Corrosion Technician Study Guide

Guide to Requirements for Certification as a Corrosion Technician

STUDY GUIDECORROSION TECHNICIAN

We congratulate you on aspiring to be a NACE International Corrosion Technician. We trust this guide will provide you with all the information necessary to successfully complete your certification program.

TABLE OF CONTENTS

Purpose of the Professional Recognition Program ……………………………………...……..2

Categories of Certification …………………………………..…………….……..…..…….….…..3

Overview of the Professional Recognition Program………………………………………..……4

Overview of Examination ……………………………………………………..…………………..12

Scope of Examination ……………………………………………………………………….……13

Recommended Texts and Sources for Exam Preparation …………………………….……..14

Highlight Digest of Pertinent Information in the Texts ………………………………….……..15

Sample Questions - Corrosion Technician Open-Book Examination ……………………….40

Answers to Sample Questions …………………………………………………………..………48

NACE International Certification Program© NACE International, 1999, 2001

January, 1999November 2001

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Purpose of the Certification Program

To provide professional recognition for individuals involved in corrosion science and technology to indicate to the general public, co-workers, employers, and others that an impartial organization has used a recognized and consistent method to assess the individual’s experience, expertise, knowledge, and education.

To build confidence in the professionalism of certified individuals working in the field of corrosion by securing an attestation of their determination; to give due consideration to the safety and best interests of the public; to apply themselves diligently and responsibly to their work; to act ethically in all matters; and to profess competence, making recommendations only in areas in which they are qualified by knowledge and experience.

To encourage the growth and updating of knowledge and understanding of corrosion mechanisms and corrosion prevention and control through continuing dissemination of topical information.

To encourage professional development of individuals working in the field of corrosion by advancement through the several categories of certification.

To provide the individual with a sense of achievement, since it reflects professional advancement in a chosen field.



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Categories of Certification

There are several categories of NACE International certification that may be attained directly by means of work experience and open-book examination(s). In addition, successful completion of specific NACE courses replaces the taking of the open-book examinations in some categories. The certification program is designed to encourage step advancement through increasing levels of certification.

Corrosion Technician requires two years of work experience in the field of corrosion and the option of either passing a two hour open-book examination, or successfully completing the NACE International Basic Corrosion course.

Corrosion Technologist requires four years of work experience in the field of corrosion and the option of either passing a four hour open-book examination, or successfully completing specified NACE International courses.

Senior Corrosion Technologist requires eight years of work experience or four years work experience and a BS in engineering or physical sciences, and the option of either passing an eight hour open-book examination, or successfully completing specified NACE International courses.

Specialty Areas: Cathodic Protection Specialist; Chemical Treatment Specialist; Materials Selection/Design Specialist; Protective Coatings Specialist requires Senior Corrosion Technologist Certification OR four (4) years corrosion work experience in responsible charge AND one of the following: [a PE license or equivalent; an EIT registration or equivalent; Bachelor’s degree in Engineering or Physical Sciences AND an advanced degree in Engineering or Physical Sciences that requires a qualification exam]. Candidates are required to successfully pass an open-book examination.

Corrosion Specialist (includes P & G) Must hold a Specialty Area certification and successfully passing an eight hour open-book examination.

Coating Inspector requires successful completion of training sessions I, II, III and the peer review. Peer review candidates must have a minimum of two years field experience, whether gained prior to, during or after attendance of the training sessions.



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Overview of the Professional Recognition Program

Requirements for Certification

Corrosion Technician category of certification has requirements for work experience in the field of corrosion, and either successful completion of required open-book examination, or successful completion the NACE International Basic Corrosion course. Certification also requires signing a NACE International Attestation concerning professionalism.

Requirements for Recertification

All individuals who have held their Corrosion Technician certification for three years will be required to recertify. Holders of multiple certification need only recertify for the highest category held - the lower categories will be automatically recertified.

Requirements for Payment of Certification Maintenance Fees

Once certified, individuals will be charged a nominal annual certification maintenance fee. This fee is added to the membership renewal statement (nonmembers will be billed separately.) Maintenance fees differ for each category of certification. Holders of multiple certifications will be charged only one maintenance fee.

Formal Education Requirements

There is no reduction in examination requirements granted for either formal education or Professional Engineering registration. The view of NACE International is that formal education and/or the effort required to attain Professional Engineering registration will assist the applicant in successfully completing the required certification examinations.

Work performed in connection with an educational experience may be submitted for consideration in fulfillment of the work experience requirement.

Parallel Path to Certification

Parallel Path is an alternative route to achieving certification. Individuals successfully completing NACE courses that equate to the level of a certification open-book examination may apply for certification. Parallel Path requirements are listed on page 11.

Only courses successfully completed within five years of the certification application being submitted to Headquarters will be accepted.



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Work Experience

Certification candidates must meet acceptable work experience requirements. See page 11 for details.

Open-Book Examinations

Each category of certification requires the applicant to pass the open-book examination for that category of certification, or successfully complete specified NACE courses for certifications offering the Parallel Path option.

Each examination is a single unit. Applicants either pass or fail the open-book examination as a whole. In case of failure, the examination must be retaken.

All examination results will be held in confidence. The applicant will be advised whether the examination has been passed or failed but will not be advised of the grade. Graded examinations are neither returned nor available for review by the applicant.

All examinations may be retaken after the established waiting period has expired. The minimum waiting period for the Corrosion Technician is three months.

Examinations may be taken at:

NACE International HeadquartersAt examination sites that NACE International Headquarters, Areas, or Sections may organize from time to time.On a proctored basis at a location agreed upon by yourself and your proctor.

The following may serve as proctors: an individual who holds certification at the Specialty level or Corrosion Specialist level; a registered Professional Engineer (or equivalent); NACE International staff. Special proctor requests, which will be referred to the chairman of the Certification Subcommittee, may be made in writing to NACE International Headquarters. The NACE International Certification Department can provide a list of proctors in your area.



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Procedures

A completed application with all necessary supporting documents must be submitted for each category of certification. When the application is received at NACE International Headquarters, it is reviewed for completeness to determine that the applicant can be considered for certification in the category requested. The applicant may be contacted for clarification, or for additional information. Also, it is not necessary that the application be typed, however, a certain standard of neatness and layout is necessary before an application will be accepted.

