Metal Finishing NovDec2012

The Plating and Coating Industries Technology Magazinewww.metalfinishing.com

November/December 2012Vol. 110

No. 9

Feature FocusUpdate on accelerated

corrosion testing methods

Technically SpeakingRole of environmental exposure simulation in predicting failures

Ask the ExpertsThe trouble with plating baths

For more than 100 years, Metal Finishing hasbeen keeping readers up to date on the technical aspects of both electroplating and paint/powder coating.

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Feature Focus12 Update on Accelerated Corrosion Testing

Technically Speaking20 Corrosion and ExposuresAn Ounce of Testing

is Worth a Ton of Recalls

Organic Finishing25 Hard Chromium Replacement Candidates for

Non-Line-of-Sight Landing Gear Applications

At Convention8 FABTECH 2012 Recap: Mega-Manufacturing

Industry Event Pleases Show Organizers and Exhibitors Alike

Columns3 Tuckers Take

Testing Your Metal

31 Adhesion and BondingHow High Temperatures Affect Adhesives and Sealants

34 Cleaning TimesType Industrial FirstUsing the Internet to Investigate Parts Cleaning Equipment

36 Quality ControlRun Charts as a Test of System Performance

39 Ask the ExpertThe Trouble With Plating Baths

Departments4 News & Briefs

43 Product Showcase/New Products53 Finishers Directory54 Classifieds55 Calendar of Events56 Ad Index

WHATSinside

Photo courtesy of Guyson

Cover image courtesy of Singleton Corp.

tuckerstake

This months issue puts the mag-nifying glass on testing and con-trols, with topics ranging from accel-erated corrosion simulation proce-dures for both organic and inorgan-ic coatings, to getting to the sourceof common (and some not-so-com-mon) electroplating bath problems.

Take, for instance, Corrosionand ExposureAn Ounce of Testingis Worth a Ton of Recalls, theinstructional article from AndersonLaboratories (page 20). In this high-ly informative piece, complete withhelpful illustrations, the authorseffectively demonstrate how accept-ed laboratory testing methods canhelp operators evaluate the efficacyof their coating materials as well astheir overall finishing processes.

Another gem is SingletonCorporations updated tutorial onthe fundamentals of accelerated cor-rosion testing (page 12). In this com-prehensive refresher, the author, RaySingleton, underscores the usefulnessof accelerated corrosion tests in com-parison to real-world exposure, whilefocusing on the consistency of thetest results. Its a pretty thoroughread, but stick with it and youll berewarded with essential knowledge ofthe prevailing theories behind accel-erated corrosion testing. (Disclosure: Ihad the fortunate opportunity toobserve this wealth of knowledgefirsthand, when I visited SingletonCorporations headquarters inCleveland, Ohio, earlier this year.)

I was pleasantly surprised to learnthat Singleton Corporation is muchmore than just a fabricator/manu-facturer of testing chambers andbarrel plating systems. The firm alsodoes double duty as an educator,teaching not only existing clients,but also providing instruction to

students and established platingshops alike. Mr. Singletons creden-tials speak volumes. He serves aschairperson for the ASTM CabinetCorrosion Tests (committeeG.01.05.03), vice-chairperson forASTM Corrosion of Metals (com-mittee G.01), vice-chairperson forASTM Laboratory Corrosion Tests(committee G.01.05), and compos-er/instructor for the ASTM TPT(Technical Professional Training)Corrosion Testing course for the last14 years.

Other major players in the field ofcorrosion testing equipment are alsoputting just as much emphasis oneducation and theory as they are onmaking stuff. During the aforemen-tioned tour, I made a pit-stop inStrongsville, Ohio, where fabricatorsand designers at the newly expandedAuto Technology Company head-quarters were busy at their craft.Kevin Smith, the companys presi-dent, provided an in-depth look atits capabilities. As chairman ofASTM B117 (G01.05.03.01) TaskGroup on Salt Spray Testing; co-chair of the SAE AutomotiveCorrosion & Prevention Committee;and U.S. voting member for ISOTC35, Smith also administers corro-sion testing courses for clients andstudents right on the premises.

Now, thats what I call one-stopshopping.

For more information on the afore-mentioned training programs and cours-es, including customized educationalopportunities, please contact the respec-tive companies.

Testing Your Metal

November/December 2012Volume 110 - Number 9

Publisher David Hopwood

EditorReginald Tucker

[email protected]

Art Director - Production ManagerSusan [email protected]

Advertising Sales ManagerArnie Hoffman

Ph: (847) 559-0909E-mail: [email protected]

Advertising Sales RepsDonald Moeller512-585-2391

E-mail: [email protected]

Lynne Arons847-853-7001


Annabelle Jacobson847-256-6850


Gabe JacobsonE-mail: [email protected]

Tel: 847-256-6818

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Marketing/Circulation ManagerCaroline Champney

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metal finishing

www.metalfinishing.com November/December 2012 I metalfinishing I 3

APPOINTMENTSRebecca Harding has been promot-ed to the position of marketing man-ager at Columbia ChemicalCorporation, effective immediately.She will report to Brett Tilberg,European sales manager.

As marketing manager, Hardingwill take a more active role in globalmarketing functions, including mar-keting strategy, brand development,and marketing communications insupport of the companys strategicinitiatives for continued growth anddevelopment. She will continue tocoordinate foreign and domesticcommunication campaigns, promo-tions, marketing collateral and web-site content.

Harding has been a key member ofColumbia Chemicals marketingteam for eight years, originally join-ing the company in 2004 as a mar-keting assistant and most recentlyholding the position of marketingcoordinator. She holds a Bachelorsdegree in Education with a concen-tration in Biology from Baldwin-Wallace College. Harding also servesas chairperson to ColumbiaChemicals Charitable Committee.

For more information, please visitwww.columbiachemical.com.

Coventya, based out of Cleveland,Ohio, recently appointed RickRauppius International productmanager, protective technologies.Rick has more than 21 years in themetal finishing industry, workingprimarily in product managementand technical support for protectiveand functional coatings. He holds aBS in Chemical Engineering fromGeorgia Tech.

Pneu-Mech SystemsManufacturing recently namedJerry Trostle its new sales manager,with responsibility for the North

American region. Trostle bringsmore than 30 years experience in thefinishing industry, most recentlyserving as general manager atWagner Systems. "Pneu-MechSystems Manufacturing and our cus-tomers will greatly benefit fromJerrys extensive background in fin-ishing," a company press release stat-ed.

"We are excited about Jerry joiningour company. He will be a great assetto our team."

Pneu-Mech SystemsManufacturing of Statesville, N.C., amember of the Brawtus Group, pro-vides paint finishing system engi-neering, design, manufacturing,installation and project manage-ment to the industrial market. Pneu-Mech Systems Mfg. has more than20 years of experience in providingquality equipment and services tothe industry.

Metabo Corporation, a leadinginternational manufacturer of pro-fessional grade portable electricpower tools and abrasives for indus-trial, construction and weldingapplications, announced it has hiredJere L. Geib, Jr. as its new marketingmanager. Geib will be responsible formarketing, advertising, and salespromotions as well as supporting thedevelopment efforts for the compa-nys distribution channel.

Over the past 16 years, Jere hasheld an array of positions in the fieldof marketing and communications,said Martin Cross, president ofMetabo. As a result, he brings well-rounded experience to our team andcompany. His vast knowledge ofsales, marketing and communica-tions will help us develop strategiesto meet the changing needs of ourcustomers as well as our sales net-work.

Before joining Metabo, Geib wasthe director of marketing for

Translogistics, Inc., Birdsboro, Pa.,where he served as a member of theexecutive management team devel-oping and executing strategic mar-keting, business and developmentplans for the company.

Prior to that, Geib held variousmarketing and public relations posi-tions for a variety of global electron-ics manufacturers and distributors,including Tyco Electronics, PhoenixContact, TVC Communications andHarsco Corporation.

Geib holds a B.A. inCommunications with concentra-tions in Public Relations andCorporate Media fromElizabethtown College,Elizabethtown, Pa.

EXPANSIONSChemetall, an innovator in surfacetreatment and metal processingtechnologies, opened a new cutting-edge facility in Blackman Township,Mich., on Oct. 24. The $25 million

chemical manufacturing plant cov-ers 200,000 square feet to houseadministrative, manufacturing,warehousing operations, and a phys-ical testing laboratory. More than900 Chemetall products will be pro-duced at the 40-acre Blackman sitefor applications in surface treatment,metal fabrication, cleaning and sani-tizing.

"The labor force, as well as thestrong support from BlackmanTownship and the State of Michigan,

NEWS&briefs REBECCA

HARDING

4 I metalfinishing I November/December 2012 www.metalfinishing.com


Americas Center in downtown St.Louis, Mo. The manufacturer ofcoating thickness devices edged outmore than 20 COATING 2012exhibitors that took part in thePowder Coating Institutes annualawards program.

DeFelskos award-winning productwas the PosiTector 6000 CoatingThickness Gage. The unit accepts all

made Blackman Township the mostlogical choice for our new plant,said Dr. Ron Felber, CEO ofChemetall NAFTA. "We have select-ed the best area talent to support ourgrowing operations."

