and introduced style tests, another procedure that corrosive environments encountered in
at a constant rate throughout a sealed can effectively detect free iron is a service can accelerated corrosion and
chamber. Test specimens are inclined potassium ferricyanide – nitric acid lead to early failure in materials as well as
and placed in the polyethylene lined (Ferroxyl) test, in accordance with MIL- stained surface finishes.
cabinet so that the test is parallel to the STD-735 and ASTM A380. The Ferroxyl Encountered different forms of corrosion
primary direction of flow of the sodium test will illuminate even the lowest are commonly encountered in service,
chloride mist. The mist wets the surface, levels of iron contamination. In this test and many can be strongly influenced by
and the excess solution runs off into the a reaction with the chemicals in the the heat treatment process. Fortunately,
bottom of the cabinet. test solution yields a chemical reaction there are many types of standardized
Humidity testing is another measurement in the form of a bluish coloration, test methods and evaluations, which
of the effectiveness of the corrosion demonstrating the presence of free iron. seek to qualify materials and quantify
resistance properties of a metal part. This It is a very sensitive test. the rates corrosion that a metal alloy
test can be performed in many ways. The Once the testing has begun, the may experience. Some examples are
first takes place in an unused NSS cabinet challenge becomes the evaluation of the noted below.
by sampling turning off the salt solution constantly changing surfaces of interest. Pitting corrosion is a localized form of
flow and plugging the drain. The second Sometimes it is helpful to add a point corrosion found in stainless steels and
test takes place in an environmental of certain failure to the test specimen, other related alloys, which does not
simulation cabinet specifically designed or scribe, to see how bad a failure typically experience uniform corrosion.
for this type of test. The requirements becomes if it should occur via damage or Pitting corrosion is typically caused by
for this test can be specified by a deficiency of the coating. There are many the breakdown of the passive surface
manufacturer’s specification or in an evaluation procedures such as ASTM layer and results in small zones of
ASTM specification publication such as D610, D714 and D1654 that oversee the corroded “pits”. These pits can act
ASTM D2247 and ISO 16961. These types evaluation of the test specimens. These as sites of crack initiation and are
of tests assist in evaluating primarily specifications use numerical values to detrimental to a materials performance
paints and their tendencies to bubble and evaluate the severity of the corrosion, and appearance.
blister. Acceptance criteria’s for the test blistering and/or creep. Intergranular corrosion (IGC) in stainless
results are generally customer specified. These laboratory type tests have one steel generally is associated with a
goal in common: to assist the surface precipitated inter-metallic phase found
Free iron detection tests and preparation industries, evaluate the at the grain boundaries of a material. For
evaluations efficacy of their coating material and/ example chromium carbide precipitation
The above two types of evaluations (NSS or process. Corrosion testing can assist at the grain boundaries of an alloy
and environmental), cabinet corrosion industries from epoxy powder coating can deplete the surrounding areas of
testing can also be very effective as free companies to chemical coating operations corrosion inhibiting chromium. In the

Table 2.0 Intergranular Corrosion Coupon Cast Stainless Steel

Tested Corrosion Coupon Corrosion Test Comments

Intergranular corrosion coupon tested in accordance with ASTM

A262, Practice B
(120 hour boiled in ferric sulfate – sulfuric acid). Sample exhibits an acceptable
mass loss of 0.7574 grams and a mass loss rate of 89.9 mils/yr.