Once the applicant’s file is complete, NACE Headquarters submits it to a three member Application Review Board to assure that all criteria have been met by the applicant. Any of the Review Board members reviewing the application may request additional information or clarification. The review is typically completed within 30 days. NACE International will advise the applicant when a decision has been reached by the Application Review Board. If the applicant is accepted for certification and either the open-book examination is passed, or the applicant has met parallel path requirements, the applicant is certified and sent a certificate. An updated membership card reflecting their certification will be sent to those who hold a current NACE International membership. Preparation of the certificate and card typically takes 4 - 6 weeks. If the application is not accepted, the applicant will be advised of the basis for nonacceptance.

The applicant’s original file is retained at NACE Headquarters, and its contents are held in confidence. NACE’s responsibility for maintaining this file is limited solely to retaining records of completed certifications. NACE International may, at its option, transfer the records to electronic storage, and discard paper documents.

NACE International assumes no responsibility for any loss or inconvenience caused as a result of the inability to locate the file of a person having attained certification under this program.

The application process is normally completed within six months. It should be noted that there are several common reasons for major delays in processing applications: incomplete applications, applications submitted in any format other than the approved, and applications containing requests for exemptions or modifications to any of the program requirements.

Applicants have one year from the time their application is approved in which to attempt the examination. Applications on which there have been no activity for one year or more will be considered “inactive” and will be deleted from the list of pending active applications. Inactive applications are those where required paperwork has not been received, fees are not paid, and/or the examination has not been taken (or retaken in the case of a failure in the first attempt). These applicants will receive no reminders from NACE International. Reapplication will require payment of the full fees in effect at the time of reapplication.



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NACE International assumes no liability for loss of any file which has become inactive.

If an individual has attained one level of certification and wants to advance to the next higher category, a new application, complete with updated work resume and a minimum of two qualification references, must be submitted for review board evaluation. Applicants pursuing higher levels of certification, whose prior applications are less than 18-months old, may choose to submit only updated work history and new qualification references.

NOTE: An application processing fee and new qualification references are required for each category of certification for which you apply, whether a new application or a prior application, with updated work history.

Recertification

Corrosion Technicians must recertify every three years. Recertification involves documentation of work experience and professional development. Certified individuals, for whom we have current address information, will receive recertification details approximately six-months prior to recertification date. A 90-day grace period for application and completion of the recertification process is granted following the last day of the month in which certification lapses. Once the grace period has elapsed, a reinstatement fee must be paid in addition to the certification maintenance fees.

NOTE: Until successful completion of the recertification process at NACE headquarters, a lapsed certification will be classified as “inactive.”

Any person recognized in the Certification Program whose recognition has been inactive for a period of 0-3 years may be reinstated by submitting the required application and work experience documentation, with payment of all monies in arrears, in addition to a $100 reinstatement fee.

Any person recognized in the Certification Program whose recognition has been inactive for a period of 3 – 5 years may be reinstated by submitting the required application and work experience documentation, with payment of all monies in arrears, in addition to a $500 reinstatement fee. The Certification Committee Chairman will appoint a 3-member panel to review the work experience documents. Approval must be by the majority of that panel.

Any person recognized under the Certification Program whose recognition has been inactive for more than five (5) years must reapply as a new applicant and meet all of the criteria current at the time of their reapplication. Persons who reapply will be reissued their original identification number upon meeting the current requirements.

Should there be an inquiry regarding the certification status of a person whose certification has become inactive, the inquirer will be so informed, no further information will be supplied.



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NACE International Membership

NACE International membership is not required for certification; however, a greater responsibility is placed on nonmembers to ensure NACE International has current address information. Furthermore, nonmember certification annual maintenance fees are greater than annual membership and certification maintenance fees for members. Also, official notices of changes to the Professional Recognition Program are placed in the NACE International journal Materials Performance. The burden for keeping up-to-date on changes and items of interest affecting the Program is solely the responsibility of the individual certificate holder.

Benefits - NACE International membership includes receiving the NACE International monthly journal, Materials Performance and provides the means whereby individuals can keep abreast of activities in the corrosion control and prevention field. These activities are some of the responsibilities of certified individuals, as stated in the Attestation.



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NACE International Attestation

Requirements for certification by NACE International include signing an Attestation. Failure to comply with the Attestation could result in disciplinary action.

The Attestation requires that an individual recognize and acknowledge that: The proper control of corrosion can be critical to the safety and welfare of the general

public and industrial facilities. The control of corrosion is obligatory to maximize conservation of our material

resources, and to reduce economic losses and to protect the environment. The entire field of corrosion and its control encompasses the application of the

knowledge and experience of many diverse disciplines and levels of technical competence.

Only through continual association and cooperation with others in this field can the safest and most economical solutions be found to the many corrosion problems.

The quality of their work reflects on the entire profession of corrosion control.

The applicant is therefore asked to: Give first consideration in corrosion control work to public safety and welfare, and to

the protection of the environment. Apply himself or herself with diligence and responsibility to the corrosion control work

that is within the applicant’s area of competence. Pursue work with fairness, honesty, integrity and courtesy, ever mindful of the best

interests of the public, the applicant’s employer, and of fellow workers. Not represent himself or herself to be proficient or make recommendations in phases

of corrosion control work in which the applicant is not qualified by knowledge and experience.

Avoid and discourage untrue, sensational, exaggerated, and/or unwarranted statements regarding the applicant’s work in oral presentations, written texts, and/or advertising media.

Treat as confidential the applicant’s knowledge of the business affairs and/or technical process of clients, employers, or customers when their interests so require.

Inform clients or employers of any business affiliations, interests, and/or connections which might influence the applicant’s judgment.

Uphold, foster, and contribute to the achievement of the objectives of NACE International.

Action Against Violations

Copies of the official procedure for action against someone who violates the Attestation are available from NACE International Headquarters. In summary, the procedure is that the person wishing to lodge the complaint should file the complaint in writing with the NACE International Executive Director. The complaint is reviewed by the NACE International Quality Committee. The person complained against is provided the opportunity to respond to the complaint. A course of appeal is available, extending ultimately to the NACE International Board of Directors.



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Costs

Certification fees in U.S. dollars include:

Application processing fee (all categories) members - $100, nonmembers - $250Note: Application processing fees are payable on each category of certification for which you apply.

Corrosion Technician Examination fee: members and nonmembers: $75

ALL FEES ARE NONREFUNDABLE

Note 1: Return check service charge $25Any person whose check for any fee is returned to NACE International as “uncollectible” for any reason, must submit a new payment plus the “Returned Check Service Charge.” Upon collection of the payment, the certification process will resume.

Note 2: Any person recognized in the Certification Program whose recognition has been inactive for a period of 0-5 years may be reinstated by submitting the required application and work experience documentation with payment of all monies in arrears in addition to a reinstatement fee.