Automation advancements,including bulk material handlingsystems, mixing vessels, and packag-ing lines, have been incorporatedinto Chemetall's BlackmanTownship facility to increase produc-tivity as well as improve productyield and quality for customers. As ameasure of its dedication to environ-mental sustainability, Chemetall hasinstalled a semi-automated wastetreatment system to reduce processwastewater by 90%.

"High-tech additions to the newBlackman Township site ensure theefficiency of operations for themanufacture of the finest qualitychemistries," Dr. Felber stated."Customers can be assured ofChemetall's commitment to theirsatisfaction through our innova-tions and service from all of ourfacilities. Our mission is to inte-grate our decades of experience inclose cooperation with our cus-tomers, employees, and communi-ties to produce customized solu-tions that enhance processes as wellas the environment."

AWARDS DeFelsko took home the ProductShowcase Award at COATING 2012,which took place Oct. 811 at The

DPM, SPG and UTG probes, easilyconverting from a coating thicknessgage to a dew point meter, surfaceprofile gage or ultrasonic wall thick-ness gage.

The Product Showcase display fea-tured products launched in the last12 months. Visit the Powder CoatingInstitutes website, www pci.org., formore information on the showcase

NEWS&briefs

Mike Wittenhagen (right), technical manager atthe Powder Coating Institute, presents the 2012Product Showcase Award to DeFelskos TerryLaRue (left), during the close of the COATING2012 show in St. Louis, Mo.

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Coventya is pleased to announcethe addition of GMW16730 to itsimpressive and continually expand-ing list of global zn/ni approvals.COVENTEC P7755B surpasses all ofthe strict requirements defined with-in GM's cosmetic black multi-layerzn/ni standard.

Products covered include: PER-FORMA 285; FINIDIP 728.2; andFINIGARD 113.

The latest GM approval joins previ-ously obtained approvals for VW,Renault, PSA, Audi, Toyota, Fiat,Honda, Ford, Volvo, Nissan and GM.For more information, please visitwww.coventya.com.

ANNIVERSARIESOsborn, a leading supplier of surfacetreatment solutions and high-qualityfinishing tools for hundreds ofindustrial and commercial applica-tions, celebrates 125 years in thebusiness.

Founded by John J. Osborn in1887, Osborn originally made horseand butcher block brushes as well asstreet cleaning brooms. Now, 125years later, Osborn--a unit of Jason,Inc., offers more than 10,000 stan-dard finishing products and morethan 100,000 customized solutionsto customers in more than 120 coun-tries. Throughout its growth,Osborn maintained its headquartersin Cleveland while adding locationsin 15 countries to better serve itsdiverse group of customers.

At Osborn, were extremely proudof our 125-year history of providingour customers worldwide with supe-rior products that meet their finish-ing needs, said Luis Hereza, vicepresident of marketing at Osborn.Under Osborns new brand identity,introduced earlier this year, were aunified team that focuses on a histo-ry of quality, innovation, excellenceand service.

In celebration of its 125th anniver-sary, Osborn is publishing the com-panys history in a coffee table book.The book captures a valuable piece ofbrush making history, and takes thereader from the companys begin-ning to present day.

contest or the COATING 2012 showin general.

PARTNERSHIPSIntegran Technologies andDynatronix, Inc., recently devel-oped a cooperative sales and mar-keting agreement designed to fur-ther strengthen their ongoing rela-tionship in the area of electrodepo-sition of nanostructured materials.Under the new agreement,Dynatronix will continue to pro-vide industry-leading pulse platingpower supplies specifically opti-mized for Integran's proprietary,patent-protected electrodepositionprocesses. Together, these processesand power supplies will be deployedinto Integran's global productionfacilities as well as by Integran'slicensees.

Dynatronix engineers have beeninstrumental in the development ofstate-of-the-art process equipment,enabling the low-cost production ofour nanostructured and nano-lami-nated materials at high productionspeeds, said Dr. Gino Palumbo,Integran's president and CEO. Iam very pleased that, as part of thenew agreement, Dynatronix person-nel will play a much more activerole in the further development andcommercialization of our nano-technology."

David Osero, vice president ofsales and marketing at Dynatronix,concurred. Dynatronix is honoredand excited to be involved in thecutting-edge technology thatIntegran continues to bring to mar-ket, he said. Their efforts toremain at the forefront of metallur-gical nano-technology developmenthave driven Dynatronix to continu-ally improve our products and serv-ices to meet Integran's needs. Welook forward to strengthening ourrelationship with Integran andhelping both companies enjoy con-tinued success in the metal finish-ing industry.

CERTIFICATIONS

Pangborn Europe, a leading manu-facturer in the surface preparationindustry, celebrates 50 years of suc-cessfully development and engineer-ing in an increasingly diverse andtechnologically challenging industry.

"With the right strategies, we haveeffectively grown over the years andgone through good and difficulttimes," said Pangborn Europe gener-al manager Renzo Boarino, whoactively engaged the daily business ofPangborn Europe since 1988. "Infact of our consistent focus on con-tinuous development and marketintroduction of new and pioneeringplant and machinery has set newstandards for surface treatment inmiscellaneous industries."

Pangborn Europe, part of theumbrella Pangborn Group organiza-tion, was founded in 1962. Sincethen the company has been provid-ing some of the most well designed,engineered and durable wheel blastand air blast equipment, Boarinostated. "Our excellence in design andengineering has earned us a stellarreputation across a number of indus-tries through our unmatched combi-nation of custom products and serv-ices, particularly those for heavy dutyapplications in the foundry, forge,automotive and steel industries. Inaddition, our on-site foundry allowsus to assist our customers with avariety of parts."

TRAININGEnthone, Inc. recently hosted a com-prehensive one-day training sessionon the recently re-issuedAutomotive Industry ActionGroup (AIAG) CQI-11 PlatingSystem Assessment, Second Edition.Enthone Automotive IndustryManagers, Linda Wing and RichardLynch chaired the training session.Ms. Wing was also a member of theAIAG CQI-11 technical committee.

Over the last decade, the ContinualQuality Improvement (CQI) assess-ment has become an industry bench-mark that is extensively employed bycomponent coating applicators toassess their suppliers, with the keyobjective of defect prevention andreduction, and supply chain opti-

NEWS&briefs



2012 NEW ENGLAND SURFACEFINISHING REGIONAL More than 120 metal finishing pro-fessionals attended the NewEngland Surface Finishing Regionalon November 2 in Sturbridge, Mass.The Host Hotel was the site for theannual one-day event, which fea-tured technical presentations, a tabletop trade show and a social hourwith entertainment.

Christian Richter, NASF execu-tive director, opened the meetingwith an update on the organization'sactivities and efforts at strengthen-ing the association and increasingmembership. He was followed byeight other speakers who presentedon technical topics such as surfacepreparation of copper and copperalloys, water purification and alter-native coatings for aerospace anddefense applications.

Other regulatory and managementissues covered included an presenta-tion by a local OSHA representativeand a presentation on state and fed-eral employment laws. A very thor-

mization. Furthermore, major auto-motive OEMs require compliancewith CQI guidelines.

The training was conducted by atrio of industry experts who were allactive members of the AIAG techni-cal committee that issued the secondedition. Mr. Ron Lash, CQI-11 tech-nical committee chairman and aretired senior engineer for Chrysler,detailed the document changes. Ms.Elizabeth Hanna, a Six Sigma masterblack belt and ASQ quality engineer,provided her experiences with sup-plier assessment as a quality manag-er. Mr. Jeff Szotek, a plating and sur-face finishing specialist withChrysler, provided an OEMs per-spective and expectations for suppli-er use of the CQI-11 assessment, aswell as the influence of the assess-ment on future specifications. Morethan 50 OEMs and tier suppliers par-ticipated in the training program.

ough presentation on the use ofcomputer software tracking forchemical use, cost and inventory wasincluded.

Personal interest topics were cov-ered as the details and story of theimpact of a massive business disasterhad everybodys attention. Attendeesalso listened to a very well-receivedpresentation on stress and energymanagement in the workplace.

Marc Pelissier of Valley Plating ofSpringfield, Mass., was the master ofceremonies and once again got around of applause for all his efforts.John Gilbert of Gilbert and Jones,Marko Duffy of MarathonManufacturing Services, ChrisCapalbo of New Method Plating andChris and Ed Ondrick of Poly Platingwere presented with Certificates ofAppreciation for al their hard workin making this day a success.

The Regional Meeting for next yearwill be held in November 2013 withthe location to be determined. Pleasevisit www namf-ne.org for moreinformation.

NEWS&briefs

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atconvention

The organizers of FABTECH2012, which took place at theLas Vegas Convention Center Nov.1214, kicked off a well-rounded,heavily attended event that lived upto its pre-show billing. Exhibitorsenjoyed robust traffic, particularlyon the first two days, with somevendors reporting purchasing activ-ity. More importantly, attendeesrepresenting various sectors of theNorth American manufacturingcommunity got the opportunitynetwork with peers as well as ven-dor partners while reviewing thelatest innovations in equipment,automated systems, and surfaceforming/finishing technologyallunder one great, big roof.

