Corrosion -testing methods electrical-resistance method

In general, the most widely used field technologies for inspection are ultrasonic thickness measurement, while for online methods they are corrosion test specimens, electrical resistance, and linear polarization probes. Both of the inspection methods and the first two online methods measure metal loss. The last method measures corrosion rate, but only in a sufficiendy conductive process environment, normally water. 

Electrochemical tests This group includes the various electrochemical tests that have been proposed and used over the last fifty or so years. These tests include a number of techniques ranging from the measurement of potential-time curves, electrical resistance and capacitance to the more complex a.c. impedance methods. The various methods have been reviewed by Walter . As the complexity of the technique increases, i.e. in the above order, the data that are produced will provide more types of information for the metal-paint system. Thus, the impedance techniques can provide information on the water uptake, barrier action, damaged area and delamination of the coating as well as the corrosion rate and corroded area of the metal. However, it must be emphasised that the more comprehensive the technique the greater the difficulties that will arise in interpretation and in reproducibility. In fact, there is a school of thought that holds that d.c. methods are as reliable as a.c. methods. 

Test methods for determining electrolytic corrosion with electrical insulating materials Method for determination of resistance to intergranular corrosion of austenitic stainless steels copper sulphate-sulphuric acid method (Moneypenny Strauss test) Specification for electroplated coatings of tin/lead alloys... 

To test the irritancy potential of substances, two tests which can reliably distinguish between skin corrosives and noncorrosives are endorsed by the European Centre for the Validation of Alternative Methods (ECVAM). The testing procedures are based on the transcutaneous electrical resistance (TER) measurements of rat skin and on a human skin model. Both test systems [141-145] will be briefly outlined below. Nevertheless, these tests are not suited for the group of mild irritants which do not induce an acute effect on the barrier function. For those substances, new markers need to be evaluated. First results are available for heat shock protein 27 where higher levels were observed in skin models after exposure to mildly irritating chemicals [146, 147]. 

In a search for reliable accelerated test methods for determining coating performance, electrochemical techniques have often been explored. The corrosion resistance of a coated steel panel is a composite of the steel quality, its surface finish and the quality of the coating. For this reason. Bonderite 40 coated steel panels were included in our work. They were employed primarily to aid in the interpretation of the electrical measurements for the nitrile-based photocured samples. 

Recent reports [30-31] on the use of atmospheric corrosion sensors based on changes in electrical resistance showed that when there were no contaminants [29], in tests of 100-110 h., corrosion rate was zero or insignificant. These sensors can determine changes in metal thickness lower than one nanometer. However, in the presence of 0.08 ppm of S02 or 20 pg/cm2 of NaCl in the system, changes in thickness where always detected over 75% of relative humidity. Corrosion rate was determined at temperatures of 20, 30 and 40°C and the Arrhenius equation was used to calculate the activation energy of the reactions. This method is very similar to the natural conditions. 

Goals of Testing and Classification of Test Methods Nonelectrochemical Methods Electrochemical and Electrical Methods Barrier Characteristics of Coatings Adhesion of Organic Coatings Transport Properties of Coatings Other Film Properties Corrosion Resistance of Painted Metals... 

Electrochemical and Electrical Methods. Electrochemical and electrical methods for studying film properties and corrosion phenomena have been extensively reviewed (29-31). Comparisons of corrosion test results with direct current measurements of conductivity suggest that visible corrosion is associated with film resistance less than about 1 Mohm/cm, but this condition may well correspond with the occurrence of virtual pores in the film allowing development of local conductive pathways. In studies of the equivalent alternating current resistance as a function of frequency, Kendig and Leidheiser (44) found that the development of a region of slope -1 on a log permittivity versus log frequency plot... 

L.G. Cooper, Sensing probes and instruments for electrochemical and electrical resistance corrosion monitoring, in G.C. Moran, P. Labin (Eds.), Corrosion Monitoring in Industrial Plants Using Nondestructive Testing and Electrochemical Methods, ASTM STP 908ASTM International, West Conshohocken, PA, 1986. 

ASTM G 96, Practice for On-Line Monitoring of Corrosion in Plant Equipment (Electrical and Electrochemical Methods)—This standard outlines procedures for online corrosion monitoring in operating systems. The test methods described in this standard are used to determine the cumulative metal loss (electrical resistance method) or instantaneous corrosion rates (electrochemical method). Reference 15 provides a summary of electrical resistance and polarization resistance theory. 

Measurement sensitivity divides the metal loss methods. Ultrasonics and radiography are usually considered as inspection methods. Typically, ultrasonics has a measurement resolution of around 50 pm (0.002 in.), and radiography 250 p,m (0.010 in.). Consequently, these types of measurements are typically made annually. Corrosion test specimens (coupons) assess metal loss typically over a one to three month interval. Electrical resistance probes, as an automatic coupon, assess metal loss typically over a few hours to a few weeks. 

ASTM G 96 Standard Guide for On-Line Monitoring of Corrosion in Plant Equipment (Electrical and Electrochemical Methods) Provides details on conducting polarization resistance and electrical resistance tests. 

Weight loss corrosion rates, which represent an average of corrosion over the test period, are useless from a predictive point of view, but are often used in conjunction with other measurements for quality assessments. Corrosion kinetics can be measured in different ways. Most favored are electrochemical techniques. They are, however, contrary to common belief, indirect techniques and must be properly calibrated and interpreted to be useful. If corrosion products are soluble in solution (as, for instance, iron carbonate), the buildup of such in solution can be used to monitor how corrosion progresses. Hydrogen, a byproduct of anaerobic corrosion, can also be used to monitor kinetics. Less common, but equally direct, are methods that use the removal of radioactivity from irradiated surfaces. Kinetic measurements have also been carried out with electrical resistance probes. As a general principle, no one method is in itself without some problems and should, therefore, always... 

ASTM B 826 Test Method for Monitoring Atmospheric Corrosion Tests by Electrical Resistance Probes... 

Successful inhibitor tests require suitable corrosion measurement and analysis techniques that are able to correctly record and interpret corrosion rate data. Many testing and monitoring techniques that were developed initially for the diagnosis and prediction of corrosion have been successful employed in laboratory and field corrosion inhibitor testing and research. These techniques include the use of corrosion coupons, solution analysis, electrical resistance probe, polarization resistance, electrochemical impedance spectroscopy and many other physical, electrical and electrochemical methods. 

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