Retakes: the examination fee is calculated to cover NACE International costs of handling the examination, which is essentially the same for retakes and initial attempts.

Maintenance Fees

Effective April 1, 1996, all individuals will pay annual maintenance fees for their highest level of certification: Corrosion Technician maintenance fees: members - $35, nonmembers - $135.

Members will be invoiced annually on their membership renewal statement. Nonmembers will be billed separately.

Other

A yearly publication of a directory of all individuals currently in the program is available free of charge upon request to NACE International Headquarters. Certification information can also be found on the NACE Web page. Staff will confirm the certification status of an individual upon specific request. Contact NACE Headquarters for more information.

Information on other NACE International certification programs, products, and services is available from: NACE International Membership Services, 1440 South Creek Drive, Houston, Texas 77084-4906, USA. Phone: 281/228-6200; Fax: 281/228-6300; Email [email protected]; Online: http//www.nace.org.



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Parallel Path for Corrosion Technician

Successful completion of the NACE International Basic Corrosion course examination may be applied toward Corrosion Technician certification.

Only courses successfully completed within five years of the certification application being submitted to Headquarters will be accepted.

Work Experience

TWO YEARS is the minimum acceptable work experience requirement for a Corrosion Technician.



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Overview of Examination for Corrosion Technician

This examination is an integral part of the certification program, being one of the requirements for certification as a NACE International Corrosion Technician.

The examination is designed to ensure that the candidate has a good understanding of the theory of corrosion and corrosion prevention, has a working knowledge of all types of corrosion and means of prevention, as well as, knowledge and experience within his particular field of specialization or activity.

Also, the examination provides an objective basis on which to make a decision regarding the candidates qualifications. Without the examination, the most critical review of the candidates qualifications would still remain subjective. Furthermore, no resume of background offers a clue as to the basic information the candidate might possess. A knowledge of fundamentals is important.

The candidate is expected to be a well-rounded technical person when attaining the status of Corrosion Technician. The examination does much to establish a minimum for this knowledge.

The examination is in no way an attempt to disqualify individuals who otherwise are eligible. The program makes no attempt to find some elite among us to identify the most erudite in theory or practice, but simply to establish a minimum standard for the grade of certification. We hope all applicants are successful in attaining the status of a Corrosion Technician. All questions will be derived from information given in the texts cited. It is the individuals responsibility to learn the principles revealed in the sections specifically cited and to be able to apply them. Hopefully, individuals will find the questions straightforward and clear. Most questions are concerned only with the application of one principle to keep them concise and obvious. No attempt is made in the examination to trick or to use time in looking up some obscure passage in a book. Obviously, the questions must be read carefully, but if ambiguities exists, these are unintentional. The texts will be required during the examination as a source of data to answer the questions.

We want individuals to pass the examination and qualify for the status of Corrosion Technician.



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Scope of Examination

The open-book examination must be taken under proctored conditions previously outlined.

The two hour open-book examination consists of four sections, each section having half an hour for completion.

It is expected that the answers will demonstrate a basic level of knowledge and experience in the corrosion field.



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Recommended Texts and Sources for Exam Preparation

The candidate is expected to be familiar with the material in the texts and sources. The applicant must provide his own texts during the examination.

*Dillon, C.P., Forms of Corrosion - Recognition and Prevention, NACE Handbook 1, NACE, 1982. (Item # 37531)*Van Delinder, L.S., Corrosion Basics - An Introduction, NACE, 1984. (Item # 37518)*Munger, C.G., Corrosion Prevention by Protective Coatings, NACE, 1985 (Item # 37507)*Peabody, A.W., Control of Pipeline Corrosion, NACE, 1967. (Item # 37501)*Treseder, R.S., Baboian, R., and Munger, C.G., NACE Corrosion Engineers Reference Book, Latest Edition, NACE. (Item # 37523)*Boyer, H.E., and Gall, T.L., eds., ASM Handbook: Volume 13, Corrosion, ASM International, Metals Park, OH. (Item # 37714)*Nathan, C.C., Corrosion Inhibitors, NACE, 1973. (Item # 37515)Atkinson, J.T.N., and Van Droffelaar, H., Corrosion and Its Control: An Introduction to the Subject, NACE, 1994, Second Edition. (Item # 37552)Gellings, P.J., Introduction to Corrosion Prevention and Control, Delft University Press, 1985.Hack, H.P., Corrosion Testing Made Easy : Galvanic Corrosion Test Methods, NACE, 1993. (Item # 37537)Lawson, H.H., Corrosion Testing Made Easy: Atmospheric Corrosion Test Methods, NACE, 1994. (Item # 37554)Sedriks, A.J., Corrosion Testing Made Easy: Stress Corrosion Cracking Test Methods, NACE, 1990. (Item # 37512)Verink, E.D., Corrosion Testing Made Easy: The Basics, NACE, 1993. (Item # 37538)

*The above list of books can be purchased as a set or individually through NACE International by contacting NACE International Membership Services, PO Box 218340, Houston, Texas 77218-8340, USA. Phone: 281/228-6200; Fax: 281/228-6300; Email: [email protected]; Online: http//www.nace.org. When ordering please refer to the item number at the end of each title.

All other books listed can be purchased separately.



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mailto:[email protected];


Highlight Digest of Pertinent Information in the Texts

Dillon, C.P., Forms of Corrosion - Recognition and Prevention, NACE Handbook 1, NACE, 1982. (Item # 37531)

Page Content

5 Chapter 1 - General Corrosion of MetalsGeneral corrosion is corrosion that proceeds without appreciable localization of attack.

19 Chapter 2 - Localized CorrosionLocalized corrosion is defined as corrosive attack limited to a specific, relativelysmall surface area; the remaining area is largely unattacked.

45 Chapter 3 - Galvanic CorrosionGalvanic corrosion occurs when a metal or alloy is electrically coupled to another, or to a conducting nonmetal in the same electrolyte.

56 Chapter 4 - Environmental CrackingThe combined actions of a tensile stress and a corrosion reaction is the principle characteristic of all environmental cracking phenomena. In the absence of either the tensile stress or the corrosive environment, cracking will not occur. Environmental cracking often results in brittle failure of an otherwise ductile metal.

71 Chapter 5 - Erosion-Corrosion Cavitation and FrettingSurface damage by erosion, cavitation or fretting is often difficult to identify. There are features of each damage mode that make them subject to confusion.