According to show organizers,1

FABTECH 2012 drew 25,903 atten-deesan 18% increase compared tothe last time the show was held inLas Vegas.2 The sheer volume,observers say, is indicative of not

only the vitality of the U.S. manufac-turing sector, but also the willing-ness of job shops and captive opera-tions to invest in capital equipmentand training.

Weve received great feedbackfrom attendees and exhibitors, saidJohn Catalano, FABTECH show co-manager. Attendees were impressedwith the size and scope of the showand the vast array of new productsand technologies on display (seeProduct Showcase in this issue).Exhibitors were enthusiastic andreport that sales activity was briskand the leads plentiful.

The heavy activity was especiallypalpable in the Finishing Pavilion,which made its debut at FABTECH2010 in Atlanta. According to AnneGoyer, executive director of theChemical Coaters AssociationInternational, or CCAI, a FABTECHco-sponsor, this years FinishingPavilion occupied its largest show

floor space in thethree years that ithas been a part ofthe show. (Morethan 25,000 netsquare feet, to bemore precise.)

By all accounts,this was the bestFinishing Pavilion& Conference atFABTECH to date,Goyer told MetalFinishing. She saidCCAI was pleasant-ly surprised that its

show floor square footage surpassedthat of FABTECH 2011, which washeld at the sprawling McCormick

Conference and Convention Centerin Chicago. In fact, Goyer said CCAIhad to expand its exhibit space threetimes to accommodate the requestsfor booth space in Las Vegas.

Likewise, Goyer said CCAI also sawa big jump in this years FinishingConference sessions. By her count,CCAI more than doubled its sessionssold to 384 this year compared to187 in Atlanta in 2010. Conferenceparticipation was up by more than30% over the Chicago event last year.

As we were tearing down, I had thechance to talk to quite a few confer-ence attendees who told me the con-ference sessions they attended pro-vided great information, said Goyer,citing conference evaluations reflect-ing very high marks.

SOLID ALL AROUND Finishing Pavilion exhibitors, not tobe outdone, providing some gener-ous scoring of their own. Cases inpoint: Kathy Wilson, marketingmanager for AkzoNobel, wasextremely pleased by the number oflegitimate leads generated at herbooth, while Mark Schmidt Jr., tech-nical support specialist, FinishingBrandsrepresenting DeVILBISS,Ransburg, BGK, and BINKSsaidthe traffic through his booth wasrock steady. Similarly, Paul Lomax ofFischer Technology had his handsfull with a stream of curious atten-dees interested in demonstrations of

atconvention

FABTECH 2012: Mega-manufacturing event pleases

show organizers and exhibitors alike.

BY REGINALD TUCKER


FABTECH 2012 consumed more than 450,000net square feet of floor space at the Las VegasConvention Center. Wheelabrator enjoyedprime space in Hall C.

Bruce Dunham, marketing manager, DuboisChemicals, demonstrates the capabilities of thecompany's new treo jel D pretreatment line.

to touch base with both existing andpotential suppliers. In recent years,Sclafani expanded into the finishingbusiness and wanted to meet withhis cleaning and pretreatment ven-dor partners, as well as suppliers ofturnkey finishing systems.

Were very loyal, Sclafani toldMetal Finishing. When we find a goodsupplier, we tend to stick with them.

MANUFACTURING PULSEFABTECH 2012 represented muchmore than a venue for suppliers toshowcase innovations in manufac-turing. The event also provided asnapshot of the state of the manu-facturing sector itself, which wasreflected in the lineup of educationalsessions. For instance, the confer-ence portion featured a special Stateof the Industry roundtable withmanufacturing chief executivesmany of whom concurred that mod-est growth in U.S. industrial produc-tion should continue in 2013. At thesame time, many cited the lack ofskilled workers in manufacturing asa major stumbling block to hiring.To remedy that situation, membersof the CEO panelcomprising firmssuch as Jay Industries, Inc.; OhioLaser, LLC; Trans-MaticManufacturing Co.; Metcam, Inc.;and SunDial Powder Coatingsemphasized that manufacturersneed to be more aggressive in influ-encing parents of students, havingstudents influence each other andhave school be a more active voice inrecruiting potential workers.

One panel member, Patrick J.Thompson, president of Trans-MaticManufacturing Co., told the audi-ence that qualified labor is closerthan one would think. The bestsource of labor is in your own back-yard, he said. Thompson suggestedcompanies work more closely withcommunity colleges, vocationalschools, and even trade associations.

Other feature presentations provedjust as timely and relevant. With theshow occurring only five days afterthe presidential election, FABTECHalso featured a Post-Election Analysispanel featuring Omar S. Nashashibi,partner with The Franklin

thickness testing equipment.And lets not forget about the con-

suming publicthose attendeescomprising shop owners and man-agers who made the trip in search ofinnovative tools and new equipmentto boost efficiency/profitability intheir operations. That descriptionfits those like Tony Sclafani, generalmanager of ARI Iron, LLC and ARPowder Coating, who primarily came

Partnership, LLC, and David Goch,partner with Webster, Chamberlain& Bean. The panelists discussed theongoing political gridlock inWashington as well as impending taxreform and other issues that stand toimpact manufacturers. Still, therewas a general consensus that themanufacturing sector has gainedinfluence in Washington over thepast two years, and panel membersstrongly encouraged manufacturersto get involved in advocacy efforts for

atconvention

Spray equipment demonstrations at theWagner Industrial Systems booth.


Despite Challenges,Metalformers Expect Slow and Steady Growth Over the Short Term

The November Precision MetalformingAssociation report shows that 19% ofparticipants anticipate that economicactivity will improve during the nextthree months, up from 15% inOctober, while 45% predict that activ-ity will remain unchanged, down from55% last month. By comparison, 36%report that activity will decline (com-pared to 30% in October).

At the same time, metalforming com-panies expect a slight uptick in incom-ing orders during the next threemonths, with 28% anticipating higheractivity, up from 24% in October, while39% forecast no change (compared to41% last month). One-third of respon-dents predict a decrease in orders(down from 35% in October).

Metalforming companies clearlyanticipate continued softening for thebalance of 2012 and are looking aheadto 2013 with very modest expectationsfor an uptick in business conditionsduring the first few months of the newyear, said William E. Gaskin, PMApresident. Results of the presidentialelection, negative stock market per-formance, significant concern over howCongress will address income taxes onSub-S and LLC pass-through compa-nies, and low expectations for howCongress will address the fiscal cliff aremajor concerns. There also is a growingconcern for resurgent regulatoryenforcement by EPA, OSHA and otherfederal regulatory agencies.

Coral Chemical talking up its environmentallyfriendly pretreatment technologies.

All smiles. Chemetall's Suresh Patel (left), DavidGotoff (center), and Gary Nelson.


I heard both on the show floor and atthe seminars was thatwhile chal-lenges and uncertainties remainmost manufacturers believe thattheir businesses are headed for con-tinued growth in 2013.

FABTECH 2013 will be held Nov. 18-21 at McCormick Place in Chicago, Ill.

REFERENCES1. FABTECH 2012 is jointly spon-

the industry via their trade associa-tions.

All things considered, the overalloutlook was generally positive. Ifyou can take the pulse of the econo-my by whats happening in manufac-turing, then you have to be optimisticthat we are headed for economicgrowth, said Mark Hoper, FABTECHshow co-manager. A constant theme

atconvention

Magic Rack's Dan Davitz (front right) explainshow the company can customize racking sys-tems for a particular part or component.

Bill and Brendan Johnsee manning the WaltherPilot booth in the Finishing Pavilion.

3Ms Jeff Simmons (front right) and BobHamilton (far right) explain the benefits of thecompanys new Cubitron II technology forgrinding wheels.

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2. Attendance as measured by thenumber of people who actuallypicked up a badge on site.


featurefocus

to be discussed in this update. The usefulness of testing coatings

for resistance to water, or highhumidity, as a good indicator of theirservice life in service environments ofthat type resulted in the ASTMD1735 Standard Practice for TestingWater Resistance of Coatings UsingWater Fog Apparatus and the ASTMD2247 Standard Practice for TestingWater Resistance of Coatings in 100%Relative Humidity. Demand forimproved evaluation of decorativecopper/nickel/chromium ornickel/chromium coatings on steel,zinc alloys, aluminum alloys, andplastics designed for severe serviceresulted in the ASTM B368 StandardTest Method for Copper AcceleratedAcetic Acid-Salt Spray (Fog) Testing,widely known by its acronym as theCASS test.

Additional needs for testing ofproduct resistance to harsh industri-al environments led to the develop-ment of the ASTM G85 StandardPractice for Modified Salt Spray (Fog)Testing with its 5 included corrosiontest variations and the ASTM G87Standard Practice for ConductingMoist SO2 Tests. The ASTM G85variations (tests): Annex 2, Annex 3,Annex 4, and Annex 5 along withASTM G87 were developed to subjecttest pieces to cycles of differing envi-ronments to more closely resemblethe changes occurring in pertinentreal-world environments. See Table Ifor information on static versuscyclic environment tests.