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 [ Corrosion Testing ]
Table 3.0 Corrosion Testing of a Sensitized Stainless Steel Sample using one as a control sample. One of
the two samples is boiled in a copper/
Microstructure Evaluation Corrosion Test Comment copper sulfate sulfuric acid solution for a
specified period of time while the other
An example of a microstructure that has been sample is placed in a desiccator.
sensitized and etched After the proper exposure, the two samples
In accordance with ASTM A262, Practice A. The undergo a U-bend test, with the apex of the
material is ASTM A351, grade CF3M (AISI 316L). The bend being examined by magnification to
above image shows a representative section of a cast
look for evidence of intergranular fissures.
test bar microstructure. The structure of the sample
revealed steps between the austenite matrix and the The presence of these fissures or ditching
isolated ferrite pools, and most closely resembles ASTM indicates that the materials susceptibility
A262, Figure 4. No grain boundary ditching or sigma to intergranular corrosion and can be used
phase is present making this microstructure acceptable. to determine if a sensitizing heat treatment
has affected the material susceptibility
to intergranular corrosion. See table 3.0
presence of a corrosive environment, heating to roughly 500°C to 800°C. The below for examples of failed corrosion
these grain boundaries are preferentially addition of carbide stabilizing elements bend samples.
attacked and are subsequently weakened. such as niobium or titanium can help The ASTM G36 test is commonly applied
Stress corrosion cracking (SCC) is to ameliorate the problem, however, test to look for susceptibility to stress
another form of corrosion that can processes such as welding a susceptible corrosion cracking (SCC). In this method,
cause normally ductile materials to fail material can still detrimentally affect its samples are polished and bolted into a
prematurely in a brittle manner. When microstructural integrity. See table 3.0 U-bend configuration. The samples are
a material is both stressed (especially at below for an example. boiled in a magnesium chloride solution
elevated temperatures) and also exposed There are many standardized methods for a specified period of time, and the
to a corrosive environment, the grain for testing a materials susceptibly to one apex of the bend is under magnification
boundaries can be attacked and the of the three forms of corrosion addressed evaluated to look for evidence of cracking
materials mechanical properties can be (pitting, SCC and IGC). See table 4.0 for formations. The presence of cracks
compromised. SCC is very alloy specific some examples of test methods used for indicates susceptibility to stress corrosion
in that certain alloys may only experience material acceptance. cracking.
SCC in the presence of specific chemical A common test for pitting corrosion is the As there are many different types of
environments. Austenitic stainless steels ASTM G48 test. How it works: A sample corrosion and common methods of testing
in particular are susceptible to SCC in the coupon is polished, dimensioned and to their applications areas of interest.
presence of chlorides. weighed before testing. A sample is See Table 5.0 below for a sampling of the
Sensitizing heat treatments in stainless then placed in a ferric-chloride solution options commonly available.
steel can aggravate problems associated for a specified time period. The sample Although corrosion can be determined
with intergranular corrosion (sensitization is reweighed after testing and visually to the service life of many stainless
is a process in which the material examined for signs of pitting corrosion. steels and related alloys, there are
is heated to a temperature in which This test can also quantify the mass loss fortunately many methods available
chromium carbides for example can rate of certain materials and can be very to help predict a materials expected
precipitate out of solution at a grain useful in ranking a materials ability to performance. The American Society
boundaries and create a chromium resist this form of corrosion in service. for Testing and Materials International
depleted region which adversely effects ASTM A262, Practice E is a common (ASTM international) has standardized
corrosion resistance). Austenitic stainless test for intergranular corrosion (IGC). many of these methods, which are part
steels are susceptible to sensitization after If two samples are polished for testing of the standard toolkit designed to help

Table 4.0 Corrosion Testing Bend Samples IAW ASTM A262, Practice E

Failed Bend Sample Failed Bend Samples of Boiled and Un-boiled Conditions

ASTM A 262, Practice E failed bend coupon. There are inclusions A pair of failed bend samples tested in accordance with ASTM A262, Practice
and fissures in the apex of the bend sample. E. Both the boiled and un-boiled samples failed prematurly with no ductility.

www.stainless-steel-world.net Stainless Steel World December 2018 3

[ Corrosion Testing ]
Table 5.0 Common Corrosion and Environmental Testing Methods