89 Chapter 6 - Intergranular CorrosionIntergranular corrosion consists of preferential attack at or adjacent to the grain boundaries of a metal or alloy.

99 Chapter 7 - DealloyingDealloying is a corrosion process whereby one constituent of an alloy is preferentially removed, leaving an altered residual structure.

105 Chapter 8 - High Temperature Corrosion PerformanceIt is somewhat difficult to categorically define “high temperature” without defining the alloy systems of interest.

Van Delinder, L.S., Corrosion Basics - An Introduction, NACE, 1984. (Item # 37518)

Page Content

3 Chapter 1 - Scope and Language of CorrosionThis chapter offers a general overview of corrosion and the reasons for studying it.A glossary of corrosion-related terms is included.

23 Chapter 2 - Basics of CorrosionCorrosion reactions are presented in the most basic terms. The influence of variousfactors on the initiation and advancement of corrosion in aqueous systems is discussed.

49 Chapter 3 - MetallurgyThis chapter discusses the effects of metal structure, alloying elements, mechanicalworking, and heat treatment on corrosion behavior.

69 Chapter 4 - MaterialsThe properties of a wide variety of materials (alloys and nonmetals) are comparedwith regard to corrosion resistance and mechanical properties.



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Page Content

93 Chapter 5 - Localized CorrosionConcentrated attack in the form of pitting, erosion, cavitation, fretting, deposition, corrosion, corrosion fatigue, and dealloying is presented in this chapter.

111 Chapter 6 - Environmental CrackingThe factors involved in stress corrosion, hydrogen embrittlement, and liquid metal embrittlement are defined, and the metals susceptible to attack in specific environments are enumerated.

127 Chapter 7 - InhibitorsAnodic, cathodic, and filming inhibitors are discussed, along with oxygen scavengers as means of reducing corrosion in aqueous and nonaqueous systems. Mechanisms of inhibition and examples of many practical applications are cited.

149 Chapter 8 - Corrosion by Water and SteamFactors affecting corrosion of various materials in fresh water, soft water, boiling H2O reactors, and superheated steam are discussed in this chapter. Several kinds of corrosion are discussed, as well as action of inhibitors and bacteria.

179 Chapter 9 - Cathodic ProtectionAn easy-to-understand chapter on the present-day factors in practical cathodic protection practices and important design features.

203 Chapter 10 - Underground CorrosionCertain electrochemical aspects of corrosion are described here, together with an excellent description of how underground corrosion is controlled in various types of soil environments using various techniques.

221 Chapter 11 - Atmospheric CorrosionThis chapter summarizes metal behavior in air atmospheres throughout the world and especially in the more corrosive areas where heavy industry and salt spray may be present. Preventive measures are discussed briefly.

245 Chapter 12 - CoatingsThe testing, selection, application, and use of organic and inorganic coatings for use in the atmosphere, or as linings, are described with emphasis on surface preparation and the function of the coating material.

275 Chapter 13 - High-Temperature CorrosionThis chapter covers the broad field of high-temperature corrosion, including air, flue gases, molten salts and metals, vacuum, etc. It also gives some attention to mechanical properties at high temperatures.

309 Chapter 14 - Testing and InspectionThe many methods of testing for corrosion and measuring corrosion rates described and evaluated. Necessary precautions and parameters to watch for in evaluating test results are given.

337 Chapter 15 - Design and Failure AnalysisSome common sense design features for industrial process equipment are presented with a discussion of problems that occur when these precautions are ignored. A brief description of practical ways of combating various types of corrosion is also presented. Economic considerations are emphasized.



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Munger, C.G., Corrosion Prevention by Protective Coatings, NACE, 1985 (Item # 37507)

Page Content

1 Chapter 1 - Introduction to CorrosionIntroduction; History; Early Materials; Emerging Technology; Terms; Definitions; Purposes; Modern Coatings Industry; Coatings Economics; Coating Manufacture; Complexities and Variables; Types of Coatings; The Finished Production; The Development of Protective Coatings; The Future of Protective Coatings.

19 Chapter 2 - Corrosion as Related to CoatingsCorrosion of Materials Other than Metal; Early Corrosion Studies; Fundamentals; Electrochemical Principles; Electromotive Force; Ionization; The Corrosion Cell; Oxidation and Reduction; Galvanic Corrosion; Electromotive Force Series; Galvanic Couples; Cathodic Protection; Oxygen Concentration Cells; Metal Concentration Cell; Chemical Corrosion; Mill Scale; Filiform Corrosion; Pitting Corrosion; Atmospheric Corrosion; Methods of Corrosion Control.

47 Chapter 3 - Essential Coating CharacteristicsCoating Function; Essential Coating Properties; Additional Coating Properties; Types of Exposure.

63 Chapter 4 - Coating FundamentalsBasic Coating Concepts; The Coating System; Basic Coating Formation; Coating Component Functions; Basic Coating Components

89 Chapter 5 - Corrosion-Resistant Organic CoatingsNatural Air-Oxidizing Coatings; Synthetic Oxidizing Coatings; Lacquers; Co-reactive Coatings; Heat-Condensing Coatings; 100% Solids Coatings.

129 Chapter 6 - Corrosion-Resistant Zinc CoatingsProtection by Zinc Coatings; Application of Zinc Coatings; Organic Zinc-Rich Coatings; Inorganic Zinc Coatings; Types of Zinc-Rich Coatings; Topcoating; Comparison Summary.

173 Chapter 7 - Structural Design for Coating UsePrinciple of Design for Coating Use; Coating Problems Related to Design; Summary.

193 Chapter 8 - The Substrate—Importance to Coating LifeTypes of Substrates; Types of Contamination

205 Chapter 9 - Surface PreparationIntroduction; Types of Adhesion; Surface Preparation Objectives; Development of Techniques; Types of Contamination; Types of Surface Preparation; Concrete Surfaces; Other Influences on Surface Preparation Selection.

247 Chapter 10 - Application of CoatingsThe Type of Coating; Preparation for Coating Application; Application Methods; Brush Application; Roller Application; Spray Application; Powder Coating; Dip Coating; Electrocoating; Multiple-Component Systems; Drying or Curing; Weather Conditions; Coating Coverage; Application Problem Areas; Cost of Application.

287 Chapter 11 - Coatings for ConcreteIntroduction; Properties of Concrete; Composition of Concrete; Problems in Coating Concrete; Properties Required for Coatings Used on Concrete; Reasons for Coating Concrete; Types of Coatings for Concrete.