With the wide variety of materialsand coatings, their uses, and the serv-ice environments in which they maybe used, manufacturers and productdevelopment personnel now canselect an accelerated corrosion testthat best suits their particular prod-uct and applicable environmentalconditions. Table I is provided to givea guide to which ASTM test standardcan be used for the representative sit-uations listed. Along with the devel-opment of new accelerated corrosiontests ASTM Standards have beendeveloped to give direction andresources for the preparation of testpieces prior to testing and evaluationof post test results. A good example is

Some of the more widely used testsare the representative ASTMStandards detailed in this article andwell known industry cyclic corrosiontests such as: General MotorsGMW14872 (formerly GM9540P),and SAE J2334. There are many othertests in use; however, those men-tioned also exhibit wider applicabilityand versatility and are, therefore,some of the more popular proce-dures. Other than the ASTM B117Salt Fog test, most widely used foron-line process and product qualitycontrol, no other single corrosion testis as dominant because of the widevariety of service conditions, productindustries and specific issues such asvarious materials, applications meth-ods, properties, and varying surfaces.

Other considerations to considerwhen choosing or specifying a partic-ular accelerated corrosion testinclude the multitude of environ-ments and customer demands facedby a product and industry. A varietyof standard tests has been developedto address these issues.

One of the firstand still mostwidely utilizedaccelerated corro-sion tests developed is ASTM B117Operating Salt Spray (Fog)Apparatus. Early development ofcorrosion tests was initiated in orderto evaluate the corrodibility of met-als and protective properties of coat-ings in a marine or near shore envi-ronment. As corrosion testing wasincreasingly used also to evaluateproduct quality and materials usedin product development, variationson the basic, or original, corrosiontest standards have been added toincrease their usefulness for a widerrange of environments and materi-als. This process has resulted in thedevelopment of the various repre-sentative accelerated corrosion tests

Accelerated corrosion testing ofmetals and coatings was firstdeveloped in the late 1890s and early1900s for testing products toincrease their useful performanceand service life. This method of test-ing the corrodibility of ferrous andnonferrous metals and organic andinorganic coatings has since beenimproved and variations added tobetter test new materials and helpoperators understand how they mayperform in, and withstand, a widerrange of real world environments.

Accelerated corrosion testing hasalso evolved from providing informa-tion to help determine durability ofproducts, and their quality assuranceduring manufacturing, to use inproduct research and development.Professional trade, industry, militaryand standards organizations, such as:ASTM International (AmericanSociety for Testing and Materials),the Society of Automotive Engineers(SAE), the Federation of Societies forCoatings Technologies (FSCT),NACE International (NationalAssociation for Corrosion Engineers), Society for Protective Coatings(SSPC) and others have developed anumber of accelerated corrosion teststo meet the demands of changes, andadvances, in technology, materials,and other performance requirementsand environmental regulations.

For instance, water-based coatingshave been developed as replacementsfor solvent-based liquid coatingmaterials in response to environmen-tal concerns. Some powder coatingsand their application methods reducethe use of solvents and ease applica-tion. In addition, the automotiveindustry has improved coatings andincreased the number of surfacescoated as part of the response to mar-ket pressures for longer warranties.

Accelerated Corrosion TestingBY RAYMUND SINGLETON, SINGLETON CORP., CLEVELAND, OHIO


tency of test results. Accelerated cor-rosion tests are performed undercontrolled conditions with a limitednumber of variables, which general-ly do not duplicate the vast varietyof variables that occur in any onelocation in a real-world environ-ment. Comparison standards can beused to compensate for this.Comparison standards are properlyprepared, representative test piecesfrom a product with a known trackrecord of exhibiting acceptable per-formance from exposure in applica-ble real-world environments and/oralso acceptable corrosion resistanceafter being exposed to the specifiedaccelerated corrosion test(s). Theythen can be used as standardsagainst which other tested pieces arecompared. This process helps espe-cially product developers and alsoquality professionals predict how anew product or production run ofan existing product will performwhen used. It is usually not possible,unless additional long-term, real-time, comparative outdoor or in-service exposure data is available,

ASTM D609 Standard Practice forPreparation of Cold-Rolled SteelPanels for Testing Paint Varnish,Conversion Coatings and RelatedCoating Products. This standard pro-vides guidelines for the preparationof test pieces before they are intro-duced into the accelerated corrosiontest. ASTM Standards: D1654Standard Test Method for Evaluationof Painted or Coated SpecimenSubjected to CorrosiveEnvironments; D610 StandardPractice for Evaluating Degree ofRusting on Painted Steel Surfaces,and; D714 Standard Test Method forEvaluating Degree of Blistering ofPaints were developed to providecommon standards for analyzing andreporting the results obtained fromthe corrosion tests and observed onthe tested specimens. These stan-dards are summarized below.

ISSUESPrimary issues that arise when dis-cussing the usefulness of accelerat-ed corrosion tests are comparison toreal-world exposures and the consis-

to directly compare any given num-ber of hours in an accelerated corro-sion test with a given number ofyears exposure in real-world envi-ronments. The development ofadditional variations on basic accel-erated corrosion tests have allowedengineers, technicians, and qualityprofessionals to better evaluatedurability of products to be used ina wider variety of environments,under multiple corrosive influences,and under constantly changingservice conditions.

The issues are: consistency in theaccuracy of test results from subse-quent runs of the same test in a sin-gle test chamber; and consistency forcomparison of test results obtainedfrom the same test run in otherchambers. These issues have beenaddressed with the development ofASTM methods for evaluating thisnecessary consistency. This verifica-tion is called repeatability of resultsfrom subsequent runs of the sametest in a single test chamber andreproducibility of results from sub-sequent runs of the same test inother test chambers (regardless ofhow many other corrosion testchambers are involved). Theseimportant verification proceduresare covered in Section X3 of theAppendix of the ASTM B117 teststandard and incorporate MassLoss Corrosion Coupons describedin that section. A similar variation ofthis Mass Loss Corrosion Couponprocedure is described in Paragraph8.7 of ASTM B368, using nickelcoupons for the CASS test.

CRITERIA FOR CYCLIC TESTSThe American Iron and SteelInstitute, in cooperation with theAutomotive Corrosion andPrevention Committee of the SAE,conducted a study of existing cycliccorrosion tests (completed in 2003,revised in 2007) in order to developtests that could be used to rank per-formance of materials used in auto-motive cosmetic applications.Approximately 20 existing corrosiontests were selected for study. Theseincluded static exposure conditiontests (tests where the exposure con-

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much wider variety of materials,finishes, and applications. ASTMG85, Annex 5, is known to be par-ticularly useful for testing both:architectural coatings and industri-al maintenance paints as well asother applications.

TYPES OF TESTSIn this case, ASTM B117 is describedfirst. The other ASTM CorrosionTest Standards discussed aredescribed in terms of how they varyfrom the basic B117 Standard. Onlythose aspects of these standards,which are different from the B117standard, will be discussed.

ASTM B117 Standard Practicefor Operating Salt Spray (Fog)ApparatusThe ASTM B117 Standard is prima-rily used to test the corrosion resist-ance of organic and inorganic coat-ings on metals. Examples are paintor plated finishes on metal itemsand exposure of products tomarine or near-shore environ-ments. This standard will also be thebase against which this article willdescribe other corrosion tests. TheB117 Standard is a static (con-stant) condition, continuous test,preferably run in multiples of 24-hour periods. The test pieces are

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ditions do not vary over the dura-tion of the test), such as ASTMB117, and cyclic exposure condi-tion tests such as ASTM G85 Annex5 and GMW14872 (formerlyGM9540P), (tests which subject testpieces to a variety of different expo-sure atmospheres and conditionsover the duration of the test). Tendifferent test materials wereexposed in each test. The results ofthe tests were compared to real-world exposure results from 10 sitesaround the globe utilizing dupli-cates of the same materials. It wasconcluded from results that anacceptable corrosion test must: (1)simulate the rank order of perform-ance of coatings in actual service; (2)produce the same type (character)of failure as found in real-worldexperience (example: blistering); (3)be reproducible; (4) be of relativelyshort duration; and (5) be feasibleand cost effective.

The test established as a result ofthis effort is the SAE J2334Laboratory Cyclic Corrosion Test.The SAE J2334, GMW14872 (for-merly GM9540P), and ASTM G85,Annex 5 meet the above criteriaand are some of the more com-monly used cyclic corrosion tests inthe U.S. and around the world. TheSAE J2334 and the GMW14872were originally developed for test-ing cosmetic finishes on automo-tive components. Fortuitously,they have been shown to producemore realistic corrosion resultsand, therefore, are used to test a


Fig. 1. Schematic drawing of a typical salt fogtest chamber.

collection area. To maintainthese conditions, the cham-ber is heated and best main-tained with a wet bottomcondition in the exposurezone. The equipment need-ed to maintain these testconditions will meet therequirements described inTable II and be made suchthat all component partsthat come in contact with the expo-sure zone, water, or solutions aremade of, or coated with, inert mate-rials. Typical test chamber compo-nents and operational connectionsare illustrated in Fig.1.

