Salt spray

Although most greases offer some inherent protection against msting, additives, eg, amine salts, sodium sulfonate, cycloparaffin (naphthenate) salts, esters, and nonionic surfactants (qv), are often used to provide added protection against water and salt-spray corrosion. A dispersion of sodium nitrite has been particularly effective in some multipurpose greases. 

Product Utilization. The principal appHcation for chromium phosphate coatings is as a paint base for painted aluminum extmsions and aluminum beverage can stock. In these appHcations, extremely demanding performance criteria are met by the chromium phosphate conversion coatings. As an example, the Architectural Aluminum Manufacturer s Association Voluntary Specification 605.2-92 requires humidity and salt spray testing for 3000 hours and allows only minimal incidence of paint failure after testing (26). 

Synthetic Applications. Oxazolines, which ate synthesized as indicated above, have been utilized in many different appHcations (25). When used in resin formulations, AMP, AEPD, and TRIS AMINO can incorporate the oxazoline stmeture into the polymer stmeture (26). Because they ate polyols, both AEPD and TRIS AMINO can be used in polyester resin modification. Oxazoline alkyd films ate characterized by improved performance, particularly salt-spray resistance and gloss (see Alkyd resins Coatings, special purpose, high performance). 

Formulation of effective corrosion-resistant coatings is made difficult by the lack of a laboratory test that can provide rehable predictions of field performance. The most widely used test is exposure in a salt fog chamber. It has been shown repeatedly, however, that the results of such tests do not correlate with actual performance (125). Outdoor exposure of panels can provide useful data, especially in locations where salt spray occurs, but predictions of performance are not always satisfactory (126). 

B287 acetic acid salt spray test... 

Sa.lt Spray Tests. One of the older accelerated corrosion tests is the salt spray test (40). Several modifications of this imperfect test have been proposed, some of which are even specified for particular appHcations. The neutral salt spray test persists, however, especially for coatings that are anodic to the substrate and for coatings that are dissolved or attacked by neutral salt fog. For cathodic coatings, such as nickel on steel, the test becomes a porosity test, because nickel is not attacked by neutral salt fog. Production specifications that call for 1000 hours salt spray resistance are not practical for quahty acceptance tests. In these cases, the neutral salt spray does not qualify as an accelerated test, and faster results from different test methods should be sought. 

The reproducibility of test results between labs using the neutral salt spray tests has not been consistent, but the repeatability, within one lab, is better, and the test has value in comparing variations in coating systems. Correlation of hours of exposure in the salt spray test to actual performance of the plated part in service, even in marine atmospheres, is not consistent and usually avoided. A classic example is that cadmium deposits outlast zinc deposits on steel in salt spray tests and clean marine atmospheres, yet zinc outlasts cadmium when exposed to real, industrial atmospheres, because of the presence of sulfur-bearing corrodents in industrial environments. An important variable in salt spray testing is the position of the surface to be tested. Whereas the surface of test panels is specified to be 15—30° from the vertical (40), when salt spray testing chromated zinc-plated specimens, this range has appeared excessive (41). 

The CASS Test. In the copper-accelerated acetic acid salt spray (CASS) test (42), the positioning of the test surface is restricted to 15 2°, and the salt fog corrosivity is increased by increasing temperature and acidity, pH about 3.2, along with the addition of cupric chloride dihydrate. The CASS test is used extensively by the U.S. automobile industry for decorative nickel—chromium deposits, but is not common for other deposits or industries. Exposure cycle requirements are usually 22 hours, rarely more than 44 hours. Another corrosion test, now decreasing in use, for decorative nickel—chromium finishes is the Corrodkote test (43). This test utilizes a specific corrosive paste combined with a warm humidity cabinet test. Test cycles are usually 20 hours. 

Salt spray tests, humidity tests, and other accelerated tests, some usiag sulfur dioxide and carbon dioxide, have shown favorable results for tin—2inc ia comparison with 2iac, cadmium, and fin deposits. Chromating improves the performance. 