305 Chapter 12 - Coating SelectionIntroduction; Consideration; Evaluating Operating Conditions; Compatibility; Substrate; Environment; Soil Problems; Internal Surface; Corrosive Conditions; Product Contamination; Coating Curing; Surface Preparation; Timing; Safety; Previous Experience; Coating Cost; Coating Properties; Summary.

325 Chapter 13 - Coatings and Cathodic ProtectionIntroduction; Cathodic Protection; Coating Characteristics; Inorganic Zinc Coatings; Chemical Reactions; Consequences of Poor Coating Selection; Testing; Coating Failure; Most Common Type of Coating; Most Common Areas of Use; Coatings; Summary.



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Page Content

347 Chapter 14 - Coating FailuresIntroduction; Formulation-Related Failures; Failures Due to Coating Selection; Substrate-Related Failures; Surface Preparation-Related Failures; Application-Related Failures; Design-Related Failures; Failures Due to Exterior Forces; Summary.

377 Chapter 15 - Coating Repair and MaintenanceIntroduction; Primary Repair Considerations; Type and Extent of Failure; Adhesion; Type of Coating; Type of Substrate; Repair of Failures; Repair of Coatings; Appendix—Procedures for Adhesion Test.

405 Chapter 16 - Safe Application of Coatings and LiningsIntroduction; Changes in the Coating Industry; Primary Hazards; Fire; Explosion; Reactivity; Health Hazards; Summary; Appendix A—Safety and Environmental Control References; Appendix B—A Manual for Painter Safety.

439 Chapter 17 - SpecificationsParts of a Specification; Types of Specifications; Areas of Specification; Appendix—Example of a Typical Specification.

459 Chapter 18 - Inspection and TestingVariables Involved in Quality Control; Types of Coating Inspectors; What Should a Qualified Inspector Know; Areas of Coating Inspection; Inspection Equipment.

481 Chapter 19 - Typical Coating UsesThe Chemical Industry; Pulp and Paper; The Mining Industry; The Steel Industry; The Power Industry; The Food Industry; Sewage Treatment; The Transportation Industry, Specialized Uses.

*Peabody, A.W., Control of Pipeline Corrosion, NACE, 1967. (Item # 37501)

Page Content

1 Chapter 1 - Preparing to be a Corrosion Engineer3 Chapter 2 - What is Corrosion?9 Chapter 3 - Coatings19 Chapter 4 - Cathodic Protection - How it works33 Chapter 5 - Criteria for Cathodic Protection38 Chapter 6 - Survey Methods and Techniques51 Chapter 7 - Instrumentation94 Chapter 8 - Ground Bed Design109 Chapter 9 - Cathodic Protection with Rectifiers116 Chapter 10 - Cathodic Protection with Galvanic Anodes128 Chapter 11 - Cathodic Protection with Other Current Sources133 Chapter 12 - Stray Current Electrolysis148 Chapter 13 - Construction Practices164 Chapter 14 - Maintenance Procedures173 Chapter 15 - Bacteriological Corrosion178 Chapter 16 - Economics



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Treseder, R.S., Baboian, R., and Munger, C.G., NACE Corrosion Engineers Reference Book, Latest Edition, NACE. (Item # 37523)

Page Content

Glossary7 NACE Glossary of Corrosion-Related Terms23 Glossary of Corrosion-Related Acronyms

Conversion Tables28 International System of Units (Sl)30 General Conversion Factors32 Temperature Conversions34 Stress Conversions36 Approximate Equivalent Hardness Numbers and Tensile Strengths for Steel38 Common Gage Series Used for Sheet Thickness38 Sheet Gage—Thickness Conversions40 Metric and Decimal Equivalents of Fractions of an Inch

Physical and Chemical Data41 Physical Properties of Gases and Liquids42 Physical Properties of Elements44 Properties of Dry Saturated Steam—English Units46 Properties of Dry Saturated Steam—Sl Units48 Vapor Pressure of Water Below 100°C49 Dew Point of Moist Air54 Vapor Pressure vs Temperature for Volatile Compounds55 Approximate pH Values at 25°C55 Boiling Points vs Concentration of Common Corrosive Media56 pH Values of Pure Water vs Temperature56 Solubility of Gases in Water57 Solubility of Air in Water and Solvents58 Solubility of Water in Hydrocarbons59 Thermocouple Data

Corrosion Testing60 Hypothetical Cathodic and Anodic Polarization Diagram61 Typical Cathodic and Anodic Polarization Diagram62 Hypothetical Cathodic and Anodic Polarization Plots for a Passive Anode63 Typical Standard Potentiostatic Anodic Polarization Plot64 Data for Tafel Equation Calculations65 Polarization Resistance Method for Determining Corrosion Rates66 Values for the Constant B for Polarization Resistance Method67 Standard Reference Potentials and Conversion Table68 Electrochemical Series74 Typical Potential-pH (Pourbaix) Diagram75 Standard Environments for Environmental Cracking Tests76 Specimen Types Used in Environmental Cracking Tests77 Planned Interval Corrosion Test78 Corrosion Rate Conversion Factors79 Densities of Common Alloys

Atmospheric Corrosion80 Atmospheric Corrosion of Steel vs Time in an Industrial Atmosphere81 Corrosion Rates of Carbon Steel Calibrating Specimens at Various Locations82 Corrosion of Structural Steel in Various Environments



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Page Content

83 Effect of Amount of Zinc on Service Life of Galvanized Sheet in Various Environments84 Development of Rust on Zinc- and Cadmium-Plated Steels in a Marine Atmosphere85 Atmospheric Corrosion of Zinc in Various Locations as a Function of Time86 Atmospheric Corrosion of Various Metals and Alloys87 Corrosion of Copper Alloys in Marine Atmospheres88 Relative Performance of Stainless Steels Exposed in a Marine Atmosphere

Seawater and Cooling Water Corrosion89 Corrosion Factors for Carbon Steel in Seawater90 Zones of Corrosion for Steel Piling in Seawater91 Rates of General Wastage of Metals in Quiet Seawater92 Suggested Velocity Limits for Condenser Tube Alloys in Seawater93 Galvanic Series in Seawater94 Practical Galvanic Series95 The Major Constituents of Seawater95 Chemical Composition of Substitute Seawater96 Calculation of Calcium Carbonate Saturation Index (Langelier Index)97 Water Analysis Conversion Factors98 Common Groups of Algae98 Common Types of Bacteria Causing Slime Problems99 Microorganisms Commonly Implicated in Biological Corrosion100 Microbiocides Used in Cooling Water Systems