ASTM D1735 Standard Practicefor Testing Water Resistance ofCoatings Using Water FogApparatusThe ASTM D1735 Standard uses astandard fog-generating chamber asused for the ASTM B117 Standard.The primary variations are thechamber temperature, which is heldat 38C (100F) and the eliminationof the corrosive salt (electrolyte).The fog is created by atomizingASTM D1193 Type IV water withoutany salt whatsoever. This testmethod is used to gauge the lifeexpectancy of coating systems bymeasuring their resistance to waterpenetration.

ASTM D2247 Standard Practicefor Testing Water Resistance ofCoatings in 100% Relative HumidityThe ASTM D2247 Standard is usedto investigate how a coating resistswater, which can help predict its use-ful life. This is generally a pass/failtest; however, the time to failure anddegree of failure can be measured. Acoating system typically passes ifthere is either no sign of water-relat-ed failure after the specified testperiod or less than an establishedspecified amount of failure.

For the ASTM B2247 Standardthe ASTM D1193 Type IV water isplaced in the bottom of the exposurezone to a depth of 6 to 8 in. and thenheated. The area of the exposurezone above the water is not heated

exposed to a salt fog atmospherefrom atomized solution made up of5% sodium chloride and 95% ASTMD1193 Type IV water by mass andheld to purity standards specifyingthat it contain: not more than 0.3%by mass total impurities. Halides(Bromide, Fluoride, and Iodide)other than Chloride, shall constituteless than 0.1% by mass of the saltcontent. Copper content shall be lessthan 0.3ppm by mass. SodiumChloride that has had anti-cakingagents added shall not be usedbecause such agents may act as cor-rosion inhibitors. This solution isthen atomized into the chamberexposure zone, which is maintainedat a temperature of 35 +/- 2C (95 +/- 3F) and a relative humidity of atleast 95%, creating a fog that has acondensate collection rate of 1.0to2.0 ml/hr per 80 m2 of horizontal

directly in order to cause condensa-tion on the test pieces. The water isintroduced into the chamber beforethe test pieces and maintained at atemperature approximately 5 to10C (1020F) higher than thetemperature of the vapor above it.The major variation in the chamberis the elimination of the foggingtower. The 100% humidity resultsfrom the vaporization of the heatedwater in the bottom of the chamberand/or having heated humidified airpumped through the water. Thehumidifying tower is used when theoption of having air pumpedthrough the heated water is chosen.The exposure zone is maintained at38 2C (100 4F) and 100% rel-ative humidity. This test method isperformed in water-jacketed cham-bers (see Fig.2) with the 6 to 8 in. ofwater mentioned above in the bot-tom of the exposure zone and thewater jacket filled to 12 in. above thebottom to ensure that the immer-sion heaters are submerged. It canalso be run in larger chambers, suchas walk-in or drive-in size units (seeFig. 3), equipped with heated watertanks in the exposure zone to gener-ate the required humidity. A primaryconcern when conducting the ASTMD2247 test is that the chamber besufficiently insulated. Figure 4 is aschematic of a typical ASTM D2247humidity test chamber configura-tion. To ensure that the ASTMD2247 test is being performed con-sistently, it is recommended that acontrol test piece with known dura-bility be included in each test run.

ASTM B368 Standard TestMethod for Copper Accelerated

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Fig. 2. Typical water-jacketed-type corrosiontest chamber, mostly used for static conditiontests.

Fig. 3. Typical large-size, drive-in-type corrosiontest chamber.

Fig. 4. Humidity test chamber schematic drawing.

until the temperature within theexposure zone has reached 49C +/-1C (120 +/- 2-F) and is then runcontinuously for 6 to 170 hours asagreed upon between purchaser andseller prior to the start of the test. Itis required that the temperaturewithin the exposure zone bechecked twice a day only on regularbusiness days when the chambermay be periodically opened forshort durations (preferably lessthan 5 min) to work with test piecesand/or replenish solution.

Another variation from the stan-dard salt spray (fog) test is in themandatory verification for consisten-cy of test exposure conditions. InASTM B using Nickel Mass LossCoupons rather than steel (as usedin the B117 Practice, Section X3[non-mandatory]). The B368Standard uses corrosion test cham-ber apparatus that meets the require-ments for the ASTM B117 Standardand will withstand the increased tem-perature and stronger electrolytesolution used for this test.

ASTM G85 Standard Practicefor Modified Salt Spray (Fog)TestingFive variations of this standard havebeen developed to accommodate itsuse to different purposes. The varia-tion that is used by interested partiesin any situation must be agreed uponprior to the start of testing. Followingare brief explanations of each of thefive individual test variations:

Annex 1Acetic-Salt Spray (Fog)TestingThe Acetic Acid-Salt Spray (Fog)Test is used to test ferrous and non-ferrous metals and inorganic andorganic coatings for resistance toadditional and more corrosive envi-ronments than the ASTM B117Standard. This test is designed as acontinuous exposure test withoutinterruptions. It uses a 5 1 part bymass solution of sodium chloride in95 parts of ASTM D1193 Type IVwater. The pH of the solution isadjusted with the addition of glacialacetic acid to be within the range of3.1 to 3.3. This solution is then

Acetic Acid-Salt Spray (Fog) Test(or CASS Test)The ASTM B368 Standard, original-ly developed by the NationalAssociation for Surface Finishing(NASF), is used primarily in thedevelopment of coated metal prod-ucts, including decorative coatings,which will be exposed to severe serv-ice and more corrosive environ-ments and also to evaluate the per-formance and protective propertiesof more durable coatings whichwould not be affected by the typicalASTM B117 type salt fog test. Thistest method is particularly applica-ble to the evaluation of the perform-ance of decorativecopper/nickel/chromium or nick-el/chromium coatings on steel, zincalloys, aluminum alloys, anodizedaluminum and plastics designed for

severe service. This test meets thechallenges of providing a simulatedservice evaluation to test productspecifications in research and devel-opment and provide manufacturingcontrols for environmental changescaused by human intervention.

The B368 Standard is a variationon the basic ASTM B117 Salt Spray(Fog) Test. For this variation, adjustthe pH of the 5% salt solution intothe range 6.0 to 7.0, and then add0.25 grams of reagent-grade copperchloride per liter of salt solution.The test is not considered to start

atomized into the exposure zone tocreate a fog that has a condensatecollection rate of 1.0 to2.0 ml/hr per80 m2 of horizontal collection areawhile the temperature of the expo-sure zone is being held at a constant35 +/- 2C (95 +/- 3F). This vari-ation is particularly useful inresearch when evaluating the effectof altering the parameters of anelectroplating process or evaluatingthe quality of the process on decora-tive chromium plating. It is used pri-marily for steel and zinc die-castingsubstrates. It should be noted byusers that even though this test isutilized as a more severe alternativeto the ASTM B117 Salt Spray (Fog)test, the type of actual corrosionproduced is not necessarily of alike-kind to that resulting fromthe B117 test on the same test speci-men material.

Annex 2Cyclic Acidified Salt FogTestFor this variation the pH of the testsolution is adjusted to a range of 2.8to 3.0, the exposure zone tempera-ture is raised to 49C (120F), andthe humidifying tower temperatureis raised to 57C (135F); however,the most significant change is thewet and dry cyclic nature of the test.This change in the test requires thatthe test chamber be equipped withapparatus to produce differingatmospheres for the various steps inthe test cycle and timing apparatusthat will cause the atmosphere with-in the chamber to vary as follows.Every 6 hours, the test pieces will beexposed to 3/4 of an hour spray ofatomized salt solution, then a 2-hrdry period, during which the cham-ber is purged of humidity. The finalcycle is 1 hours of high humidityas described by the temperature andcollection rates specified. Addingthe cycles to this test increases itseffectiveness if evaluating how prod-ucts perform in a continuouslychanging environment.

Annex 3Acidified Synthetic SeaWater (Fog) TestThe addition of 42 g of synthetic seasalt and 10 ml of glacial acetic acid

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Fig. 5. Typical cyclic-type corrosion test chamber with PLC control for automaticoperation of changeable atmospheres, temperatures, and durations of various steps in cycle.


SO2 in accordance with any set cycle.It is imperative to address all safetyissues: equipment, personnel, appa-ratus, and procedures prior to test-ing with SO2, since it is a very haz-ardous highly toxic gas. Note thatthe primary changes to the chamberare to allow for the correct introduc-tion of the SO2. All parts of thechamber that come into contactwith the SO2 must be made of mate-rials that are inert to SO2 gas.

Annex 5Dilute Electrolyte CyclicFog/Dry TestFor this test the electrolyte solutioncontains 0.05% sodium chloride and0.35% ammonium sulfate in 0.60%by mass of ASTM D1193 Type IVwater. This solution is much moredilute than the standard salt spray(fog) test and is run using 2-hr cycletimes comprised of 1-hr fog at ambi-ent 24C 3C and relative humidi-ty below 75%, followed by 1-hr dryoff at 35C. That is, the test piecesare exposed to 1 hour of spray fog atcontrolled room temperature,then 1 hour dry-off time at 35C(95F). The collected condensateshall have a pH within the range of5.0 to 5.4. Because of the cyclicnature of this test, a separate 16-hrsalt fog test is necessary to establishand verify proper condensate collec-tion rates prior to starting the cyclictest. Because of the differences inhumidity in this test method andthe cyclic nature of the test, thechamber will need to have a separateair line and valve to allow the atom-izing air to bypass the humidifyingtower and timing apparatus to con-trol the cycle times, temperaturechanges, spray, and airflow. This testis a modification of the British RailProhesion test developed in the1960s for the industrial mainte-nance coatings industry. This test isbest suited for the testing of paintson steel.