As of this writing the 2inc alloys are too new to have actual corrosion resistance data, except for that based on accelerated tests. Zinc—nickel usually shows better results than 2inc-cobalt in salt spray tests. The reverse is tme when the Kesternich test is used. Tin—2inc performs well in both salt spray and Kesternich tests, but appears only to equal 2inc plating and 2inc—nickel in humidity tests. 

Zinc—Nickel. Steel has the best salt spray resistance when the nickel is 12—13% of the alloy. At increasing nickel contents, the deposit becomes more difficult to chromate and more noble, eventually becoming cathodic to steel. At those levels and above, corrosion resistance usually decreases and is dependent on a complete lack of porosity for protection of the steel. In efforts to replace cadmium and nickel—ca dmium diffused coatings in the aircraft industry, 2inc—nickel has insufficient wear properties for some appHcation, but is under study as an undercoat to various electroless nickel top coats (153). 

MSTM B117, Std Test Method of Salt Spray (Fog) Testings American Society for Testing and Materials, Philadelphia, Pa., 1990. 

In many commercial brochures, chemical resistance is indicated as excellent, good, fair, or poor. Although the test method is usually outlined, wide interpretation is possible. Immersion tests are usually described in this manner. Hydrolytic stabiUty is tested by salt-spray cycling or autoclave cycling. 

Corrosion-resistance test This can be done with the help of a salt spray test. The test piece is suspended in a salt spray chamber (Figure A13.6) for. seven days in 100% relative humidity (IS 101 and IS 11864). After the test, the surface should have no signs of deterioration or corrosion. 

Standard method for evaluation of painted or coated specimens subjected to corrosive environments Standard test method of salt spray (FOG) testing... 

NaCl, interact with the sulphur and vanadium oxides emitted from the combustion of technical grade hydrocarbons and die salt spray to form Na2S04 and NaV03- These conosive agents function in two modes, either the acidic mode in which for example, the sulphate has a high SO3 thermodynamic activity, of in the basic mode when the SO3 partial pressure is low in the combustion products. The mechanism of coiTosion is similar to the hot coiTosion of materials by gases widr the added effects due to the penetration of tire oxide coating by tire molten salt. 

Effect of corrosion inhibiting primer on strength retention after exposure to salt spray [29]... 

Redux was soon extended to other aircraft including the DeHavilland civilian airliner Dove and the jetliner Comet [202]. In the Fokkcr F27/F50 Friendship , it accounted for about 70% of stmctural bonds (about 550 parts). Over 1000 F27/F50 aircraft were constructed and were in service for over 30 years, indicating high fatigue resistance and durability ([198], pp. 80-81). When attempts were used to substitute low-temperature curing epoxies for PVF, joint corrosion due to salt spray exposure required expensive repairs. 

Lap shear at 75°F after 30 days salt spray Less than 15% loss from room-temperature... 

Honeycomb peel at 75°F Honeycomb peel at 75°F after 30 days exposure at 95°F, 100 percent R.H. Honeycomb peel at 75°F after 30 days salt spray exposure at 95°F Flatwise tensile at 75°F Flatwise tensile at 180°F 45 lb-in/3 inch 75 lb-in/3 inch 75% of actual room temperature peel strength 75% of actual room temperature peel strength 900 psi 1100 psi 500 psi 750 psi... 

Composite materials must survive in the environment to which they are subjected at least as well as the conventional materials they replace. Some of the harmful environments encountered include exposure to humidity, water immersion, salt spray, jet fuel, hydraulic fluid, stack gas (includes sulfur dioxide), fire, lightning, and gunfire as well as the combined effects of the space environment. 

Lack of lubrication. Exposure to salt spray, corrosive gases, alkaline water, acid water, mud, or dirt. Period of inactivity without adequate protection. 

Ductile and easily buffed chromium deposits having satisfactory corrosion resistance have been produced thus 0.005 mm-thick chromium deposits applied to steel by chemical deposition or by eiectrodeposition gave simiiar results when subjected to a salt-spray test . 

Table 13.1 Performance of various crimped metallic couples in l< o salt spray...

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