Cathodic Protection101 Approximate Current Requirements for Cathodic Protection of Steel102 Design Criteria for Offshore Cathodic Protection Systems103 Effect of Applied Cathodic Current on Corrosion and Potential of Steel in Flowing Seawater104 Energy Capabilities and Consumption Rates of Galvanic Anode Materials in Seawater104 Consumption Rates of Impressed Current Anode Materials105 Platinum Consumption Rates for Cathodic Protection Anodes106 Resistance of Galvanic AnodesDwight’s Equation108 Typical Resistivities of Some Waters and Soil Materials109 Properties of Concentric Stranded Copper Single Conductors109 Temperature Correction Factors for Resistance of Copper110 Steel Pipe Resistance110 Alloy Pipe Resistance111 Corrosion of Galvanized Pipe in Various Soils112 Estimating Service Life of Galvanized Steel in Soils

Process and Oil Industries Corrosion113 Caustic Soda Service Chart114 Alloys for Sulfuric Acid Service117 Alloys for Nitric Acid Service118 Alloys for Hydrochloric Acid Service119 Alloys for Hydrofluoric Acid Service120 Estimate of Sulfur Trioxide in Combustion Gas120 Calculated Sulfuric Acid Dewpoint in Flue Gas121 Operating Limits for Steels in Hydrogen Service to Avoid Decarburization and Fissuring122 Combinations of Alloys and Environments Subject to Dealloying123 Liquid Metal Cracking124 Stress Corrosion Cracking Systems125 Hydrogen Degradation126 Potential Sulfide Stress Cracking Region as Defined by the 0.05 psia Criterion



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127 Maximum Temperature for Continuous Service in Dry Hydrogen Chloride and Chlorine128 Maximum Service Temperature in Air for Stainless Steels and Alloy Steels129 High Temperature Sulfidic Corrosion of Steels and Stainless Steels130 High Temperature H2S/H2 Corrosion of 5Cr-0.5Mo Steel131 High Temperature H2S/H2 Corrosion of Stainless Steels132 Ash Fusion Temperatures of Slag-Forming Compounds133 Distribution Ratio of Ammonia and Amines in Steam and Steam Condensate134 Oilfield Corrosion InhibitorsMolecular Structures136 Design Details to Minimize Corrosion138 Common Types of Scale Forming Minerals139 Chemical Cleaning Solutions for Specific Scales140 Components of Boiler Deposits141 Non-destructive Methods for Evaluating Materials148 Dimensions of Seamless and Welded Wrought Steel Pipe152 Standard Wall Steel PipeDimensions, Capacities, and Weights

Metallic Materials153 Unified Numbering System for Metals and Alloys154 Common Names of UNS Alloys156 Comparable Alloy Designations

Compositions and Typical Mechanical Properties 158 Aluminum Alloys160 Copper Alloys162 Carbon and Low Alloy Steels164 Cast Irons165 Cast Heat Resistant Stainless Steels166 Cast Corrosion Resistant Stainless Steels168 Austenitic Stainless Steels170 Austenitic Stainless Steels (High Mn)171 Martinsitic Stainless Steels172 Ferritic Stainless Steels174 Duplex Stainless Steels176 Precipitation-Hardenable Stainless Steels178 Nickel Alloys180 CrMo Nickel Alloys184 Cobalt Alloys186 Refractory Alloys (Mo, Cb, Ta, W, Zr)187 Titanium Alloys188 Lead Alloys188 Magnesium Alloys189 Precious Metals (Au, Ag, Pt, Pd)189 Zinc Alloys190 API Grades of Casing and Tubing192 Maximum Allowable Stress in Tension (ASME Code)192 Aluminum Alloys192 Copper Alloys193 Carbon and Low Alloy Steels194 Stainless Steels196 Nickel Alloys197 Titanium and Zirconium Alloys198 Creep Strength of Metals



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Page Content

200 Temper DesignationsCopper Alloys201 Temper DesignationsMagnesium Alloys202 Temper DesignationsAluminum Alloys205 Melting Temperatures of Common Alloys206 Coefficients of Thermal Expansion of Common Alloys207 Iron-Carbon Equilibrium Diagram208 Critical Transformation Temperatures for Steels209 Temper and Radiation Color of Carbon Steel210 Annealing Temperatures for Austenitic Stainless Steels and Related Alloys211 Annealing Treatments for Ferritic Stainless Steels211 Annealing Temperatures and Procedures for Martensitic Stainless Steels212 Schoefer Diagram for Estimating Ferrite Content in Austenitic Fe-Cr-Ni Alloy Castings213 Delta Ferrite Content of Stainless Steel Weld Metals214 Overview of Joining Processes218 Preheat Temperatures for Welding Carbon and Low Alloy Steels220 Postweld Heat Treatment Requirements for Carbon and Alloy Steels222 Filler Metals Suitable for Welding Joints Between Dissimilar Austenitic Stainless Steels223 Electrodes and Filler Metals for Dissimilar Joints Between Nickel Alloys and Other Metals

Nonmetallic Materials224 Typical Property Ranges for Plastics230 Properties of Elastomers234 Oxygen and Water Permeability in Plastic Films236 Polyethylene Line PipeDimensions and Properties238 PVC and CPVC Line PipeDimensions and Properties240 Reinforced Thermosetting Resin Line PipeDimensions and Properties242 Types of Portland Cement243 Chemical Requirements for Portland Cement244 Hydraulic Cements245 Chemical Resistant Mortars and Grouts246 Properties of Graphite and Silicon Carbide246 Properties of Glass and Silica247 Properties of High Temperature Refractories248 Typical Properties of Ceramic Bricks and Chemical Stoneware

Protective Coatings250 Surface Preparation Standards251 Abrasive/Profile Comparative Chart252 Summary of SSPC Surface Preparation Specifications 253 Comparative Maximum Heights of Profile Obtained with Various Abrasives254 Properties of Abrasives255 Protective Coating Classifications256 Alkyd CoatingsProperties257 Solvent Dry LacquersProperties258 Epoxy CoatingsProperties259 100% Solids CoatingsProperties260 Urethane CoatingsProperties261 Heat-Condensing CoatingsProperties262 Coalescent-Emulsion CoatingsProperties263 Zinc CoatingsSummary of Properties264 Zinc CoatingsProperties266 Compatibility of Coating Materials with Various Primers267 Resistant Properties of Binders for Coatings