ASTM G87Conducting MoistSO2 TestsThe ASTM G87 standard is an adap-tation of the sulfur dioxide testsused in Europe and is particularlyeffective in producing easily visible

per liter of solution, in this varia-tion, is to increase its usefulness forproduction control of exfoliation-resistant heat treatments used inproducing 2000, 5000, and 7000series aluminum alloys. The pH isadjusted into the range 2.8 to 3.0and the test is performed at a tem-perature of 49C (120F). Whenusing this variation to test organiccoatings on metallic substrates thetest is performed at a pre-selectedtemperature in the range 24 to 35C(7595F). The collection rate speci-fication for fog cycles of this test isunchanged from the B117 Standardat 1 to 2 ml/hr of operation; howev-er, 2-hr cycles are used throughoutthe test period. Because of the cyclicnature of this test, prior to startingthe test a separate 16-hour salt fogtest is necessary to establish and ver-ify proper condensate collectionrates. The test chamber must beequipped with apparatus and con-trols that will cycle the exposurezone repeatedly through a -hrspray step then 1 hours of soaktime at 98% relative humidity (seeFig. 5).

Annex 4Salt/SO2 Spray (Fog)TestIn this test either a sodium chlorideor synthetic sea salt solution can beused. The determination of whichwill be used is dependent on theproduct being tested and therequirements of the interested par-ties. A primary difference in this testprocedure is the addition of sulfurdioxide (SO2) to the exposure zoneusing a predetermined cycle. Therequirement of the ASTM G85,Annex 4 standard is that all thecycles during the test period be equalin length. Introducing SO2 into theexposure zone on a periodic basisrequires additional apparatus. Thechamber can be equipped with adevice that will disburse the SO2evenly throughout the chamberwithout directly impinging on anytest pieces. The SO2 supply sourceattached to the chamber must have aregulator, flow meter, and timer toallow for accurate introduction of

corrosion on metals as would beobserved in an industrial or marineenvironment. This test requires 20.2 L (122 in3 12 in3) Type IVwater in the bottom of the test cham-ber and does not use a fogging appa-ratus. The apparatus used to gener-ate the necessary humidity is thesame used in the ASTM D2247 test.The gas introduction apparatus isthe same as used in the ASTM G85Annex 4 test. Once the test pieces areplaced in the chamber 0.2, 1, or 2 L(12, 61, or 122 in3 12 in3) of sulfurdioxide (SO2) with a purity of 99.9%(liquid phase) is introduced. Thenthe temperature of the chamber israised to 40 C (104 5.4F) in 1 hours and remains at this level forthe duration of the test cycle. Onetest cycle is 24 hours. A test can berun for as many cycles as are agreedupon between the purchaser and sell-er; however, the SO2 and water mustbe changed for each 24-hr cycle.

The 24-hr test cycles are executedin one of the following ways: 1.Continuous change of water andSO2 with as little disturbance as pos-sible 2. Alternating Exposure 8-hrexposure; drying in ambient for 16hours with 2030C (6886F) and75% relative humidity The variationsdiffering from the B117 practice arethat for this test method all testpieces be placed on the same hori-zontal plane and all test pieces in agiven test run be of similar reactivity.NOTE: While adding corrosive gasesmay expedite degradation of the pro-tective properties of the coating onthe steel substrate, the purpose ofthe test must be kept in mind. Thisgas introduction may be acceptablewhen testing materials used in anenvironment that may include simi-lar acids, such as roofing materials,

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Fig. 6. Custom-sized, computer-controlled cor-rosion test chamber for cyclic testing.

recording capabilities.Programmable logic controller(PLC) systems provide for increas-ingly sophisticated data acquisition,manipulation, and display (see Fig.6). As a result, both test chamberswith manually entered settings forautomatic operation, and test cham-bers with increasingly sophisticatedprogrammable controls for auto-matic temperature changes; varyinglevels of controlled humidity; auto-matic changes for different environ-mental atmosphere cycles; and auto-matic data logging/accumulation,record keeping, and output withgraphic data display, are availablethrough a variety of suppliers. Thesecomprehensive capabilities alloweach laboratory to find acceleratedcorrosion testing equipment that

that could be exposed to acid rain.

EQUIPMENTWith continued developments inaccelerated corrosion testing, basicchanges and improvements havebeen made to the equipment. Thebasic requirements for acceleratedcorrosion testing equipment are list-ed on Table II under the ASTM B117Standard. The adjustments requiredfor each variation on the acceleratedcorrosion-testing model are thenlisted next to the appropriate ASTMstandard. Typical applications arelisted in Table III. Along with thebasic operating requirements,improvements have been made inthe materials used in the construc-tion of the chambers, the hardwareand software controls, and data

meets their specific needs.

TEST PIECE PREPARATION/CLEANINGIn order for any of the above acceler-ated corrosion tests to obtain com-parable results, all test pieces muststart the test in a similar conditionwithout contaminants present onthe surface of interest. The ASTMtest standards discussed above indi-cate reference standards to be usedfor the preparation and cleaning oftest pieces. Particular attentionmust be paid to the wide variety ofmaterials being cleaned and recogni-tion of differing specialized materialand coating operations. ASTM teststandards state that the cleaningmethod is to be dependent on theproduct being cleaned and thenrefer to ASTM D609 StandardPractice for Preparation of Cold-Rolled Steel Panels for Testing Paint,Varnish, Conversion Coatings andRelated Coating Products whererequired. This standard describesfive cleaning and preparation meth-ods. The preparation methodsdescribed are: Procedure AConversion Coating; Procedure BVapor Degreasing; Procedure CSolvent Brushing; Procedure DSolvent Wiping; and Procedure EAlkaline Cleaning. Procedure A(Conversion Coating) addresses theissue of ensuring that the test piecebe protected from rusting betweenthe manufacturing process and thecorrosion test. Procedure B (VaporDegreasing) exposes the test piecesto solvent vapors within controlledconditions to remove contaminants.This procedure is currently discour-aged for environmental reasons.Procedures C (Solvent Brushing)and D (Solvent Wiping) both useMineral Spirits as the cleaningagent. Procedure E (AlkalineCleaning) describes methods forcleaning with an alkaline cleaningagent that is appropriate for theproduct. The cleaning method andcleaning agent chosen for any testrun should be as agreed uponbetween the purchaser and seller.ASTM D609 refers to the water breaktest as a method of checking test

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back (perpendicular distance offailure from the scribe line) of thecoating is measured at uniformintervals and the rating systemdescribed in the standard applied.

ASTM D610 provides a series ofphotographic reference standardsthat demonstrate degrees of rust onthe surface of a test piece. The testpieces are first gently cleaned then theamount of rust observed is reportedfrom comparison to the photograph-ic standards and the additional use ofestablished standardized terminologyfrom the test standard. It is importantto compare only rust and not surfacesstained by rust.

ASTM D714 is used to evaluatecoating adhesion by observing theamount of blistering that hasoccurred. The test pieces are first gen-tly cleaned then compared to theseries of included photographic refer-ences and the additional use of theappropriate standardized terminol-ogy indicated in the test standard.They are gradedfirst by the size ofthe blisters thatappear on thesurface and thenthe number ofblisters thatappear per unitarea.

CONCLUSIONThe corrosiontests discussedin this article aresome of themost utilizedtests of this type.They alsodemonstrate thediversity of thetests and someof the advance-ments in acceler-ated corrosiontesting and com-plexity of thesubject. Theyalso provide asolid basis forevaluating theperformance of awide variety of

pieces for contaminants. The proce-dure is simply to run a small amountof water over the surface of the testpiece. If it is free of oils and contami-nants the water will run over it in asheet and off in one fall with nobreaks. Finally, ASTM D609 discuss-es the handling of cleaned test piecesand storage in paper impregnatedwith volatile corrosion inhibitor(VCI) if the test pieces are not to berun immediately after cleaning.

EVALUATION OF RESULTSSome primary ASTM Standards thathave been developed to assist in theevaluation of corrosion test resultsare: ASTM D1654Standard TestMethod for Evaluation of Painted orCoated Specimen Subjected toCorrosive Environments; ASTMD610Standard Test Method forEvaluating Degree of Rusting onPainted Steel Surfaces; ASTM D714Standard Test Method for EvaluatingDegree of Blistering of Paints; andASTM B537Standard Practice forRating of Electroplated PanelsSubjected to Atmospheric Exposure.Irrespective of the title wording, thetext of ASTM B537 states that it isalso used to evaluate panels subjectedto laboratory accelerated corrosiontests. Other standards are also avail-able for evaluation of specific materi-als and finishes.

