1

MODUL PERKULIAHAN

ANALISA KEGAGALAN DAN KOROSI

(MODUL 11)

Corrosion Testing, Monitoring

and Inspection (Bagian 1)

Abstract Kompetensi
Analisis Korosi,memonitoring Mampu memahamibagaimana cara
daninspeksi sangatlah penting mengatasi korosi danmemonitoring

Fakultas Program Studi Tatap Muka Kode MK Disusun Oleh

Fakultas Teknik Magister Teknik Mesin W582100006 Sagir Alva,Ph.D

11
\Z cannot be stopped even when inhibitors are used. SuchAtmo
Corrosion Parameters spheric corrosion of carbon steel proceedsat
rates up to Corr Corrosion Testing in Generalosion

Corrosion Testing in General

Typical main objectives of corrosion testing are:

1. Evaluation and selection of material or protection method for a specific

environment and a certain application. Testing for this objective is initiated by the user, often
by engagement of consultants, testing laboratories or research institutions. People
determining test conditions are often faced with the following :environment and a certain
application. Testing for this objective is initiated by the user, often by engagement of
consultants, testing laboratories or research institutions.

2. General information about the behaviour of certain materials and groups ofmaterials in the
main types of environment. Testing is often done by the material producer or vendor, and the
results aid the selection of materials to be tested for a certain application

3. Routine control of materials including coatings, e.g. for acceptance or reclamation of

deliveries. Test methods and conditions may be given in specifications of the actual delivery.
Various standardized tests are used, such as the salt spray test .

4. Investigation of corrosion mechanisms and fundamental effects of various conditions,

development of test methods, e.g. reliable model experiments for the prediction of lifetime
(see next section), and other studies in research laboratories. This includes also
contributions to the development of materials and coatings with special corrosion properties.

Test Methods

To cover the objectives stated in the previous section, numerous test methods are available.
The methods can be arranged in the following groups:

1. Laboratory testing, comprising accelerated testing, model testing, and special tailor-made
investigations in research. Accelerated test methods give measurable attacks after short
time, which can be obtained by using a more aggressive environment, higher potential,
higher temperature or higher mechanical stress than under the actual service conditions.
These methods are suitable only for qualitative comparison and ranking of various materials
with respect to specific properties, and for routine control and approval of delivered
materials. Accelerated testing cannot answer questions about lifetime without knowing the
degree of corrosion acceleration. Model testing aims at realistic conditions. Possible
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acceleration must be limited to avoid change of the corrosion mechanism. The testing takes
longer than the accelerated test dealt with above, and will often require a sensitive
measuring technique. For the extrapolation of results to a realistic service period or lifetime,
a thorough understanding of the corrosion mechanism and the change of corrosion
conditions and rate with time is necessary. New measuring techniques contribute to
improvements in this direction.

2. Service (plant) and field testing, including exposure of coupons, test specimens or
components in process environments of industrial plants as well as in special natural fields
(in seawater, atmospheres, soils etc.)

3.Testing in a pilot plant, which is a true model (up to half scale) of the actual industrial plant.
Pilot plant testing is used as a basis for appropriate design and selection of materials in
cases where the condition cannot be satisfactorily modelled in laboratory tests. Pilot plants
for modelling are suitable for relatively expensive installations, in which the corrosion
conditions are complex and aggressive and the consequences of failure are great.

Testing Procedure

A typical testing procedure includes most of the following items.

1.Selection and pre-treatment of materials and test specimens.

Attention must be paid to orientation of the specimen in relation to the rolling direction and
texture, the surface of the component and welds. This is particularly important for testing of
the susceptibility to corrosion forms such as stress corrosion cracking, corrosion fatigue,
intergranular and pitting corrosion. It should be taken into account that the structure of the
surface material of a rolled component may be different from that of the bulk material. The
analysis and production history of the component must be considered, e.g. whether it has
been formed by continuous or die casting, by hot or cold forming etc. Sometimes the
specimen must be given an additional heat treatment. Parallel test specimens in an
investigation should be taken from the same charge of material. Thus, for a larger test
program, a sufficient amount of material from the actual charge must be available from the
beginning. The geometry of the specimens is in many cases most important. Undesired
crevices must be avoided. In order to reduce misleading effects of cut edges, which may be
subject to a corrosion rate which is different from that of rolled surfaces, the specimens
should have large area ratio between faces and edges. The specimens must be sufficiently
large to allow reliable weight loss measurements. In some cases the shape of the specimen
must correspond to the shape of a certain component. For later identification it is necessary

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to carefully mark the specimens, in such a way that the marks are visible after the testing
and post-treatment.

2. Surface preparation.

For prediction of the performance of a material in a particular service, the ideal surface of the
test specimen would have to duplicate the surface of the component in service, both with
respect to cleanliness, roughness and material structure. However, usually it is necessary to
deviate from this ideal demand in order to get reproducible specimens and be able to
measure the degree of corrosion with sufficient accuracy. Therefore, a metallically pure
surface, and a roughness and state of surface material defined by a certain grade of grinding
or mechanical polishing, or a certain procedure for pickling or electrolytic polishing, are
commonly used. Increased reproducibility is obtained by removing at least 10–20 µm of the
original surface material. Metallographic studies may also necessitate a smoother surface
than in practice. The surface preparation must be the same for all specimens in a test series
except when the preparation is a planned and defined variable. It is important to use clean
emery papers and polishing belts or discs, and particularly to ensure that these are not
successively used on different materials, as they may contaminate the surface of the
specimen.