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Page Content

268 Properties of Generic Coatings for Atmospheric Service270 Temperature Limits of Coatings270 Radiation Toleration of Coatings271 Coefficient of FrictionSlip Factors for Various Coatings and Surface Finishes272 Chemical Resistance of Coatings for Immersion Service276 Typical Physical Properties of Coatings for Concrete278 Dry Film Thickness of Coatings as a Function of Solids Content and Coverage Rate279 Effect of pH on Corrosion of Zinc in Aerated Aqueous Solutions280 Rust Preventives282 Pressure Loss in Hose284 Approximate Square Feet per Linear Foot and per Ton for Different Steel Members288 Surface Area per Ton of Steel for Various Types of Construction289 Square Feet of Area and Gallon Capacity per Foot of Depth in Cylindrical Tanks290 Properties of Flammable Liquids Used in Paints and Lacquers291 Do’s and Don’ts for Steel Construction to be Coated292 Surface Finishing of Welds in Preparation for Lining

Standards294 Standards Organizations296 Metallic Materials SpecificationsAPI, ASTM, CSA300 Nonmetallic Materials SpecificationsAPI, ASTM, AWWA301 Nonmetallic Materials StandardsASTM301 Protective Coatings NACE, ASTM, SSPC305 Pipeline CoatingsNACE, ASTM, AWWA, CSA, DIN306 Metallic and Anodic CoatingsASTM306 Cathodic ProtectionNACE, ASTM307 Atmospheric CorrosionASTM307 Oil ProductionNACE, API309 Oil ProductsASTM309 Automotive, AircraftASTM309 Process and Power IndustriesNACE, ASTM, API311 GeneralNACE, ASTM312 ElectrochemistryASTM312 Localized CorrosionASTM312 Erosion, Wear, and AbrasionASTM313 Environmental CrackingASTM

Boyer, H.E., and Gall, T.L., eds., ASM Handbook: Volume 13, Corrosion, ASM International, Metals Park, OH. (Item # 37714)

Page Content

15 Fundamentals of Corrosion17 Introduction18 Thermodynamics of Aqueous Corrosion29 Kinetics of Aqueous Corrosion37 Effects of Environmental Variables on Aqueous Corrosion45 Effects of Metallurgical Variables on Aqueous Corrosion50 Fundamentals of High-Temperature Corrosion in Molten Salts56 Fundamentals of High-Temperature Corrosion in Liquid Metals



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Page Content

61 Fundamentals of Corrosion in Gases77 Forms of Corrosion79 Introduction80 General Corrosion104 Localized Corrosion123 Metallurgically Influenced Corrosion136 Mechanically Assisted Degradation145 Environmentally Induced Cracking191 Corrosion Testing and Evaluation193 Planning and Preparation of Corrosion Tests197 In-Service Monitoring204 Simulated Service Testing212 Laboratory Testing229 Evaluation of Uniform Corrosion231 Evaluation of Pitting Corrosion234 Evaluation of Galvanic Corrosion239 Evaluation of Intergranual Corrosion242 Evaluation of Exfoliation Corrosion245 Evaluation of Stress-Corrosion Cracking283 Evaluation of Hydrogen Embrittlement291 Evaluation of Corrosion Fatigue303 Evaluation of Crevice Corrosion311 Evaluation of Erosion and Cavitation314 Evaluation of Microbiological Corrosion316 Interpretation and Use of Corrosion Test Results319 Designing to Minimize Corrosion321 Materials Selection338 Design Details to Minimize Corrosion344 Corrosion of Weldments369 Corrosion Economic Calculations375 Corrosion Protection Methods377 Fundamentals of Corrosion Protection Aqueous Solutions380 Cleaning for Surface Conversion383 Phosphate Conversion Coatings389 Chromate Conversion Coatings396 Aluminum Anodizing399 Organic Coatings & Linings419 Electroplated Coatings432 Hot Dip Coatings446 Porcelain Enamels453 Chemical-Setting Ceramic Linings456 CVD/PVD Coatings459 Thermal Spray Coatings463 Anodic Protection466 Cathodic Protection478 Corrosion Inhibitors for Oil and Gas Production485 Corrosion Inhibitors for Crude Oil Refineries487 Control of Environmental Variables in Water Recirculating Systems498 Surface Modification507 Corrosion of Specific Alloy Systems509 Carbon Steels



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Page Content

531 Alloy Steels547 Stainless Steels566 Cast Irons573 Cast Steels583 Aluminum and Aluminum Alloys610 Copper and Copper Alloys641 Nickel-Base Alloys658 Cobalt-Base Alloys669 Titanium and Titanium Alloys707 Zirconium and Hafnium722 Niobium and Niobium Alloys725 Tantalum740 Magnesium and Magnesium Alloys755 Zinc770 Tin and Tin Alloys784 Lead and Lead Alloys793 Noble Metals808 Beryllium813 Uranium and Uranium Alloys823 Powder Metallurgy Materials846 Cemented Carbides859 Metal Matrix Composites 864 Amorphous Metals871 Electroplated Hard Chromium876 Brazed Joints887 Clad Metals891 Corrosion in Specific Industries and Environments893 Marine Corrosion927 Nuclear Power Industry985 Fossil Fuel Power Plants1011 Automotive Industry1019 Aircraft Industry1058 Aerospace Industry1107 Electronics Industry1127 Telephone Cable Plants1134 Chemical Processing Industry1186 Pulp and Paper Industry1221 Brewery Industry1226 Pharmaceutical Industry1232 Petroleum Production Operations1262 Petroleum Refining and Petrochemical Operations1288 Pipelines1293 Mineral Industry1299 Structures1311 Metal Processing Equipment1317 Batteries and Fuel-Cell Power Sources1324 Metallic Implants and Prosthetic Devices1336 Dental Alloys1367 Emission-Control Equipment1371 Metric Conversion Guide



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Nathan, C.C., Corrosion Inhibitors, NACE, 1973. (Item # 37515)

Page Content

1 Scope and Importance of Inhibitor Technology7 Theoretical Aspects of Corrosion Inhibitors and Inhibition28 Methods of Evaluation and Testing of Corrosion Inhibitors