ASTM D1654 is used for the eval-uation of substrates, pretreatments,coating systems, or a combinationthereof. This standard is also usedwhen the coating has been scribedprior to exposure to the corrosiveenvironment. ASTM D1654 recom-mends a straight-shank tungstencarbide tip or equivalent scribingtool to produce a cut through thecoating to the substrate of the testpiece. The scribe serves as a deliber-ate failure of the coating systemprior to corrosion testing. Once thetest piece has been through theselected accelerated corrosion test itis then cleaned by rinsing with a gen-tle stream of water at 45C (110F).Loose coating is then removed usingcompressed air to blow it off or ascraper to scrape it off. The creep-

products and materials. These stan-dards have been developed, evolvedand refined through cooperativeefforts of experts and interested par-ties from: ASTM International,industry, government, and othertrade organizations worldwide.

ABOUT THE AUTHOR Ray Singleton is the Chairperson for theASTM Cabinet Corrosion Tests (commit-tee G.01.05.03) and Vice-Chairperson forASTM Corrosion of Metals (committeeG.01) and Vice-Chairperson for ASTMLaboratory Corrosion Tests (committeeG.01.05) as well as the composer/instruc-tor for the ASTM TPT (TechnicalProfessional Training) Corrosion Testingcourse for the last 14 years. He has writ-ten various magazine articles and con-tributed to industry directories on thistopic over the years. Singleton was alsopresented with the Francis L. LaQueaward by ASTM in 2010 for contribu-tions corrosion testing and the field of cor-rosion technology.

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Tel. 716.763.4343www.miraclean.com

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Corrosion and Exposures An Ounce of Testing Is

Worth a Ton of Recalls

INTRODUCTIONThere are many options for surface finishes when it comesto metal products. Chemical coatings and paints are com-mon in metal parts (Figure 1). Surface preparation andcoating options range from polishing and blasting topickling, passivating and plating. Application of the coat-ing adds another layer of complexity to the finishingprocess. So, how do you know if your coating is going tohold up over time and exposure to the elements beforegoing into production? The answer is simple; environ-mental simulation and/or accelerated corrosion testing.

Corrosion Costs to America. The products of corrosionthat are at times an aesthetic annoyance cannot be com-pared to the potential of failure to many corrosionmodes. The numerous hidden costs of corrosion struc-tures, equipment, bridges, proactive coatings, specialtymaterials, cathodes, anodes, and other manufacturedparts are just some of the items that suffer the effects ofcorrosion.

The coatings industry is experiencing pressure fromenvironmentalist groups, corporate sustainability pro-

TECHNICALLYspeaking

BY BENJAMIN CARDENAS, ICP ANALYST/SALT SPRAYSPECIALIST; PHILIP SCHMIDT, CHEMICALANALYST/CORROSION SPECIALIST; AND MICHAELPORFILIO, DIRECTOR OF OPERATIONS, ANDERSONLABORATORIES, INC., GREENDALE, WIS.

grams and individuals to produce greener products.Environmentally friendlier coatings usually have less cor-rosion resistance over the lifetime of the coating or finish.This had left the industry, in some situations, strugglingto come up with new alternative formulations that per-form as well as their less environmentally friendly coun-terparts.

The price of corrosion is staggering. Some quick costsfor corrosion include $108 billion in protective coatings,$7.7 billion for Corrosion Resistant Alloys (CRA), and$1.1 billion spent on corrosion inhibitors, to name a few.The total direct cost of corrosion in America is $276 bil-lion in 2012. To emphasize how large this number is in2012, it is projected to be 3.1% of the United States GDP.

Cabinet Salt Spray and Humidity Testing. Tests such asneutral salt spray testing (NSS) and humidity testing canhelp a manufacturer or end user determine the efficacy oftheir coating/finishing process. By examining test speci-mens throughout the duration of the test, obvious sur-face effects are noticeable sometimes within a single dayor two, preventing expensive and time-consuming reworkand recalls. This comparison to an unfinished, or controlspecimen will help to determine the best surface finish forthe intended application (Figures 1-5). The followingimages illustrate failures of coating application and/orperformance.

There are many specifications and standards written tohelp perform this testing and, equally as importantly,evaluate the results. The most common specifications forperforming an NSS test are ASTM B117 and ISO 9227,which outline the test conditions required for the neutralsalt spray test. These specifications unify the test parame-ters across the globe in the effort to evaluate the efficacyof paints, coatings and finishes.


Figure 1 (left): Painted Power Transfer Assembly Prior to Exposure to Neutral Salt Spray (NSS). Figure 1a (right): Salt Spray Exposure IAW ASTM B117-11 inProcess.


These specifications unify the test parameters world-wide in order to evaluate the efficacy of paints, coatingsand finishes. In this test, an atmosphere of a 5% solutionof sodium chloride is atomized and introduced at a con-stant rate throughout a sealed chamber. (see Figure 1a)Test specimens are inclined and placed in the cabinet sothat the test surface is parallel to the primary direction offlow of the sodium chloride mist. The mist wets the sur-face, and the excess solution runs off into the cabinet.

Humidity testing is another measurement of the effec-tiveness of the corrosion resistance properties of a metalpart. This test can be performed is several ways. The firsttakes place in an unused NSS cabinet by simply turningoff the salt solution flow and plugging the drain. The sec-ond test takes place in an environmental simulation cab-inet specifically designed for this type of test. The require-ments for this test can be laid out in a manufacturersspecification or in an ASTM publication such as ASTMD2247. This type of testing helps to evaluate primarilypaints and their tendencies to bubble and blister.

These two types of cabinet corrosions testing can alsobe very effective as free iron detection tests. Free iron test-ing can be an excellent predictor of corrosion resistanceproperties and surface finish success. Locations on a cast-ing or finished part, which are high in free iron, can

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become epicenters for corrosion while in service. In mostcases, a free iron test can be done via salt spray testing inabout 2 hours or in a humidity chamber in about 24hours (see Figure 6).

These different combinations of coatings and hours ofexposure have led to a number of different conclusionsfor these companies. The most important being costeffectiveness of coating and surface finishes vs. corrosionresistance.

Additional Free Iron Detection Tests. In addition tothese two cabinet style tests, another procedure that caneffectively detect free iron is a potassium ferricyanide-nitric acid (Ferroxyl) test, in accordance with MIL-STD-753 and ASTM A380. The ferroxyl test will illuminateeven the lowest levels of iron contamination. In this test,a reaction with the chemicals in the test solution yields achemical reaction in the form of a bluish coloration,demonstrating the presence of free iron (see Figure 7).

Once the testing has begun, the challenge becomes theevaluation of the constantly changing surfaces of interest.Sometime it is helpful to add a point of certain failure tothe test specimen, or scribe, to see just how bad a failurebecomes if it should occur via damage or deficiency of thecoating. There are many evaluation procedures such asASTM D610, D714 and D1654 that oversee the evalua-tion of test results. These specifications use numerical

Figure 2. Failed Painted Power Transfer Assembly After Exposure to NSS.

Figure 3. Base Metal and Surface Corrosion in Galvanized SteelConstruction Stud After 24 Hours of Exposure to NSS.

Figure 4. Failed Galvanized Plating on a Spring After 48 Hours of Exposureto NSS.

Figure 5. Failed Powder Coating on a Ductile Iron Casting After 72 HoursExposure to NSS.

values to evaluate the severity of the corrosion, blisteringand/or creep.

These laboratory tests have one goal in common: toassist the surface preparation industries evaluate the effi-cacy of their coating material and/or process. Corrosiontesting can help everyone from epoxy powder coatingcompanies to chemical coating operations to zinc/cadmi-um/chrome plating providers, and everyone in between.The ultimate goal in applying a coating or perform sur-face treatments is to protect surfaces providing the high-est quality product with the least amount of overhead inorder to yield maximum profit.

Accelerated Corrosion Testing. Accelerated corrosiontesting allows base material verification prior to finalapplication of surface treatments such as plating or pol-ishing. Unwanted corrosion in stainless steels and otherrelated alloys is of significant concern in their engineer-ing. Rough surface finishes, elevated temperatures andcorrosive environments encountered in service can accel-erate corrosion and lead to material early failure.

Different forms of corrosion are commonly encoun-tered in service, and many can be strongly influenced byheat-treating. Fortunately, there are many types of stan-dardized test methods, which seek to qualify materials

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and quantify the rates corrosion that the alloy may expe-rience. Some examples are noted below:

Pitting corrosion is a localized form of corrosion foundin stainless steels and other related alloys, which do nottypically experience uniform corrosion. Pitting corrosionis typically caused by the breakdown of a passivating sur-face layer and results in small areas of corroded pits.These pits can act as sites of crack initiation and are detri-mental to a materials performance.

Intergranular corrosion in stainless steels is usuallyassociated with a precipitated inter-metallic phase foundat the grain boundaries of a material. For example,chromium carbide precipitation at the grain boundariescan deplete the surrounding material of corrosion-inhibiting chromium. In the presence of a corrosive envi-ronment, these grain boundaries are preferentiallyattacked and are subsequently weakened.

