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Questions and Answers about Corrosion Testing

By: Stork SwL Laboratories 222 Cavalcade Street Houston, TX 77009-3213 www.storksmt.com/swl

What is corrosion? It has been said that metallurgy is the study of the making of metals; and corrosion is the study of the unmaking of metals. Metals corrode because we use them in environments where they are chemically unstable. Only copper and the precious metals (gold, silver, platinum, etc.) are found in nature in their metallic state. All other metals, including ironthe metal most commonly usedare processed from minerals or ores into metals which are inherently unstable in their environments. It is the tendency of these metals to return to a stable state.

How big a problem is corrosion? According to a study by the U.S. Federal Highway Administration, the total annual estimated direct cost of corrosion in the U.S. is $276 billion, approximately 3.1% of the U.S. Gross Domestic Product (GDP). Corrosion of bridges, highways, and vehicles are part of these costs.

What are the triggers for corrosion? Galvanic corrosion occurs when dissimilar metals are electrically connected in the presence of an electrolyte. General corrosion is caused by a reaction with the environment, such as oxidation and chemical attack of the metallic surface.

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How is corrosion "diagnosed?" Corrosion testing experts, like those at Stork Materials Technology laboratories around the country, typically identify corrosion in three ways: 1. By visual examination. Uniform corrosion, pitting, crevice corrosion, pack rust, Lamellar corrosion and galvanic corrosion can usually be readily identified by an expert on sight. 2. By visual examination with supplementary means. Erosion corrosion, cavitation, fretting corrosion, intergranular corrosion, exfoliation, and dealloying may need more than visual examination to identify. For example, dealloying corrosion usually takes place below the surface of a material and will be revealed after that layer is scraped away. 3. By microscopy. Optical or electron microscopes are necessary to confirm environmental cracking corrosion, stress corrosion cracking (SCC), corrosion fatigue, and hydrogen embrittlement.

What can help slow or prevent corrosion? Environmental testing Protective coatings Corrosion-resistant alloys Cathodic and anodic protection Use of corrosion inhibitors

Stork knows how. Many Stork metallurgists, engineers, and chemists are experts in corrosion identification, prevention, and treatment. If you have questions about corrosion regarding your materials, products, or parts, contact info.swl@stork.com and one of our metals professionals will be in touch with you soon.

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