ASTM Test Method Applicable Forms and Alloys Relevant Type of corrosion

ASTM B117 Cast and Wrought stainless steels, painted items, plated and Surface corrosion, rust and oxidization
coated materials, etc.
ASTM G85, Annex A1 through Cast or wrought metals but primarily steels and aluminum Corrosion on plating / coatings, aluminum, sea water,
5A alloys SO2, paints and steel components

ASTM A262, Practice B Cast and wrought austenitic stainless steels Intergranular corrosion
ASTM A262, Practice C Cast and wrought austenitic stainless steels Intergranular corrosion
ASTM A262, Practice E Cast and wrought austenitic stainless steels Intergranular corrosion
ASTM G28, Method A Wrought nickel rich chromium bearing alloys Intergranular corrosion
ASTM G28, Method B Wrought nickel rich chromium bearing alloys Intergranular corrosion

ASTM A923, Method A Cast and wrought duplex austenitic / ferritic stainless steels Detecting detrimental intermetallics phases
ASTM A923, Method C Cast and wrought duplex austenitic / ferritic stainless steels Detecting detrimental intermetallics phases
ASTM A262, Practice A Cast and wrought austenitic stainless steels Detection of Sigma phase in the microstructure

ASTM A923, Method B Cast and wrought duplex austenitic / ferritic stainless steels Detecting detrimental intermetallics phases utilizing
Charpy V-notch impact testing

ASTM G36 Wrought, cast, welded stainless steel and related alloys Stress corrosion cracking

ASTM G48, Method A Stainless steels, nickel based and chromium bearing alloys Pitting corrosion
ASTM G48, Method B Stainless steels, nickel based and chromium bearing alloys Pitting corrosion

minimize the costly effects of corrosion was formed in 1964 meeting twice per can be informative and value added. To
in metals. year and has more than 350 members. have a solid concept of the product life and
The committee has many manufacturing usefulness before elemental degradation is
Corrosion societies and technical members to drive the process for the key to the selection of materials, coatings,
committees specifications contained in the corrosion and/or manufacturing processes. Better,
There are a few organizations in the testing volume 3.02 of the ASTM family of more reliable products can be achieved
Unites States to assist manufacturers in standards. through proper testing selection.
matters pertaining to corrosion. The most On a global level, there is the World
prominent is the National Association Corrosion Organization (WCO), which Referenced works
of corrosion Engineering International is based out of the European Union (EU) 1. NACE International – International
(NACE International) which is based and discusses attends meetings, and Measures of prevention, Application and
out of Houston, Texas. This organization drafts many of the NACE International Economics of Corrosion technologies
focuses on corrosion on numerous type material codes and testing Study, 3/01/2016
grades of steels, heat treatments and protocols. The mission of the WCO is
surface treatments. Most of the specified to alert and make industry aware of the
material types are austenitic stainless problems and solutions applicable to
About Michael Porfilio
steels, duplex stainless steels and nickel corrosion while identifying best practices Michael has been in
based alloys as dependent upon the sour to deal with and prevent corrosion; and servicing the
gas and corrosive environments. NACE facilitate corrosion related control foundry industry since
International works with its individual through the industry, and normalize 1985. His background
members as well as manufacturing world corrosion standards. As the ISO is in the fields of
organizations. and other EU states begin to solidify their Metallurgy, Quality
More support can be found for stances of corrosion and its byproducts Management, Sales
manufacturers from ASTM. ASTM has the WCO is making a unified approach. and Marketing as well as Operations
hundreds of committees and sub- Management. He currently is a Certified
committees on technical topics from Final thoughts
Nuclear Quality Systems Auditor and NDT
testing, to materials specifications, The application of corrosion tests can be
Level III. He is employed at Stainless Foundry
to manufacturing practices and test a complicated subject. If you know your
& Engineering, Inc. as the Director of Quality.
parameters. Technical committee G01 specific goals, the usefulness of the process

4 Stainless Steel World December 2018 www.stainless-steel-world.net