Stress corrosion cracking is another form of corrosionthat can cause normally ductile materials to fail in a brit-tle manner. When a material is both stressed (especially atelevated temperatures) and also exposed to a corrosiveenvironment, the grain boundaries can be attacked andthe materials mechanical properties can be compro-mised. Stress corrosion cracking (SCC) is very alloy-spe-cific in that certain alloys may only experience SCC in thepresence of specific chemical environments. Austeniticstainless steels in particular are susceptible to SCC in thepresence of chlorides.

Sensitizing heat treatments in stainless steels can aggra-vate problems associated with intergranular corrosion.(Sensitization is a process in which a material is heated toa temperature in which chromium carbides, for example,can precipitate out of solution at the grain boundariesand create a chromium depleted region which adverselyaffects corrosion resistance). Austenitic stainless steels aresusceptible to sensitization after heating to ~500C800C. The addition of carbide-stabilizing elements suchas niobium or titanium can help to ameliorate the prob-lem; however, processes such as welding a susceptiblematerial can still detrimentally affect its microstructuralintegrity.

There are many standardized methods for testing amaterials susceptibility to one of the three forms of cor-


Figure 6.

Figure 7. Free Iron Indications after Ferroxyl Test on High Alloy StainlessSteel Casting. The blue coloration indicates presence of surface free iron.

Figure 8. Conforming and Non-conforming G48C Corrosion Coupons.Pitting indications correspond to dark spots on left-hand samples.


rosion addressed. A common test for pitting corrosion isthe ASTM G48 test. How it works: A sample coupon ispolished, dimensioned and weighed prior to testing. It isthen placed in a ferric-chloride solution for a specifiedperiod of time. The sample is re-weighed after testing andvisually examined for signs of pitting corrosion. This testcan also quantify the mass loss rate of certain materialsand can be very useful in ranking a materials ability toresist this form of corrosion.

ASTM A262 Method E is a common test for intergranu-lar corrosion. In illustration: Two samples are polished fortesting, with one as a control. One of the two samples isboiled in a copper/copper sulfate sulfuric acid solution fora specified period of time while the other is desiccated.

After testing, the two samples undergo a U-bend test;

TECHNICALLYspeakingthe apex of the bend is examined by microscope to lookfor evidence of intergranular fissures. The presence ofthese fissures indicates the materials susceptibility tointergranular corrosion, and can be used to determine ifa sensitizing heat treatment has affected a materials sus-ceptibility to intergranular corrosion.

The ASTM G36 test is another commonly used test tolook for susceptibility to stress corrosion cracking. In thismethod, samples are polished and bolted into a U-bendconfiguration. These samples are boiled in a magnesiumchloride solution for a specified period of time, and theapex of the bend is microscopically evaluated to look forevidence of crack formation. The presence of cracks indi-cates susceptibility to stress corrosion cracking.

Other common forms of testing and their applicationsareas of interest are listed in Table 1.

Although corrosion can be detrimental to the servicelife of many stainless steels and related alloys, there are,fortunately, many methods available to help predict amaterials expected performance. The American Societyfor Testing Methods has standardized many of thesemethods, which are part of the standard toolkit designedto help minimize the costly effects of corrosion in metals.

Corrosion Societies and Technical Committees. Thereare a few organizations in the United States to assist man-ufacturers in matters that regard corrosion. The mostprominent is NACE International, the NationalAssociation of Corrosion Engineers, based out ofHouston, Texas, which focuses on corrosion of numerousgrades of steel and surface treatments. Most of the speci-fied material types are austenitic stainless steel, duplexstainless steel, and nickel-based alloys as dependent uponthe environ-ment or expo-sure to sour gasand corrosiveenvironments.NACE workswith individualmembers aswell as organi-zations.

More sup-port can befound for man-ufacturers fromASTM, theA m e r i c a nSociety forT e s t i n gMaterials. Theorganizat ionhas hundredsof committeesand sub-com-mittees ontechnical topics

Figure 9. Intergranular Corrosion of Metallographic Cross Section of 304Stainless Steel.

Figure 10. Lab technician conducting the ASTM G48 test, a common pro-cedure for detecting pitting corrosion.

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from testing, to material specifications, to manufacturingpractices and parameters. Technical committee G01 wasformed in 1964, meets twice per year and has more than350 members. This committee has many manufacturingmembers to drive the process for the specifications con-tained in the corrosion testing volume 3.02 of the ASTMfamily of standards and specifications.

On a global level, theres the World CorrosionOrganization (WCO), which is based out of the EuropeanUnion (EU) and discusses, attends, and drafts manyNACE-type material codes and testing protocols. Themission of the WCO is to: alert and make industry awareof the problems and solutions associated with corrosion;identify best practices to deal and prevent corrosion; facil-itate corrosion-related control through the industry; andnormalize world corrosion standards. As the ISO andother EU states begin to solidify their stances of corrosionand its by-products, the WCO is making a unifiedapproach.

Final Thoughts. The application of corrosion tests can bea complicated subject. If you know your specific goals, theusefulness of the process can be informative and valueadded. To have a solid concept of the product life and use-

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fulness before elemental degradation is key for the selec-tion of materials, coatings and/or manufacturingprocess. Better products can be achieved through propertesting selection.

ABOUT ANDERSON LABORATORIES, INC. Anderson Laboratories, Inc., was established in 1939 inMilwaukee, Wis. Currently located in Greendale, Wis., the com-pany is an independent materials testing laboratory specializingin chemical analysis, mechanical testing, welding procedure andperformance qualification, failure analysis, environmental andcorrosion testing, as well as on-site evaluations. AndersonLaboratories, Inc. has quality and system programs accredited orcompliant to ISO/IEC 17025, 10CFR50 Appendix B, ASMENQA-1, 97/23/EC PED, RoHS, NORSOK M-650, ISO 9001, toname a few. For more information, please contact AndersonLaboratories, Inc. at (800) 950.6330, via e-mail at [email protected], or online at www.andersonlabs.com.


ASTM Test Method Applicable Forms and Alloys Relevant Type of Corrosion

ASTM A262 Method A Cast and Wrought Austenitic StainlessSteels

Detection of Sigma Phase

ASTM A262 Method B (Streicher Test)

Cast and Wrought Austenitic StainlessSteels

Intergranular Corrosion

ASTM A262 Method C (Huey Test)



ASTM A262 Method E (Modified Strauss Test)



ASTM A923 Method A Cast and Wrought Duplex Austenitic /Ferritic Stainless Steels

Detecting Detrimental IntermetallicPhases

ASTM A923 Method B Cast and Wrought Duplex Austenitic /Ferritic Stainless Steels

Detecting Detrimental IntermetallicPhases (Utilizing Charpy V-Notch

Impact Testing)

ASTM A923 Method C Cast and Wrought Duplex Austenitic /Ferritic Stainless Steels

Detecting Detrimental IntermetallicPhases

ASTM G28 Method A Wrought Nickel-Rich, Chromium-Bearing Alloys


ASTM G28 Method B Wrought Nickel-Rich, Chromium-Bearing Alloys


ASTM G36 Wrought Cast and Welded StainlessSteels and Related Alloys

Stress Corrosion Cracking

ASTM G48 Method A Stainless Steels, Nickel-Based andChromium-Bearing Alloys

Pitting Corrosion

ASTM G48 Method C Stainless Steels, Nickel-Based andChromium-Bearing Alloys

Pitting Corrosion

Table 1. Common Forms of Testingand Their Associated Applications.


Hard Chromium ReplacementCandidates for Non-Line-of-Sight

Landing Gear Applications

Introduction. Electroplated hardchromium (EHC) is a proven coat-ing process, but many environmen-tal, health, and safety (EHS) issuesand regulations are associated withits use. As a result, the Departmentof Defense (DoD) has investigatedand implemented thermal spraycoatings to replace EHC in its main-tenance facilities. High velocity oxy-gen-fuel (HVOF), a type of thermalspray process, deposition of tung-sten carbide-17 percent (%) cobalt(WC-17Co) has largely replaced EHCin line-of-sight (LOS) applications;

however, it has been incapable ofrepeatedly depositing uniform coat-ing thicknesses on complex (i.e.,non-LOS [NLOS]) geometries[1].

Therefore, the United States AirForce Research Laboratory Advanced Power Technology Office(AFRL APTO), in conjunction withConcurrent TechnologiesCorporation (CTC), sought bothelectroless and electrochemicallydeposited chromium- (Cr-) free coat-ings that could treat NLOS parts.Most suitable candidates containednickel (Ni), which has other healthconcerns, denoted in Table 1. It also

is listed on the EnvironmentalProtection Agencys list of hazardoussubstances and is on the watch list asan emerging contaminant by theOffice of the Deputy Under Secretaryof Defense for Installations andEnvironment Chemical and MaterialRisk Management Directorate(CMRMD).1 As a result, Ni-basedproducts are expected to becomemore heavily regulated and, thus, notsuitable for mid- to long-term solu-tions. To address this problem, theteam investigated non-Cr and non-Ni technologies (i.e., largely cobalt-based coatings), with fewer healthconcerns and potentially reducedrestrictions as compared to EHC (seeTable 1).

Background. Numerous electrolessand electrochemically depositedalternatives to EHC were evaluatedand found to be s

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