3. Measurement of surface area and possibly thickness.

The accuracy of thickness measurement must correspond to the expected reduction of

thickness during the test

4. Degreasing, e.g. by acetone.

5. Weighing.

The accuracy of the weight must correspond to the expected weight loss during the test.

6. Masking.

Surfaces that are not to be exposed, must be masked, by means of materials such as wax,
lacquer, paint, tape, glue or enamel.

7. Exposure.

In some laboratory testing and particularly in field testing, standardized racks are used with
prescribed position and orientation of the specimens. In other cases, adjustments are made
with the actual practical purpose in mind.
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In laboratory testing, a number of environmental parameters must usually be controlled:

- Oxygen concentration, often controlled by bubbling air (in special cases oxygen) through
the electrolytic solution until saturation, or by bubbling nitrogen for removal of oxygen.

- pH of the electrolyte, particularly in long-term testing’

- Concentrations in general. Mechanical agitation to obtain a homogeneous solution.

- Temperature

- Relative humidity, in various test chambers containing air and vapour.

- Relative velocity between corrosion medium and specimen.

8. Inspection of the specimens after exposure, including a preliminary visual inspection (with
the naked eye or a microscope), followed by surface cleaning (mechanically, chemically or
electrochemically), weighing and/or thickness measurement, and finally metallographic
investigation using an optical or electron microscope.

9. Determination of corrosion rate, on the basis of weight loss or thickness reduction

measurements, or electrochemical measurements during the exposure.

Numerous test methods have been standardized. Examples of extensive collections are the
NACE (National Association of Corrosion Engineers) standards and the ASTM (American
Society for Testing and Materials) standards.

Electrochemical Testing

A simple form of electrochemical testing is to measure the corrosion potential, applying a

reference electrode and a voltmeter with high internal resistance. In other respects, modern
electrochemical testing most often makes use of a potentiostat. Polarization curves can be
recorded with the aim to investigate passivation properties of materials, to clarify
environmental effects, and to determine corrosion rates in galvanic and crevice corrosion,
critical potential for pitting corrosion, as well as potential ranges where the material is liable
to stress corrosion cracking. Potentiostatic tests (i.e. tests where the potential is kept
constant at certain values) can be used to determine intergranular corrosion tendency.
Potentiostatic tests combined with stepwise increase of the temperature are applied to
determine critical crevice corrosion temperature (CCT) and critical pitting corrosion
temperature (CPT) (see Sections 7.5.4 and 7.6.5). Another method is simply to measure
current between two test samples that are different in some way, for example in chemical
composition. Electrochemical methods are also used for testing painted surfaces [9.8]. Both
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direct and alternating current (DC and AC) methods are used in electrochemical corrosion
testing. Recently, advanced methods, such as the scanning vibrating electrode technique
(SVET), have been developed [9.9]. SVET is used to determine the variation of current
density over the surface being studied.

We shall look a little closer at the two most frequently applied electrochemical methods for
determination of corrosion rate. They were originally developed for general corrosion, but
with some precautions they may also be used for the determination of average corrosion
rate in pitting corrosion, selective corrosion, and – depending on the geometry – galvanic
corrosion. One of the methods is the determination of polarization curves and extrapolation
of linear parts of the polarization curves, as described in Section 4.9. The intersection point
between the extrapolated Tafel regions, in other words the overvoltage curves, gives the
corrosion current. Unfortunately, the overvoltage curves are not always pure Tafel curves.
But if either the anodic or the cathodic overvoltage curve has a sufficiently long linear part
around the corrosion potential, the necessary basis for the determination of corrosion rate is
present: the linear part of the actual polarization curve can be extrapolated to the corrosion
potential. Thus, the corrosion rate is determined regardless of the other polarization curve.
In Figure 9.1 four different cases are shown, in which the corrosion rate is determined by
extrapolating linear parts of both or one of the polarization curves.

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Determination of corrosion current density by extrapolation of linear parts of the polarization
curves. a) Both the cathodic and the anodic reaction are under activation control (the
overvoltage curves are Tafel lines). b) The cathodic reaction is diffusion controlled and the
anodic reaction activation controlled. c) The cathodic reaction is activation controlled, the
anodic curve is irregular. d) The cathodic curve is irregular, the metal is passive, i.e. the
corrosion current equals the passive current.

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 DAFTAR PUSTAKA ddPustaka

1. Fontana, M. G., and Greene, N. D., Corrosion Engineering, McGraw-Hill Book Co.,
New York, 1967.

2. Uhlig, H. H., Corrosion and Corrosion Control, 2nd. ed., John Wiley & Sons, I'lew
York, 1971.

3. Perry, R.H., and Chilton, C. H., Chemical Engineers' Handbook, 5th ed., McGrawHill
Book Co., New York, 1973.

4. System Design Manual, Part 5, Water Conditioning, Carrier Air Conditioning Com-
pany, 1972.

5. Puckorius, P.R., "Controlling Corrosive Microorganisms in Cooling-Water Systems,"

Chem. Eng., Oct. 1978, p. 171.

6. Corrosion Data Survey - Metals Sections, 5th ed., National Association of Corrosion
Engineers, Houston, Texas, 1974.

7. Uhlig, H. H., Triadis, D. N., and Stern, M., "Effect of Oxygen, Chlorides, and Calcium
Ion on Corrosion Inhibition of Iron by Polyphosphates," J. Electrochem. Soc., Feb.
1955. p. 59.

8. Kirby, G. N., "Corrosion Performance of Carbon Steel," Chem. Eng., Mar. 1979 p.72.

1.

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