Corrosion Inhibitors in Refineries and Petrochemical Plants42 Part 155 Part 2 - Control of Fouling61 Corrosion Inhibitors in Petroleum Production Primary Recovery76 Corrosion Inhibition in Secondary Recovery89 Control of Internal Corrosion of Pipelines Carrying Refined Petroleum Products95 Control of Internal Corrosion of Pipelines Carrying Crude Oil96 Inhibition of Natural Gas Pipelines98 Inhibition of Tanks and Other Structures Handling Crude Petroleum100 Inhibition of Tankships Transporting Refined Petroleum Products102 Controlling Corrosion in Petroleum Drilling and in Packer Fluids114 Inhibitors for Potable Water126 Inhibition of Cooling Water148 Inhibitors in Desalination Systems156 Inhibitors in Acid Systems173 Application of Inhibitors in Automobiles and Their Environment190 Inhibitors in Organic Coatings196 Inhibition and Corrosion Control Practices for Boiler Waters

Inhibitors for Temporary Protection220 Part 1 - Oil and Grease Coatings224 Part 2 - Vapor Phase Corrosion Inhibitors228 Microbiological Corrosion and Its Control236 Controlling Corrosion in Pulp and Paper Mills240 Inhibition of Aluminum245 Inhibition of Corrosion From Caustic Attack251 Application of Inhibitors in Miscellaneous Environments

Atkinson, J.T.N., and Van Droffelaar, H., Corrosion and Its Control: An Introduction to the Subject, NACE, 1994, Second Edition. (Item # 37552)

Page Content

1 Chapter 1 - Electrochemical Background for Corrosion23 Chapter 2 - Electrochemistry of Corrosion Cells37 Chapter 3 - Metallurgical Aspects of Corrosion and Its Control47 Chapter 4 - The Corrosion Product as a Factor in Corrosion Control67 Chapter 5 - Oxidation and High Temperature Corrosion83 Chapter 6 - Synergistic Modes of Attack105 Chapter 7 - Control Measures - Modification of the Environment125 Chapter 8 - Control Measures - Protective Coatings141 Chapter 9 - Control Measures - Action at the Design State149 Chapter 10 - Corrosion Economics165 Chapter 11 - Corrosion Testing



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Page Content

179 Chapter 12 - Detecting and Monitoring Corrosion195 Chapter 13 - Regulations and Specifications203 Chapter 14 - Safety and the Corrosion Engineer219 Chapter 15 - Engineering Materials263 Chapter 16 - Stainless Steels289 Chapter 17 - Failure Analysis311 Chapter 18 - Computers in the Practice of Corrosion

Gellings, P.J., Introduction to Corrosion Prevention and Control, Delft University Press, 1985.

Page Content

1 Chapter 1 - Definition and Importance of Corrosion1 Definition of Corrosion2 Importance of Corrosion3 Corrosion Resistance and Materials Selection4 General Plan of the Book5 References5 Problems6 Chapter 2 - The Driving Force for Corrosion Reactions6 Introduction8 Thermodynamics of Oxidation Reactions8 Reactions in Solution9 Electrochemical Cells11 Electrodes and Electrode Potentials13 Electrochemical Series and Their Applications16 Potential-pH Diagrams21 Limitations of Thermodynamic Consideration22 Summary23 References24 Problems26 Chapter 3 - The Rates of Electrochemical Reactions26 Introduction28 Polarization Diagrams29 Polarization of Single Polarization30 Charge-Transfer Polarization32 Diffusion Polarization33 Passivity and Polarization35 Summary36 Problems37 Chapter 4 - Rates of Electrochemical Corrosion Reactions37 Introduction39 Polarization Diagrams for Polyelectrodes41 Corrosion in Acid Solutions45 Corrosion in Neutral Solutions: ‘Oxygen Corrosion’47 Influence of Electrolyte Resistivity on Corrosion Rate49 Bimetallic Corrosion51 Cathodic Protection54 Passivity58 Problems



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Page Content

59 Chapter 5 - Characteristic Forms of Electrochemical Corrosion59 Introduction59 Rusting and Atmospheric Corrosion of Iron and Steel63 Pitting Corrosion66 Crevice Corrosion and Deposit Attach67 Selective Dissolution69 Intercrystalline Corrosion73 Stress Corrosion Cracking and Corrosion Fatigue77 Erosion and Cavitation Corrosion. Impingement Attack81 Fretting Corrosion82 Concluding Remarks82 References83 Chapter 6 - Prevention and Control of Electrochemical Corrosion83 Introduction83 Obtaining and Using Corrosion Data85 Protective Coatings85 Metallic Coatings88 Inorganic Non-metallic Coatings89 Organic Coatings91 Temporary Corrosion Preventives92 Designing Against Corrosion97 The Economics of Corrosion Control101 References102 Chapter 7 - High Temperature Oxidation and Its Control102 Introduction103 Kinetic Equations for High Temperature Oxidation105 Parabolic Oxidation106 Rate of Parabolic Oxidation109 Prevention and Control of High Temperature Oxidation112 Dew Point Corrosion113 References113 Problems114 Epilogue: How to Prevent or Control Corrosion

Hack, H.P., Corrosion Testing Made Easy : Galvanic Corrosion Test Methods, NACE, 1993. (Item # 37537)

Page Content

1 Chapter 1 - Introduction1 The Nature of Galvanic Corrosion2 Galvanic Corrosion Testing2 Galvanic Corrosion Theory2 The Importance of Theory2 Electricity and Corrosion4 Determining the Rate of Corrosion4 Current vs Corrosion - Faraday’s Law



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Page Content

5 Current vs Potential6 The Galvanic Couple7 Complicating Factors9 References10 Bibliography11 Chapter 2 - Factors to Consider When Testing11 Making the Test Resemble Reality11 Materials13 Environment13 Composition13 Dissolved Gases14 Minor Constituents14 Conductivity14 Organics14 Bio-Constituents15 Temperature15 Flow16 Atmospheric Variables16 Geometry17 Specifics for the Forms of Corrosion17 Duration of Test17 Replication18 References18 Bibliography19 Chapter 3 - Laboratory Testing19 Standardized Tests19 Accelerated Tests19 Common Issues20 Mounting and Electrical Connection21 Gasketed Mounting22 Rod Mounting22 Partial Immersion23 Wall Mounting24 Epoxy Mounting25 Press-Fit Mounting25 Full Immersion26 Other Mounting Methods26 Connecting the Wire28 Solution Volume28 Basic Tests28 Galvanic Series33 Galvanic Couple Test36 Polarization Tests36 Galvanostatic Test36 Potentiostatic Test37 Potentiodynamic Test38 Preexposure39 References39 Bibliography



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Page Content

41 Chapter 4 - Component Testing and Scale Modeling41 Full-Scale Components41 Advantages42 Disadvantages42 Conducting Full-Scale Component Tests42 Geometry42 Initial Conditions - History of Surface42 Operating Cycle42 Measurements

43 Scale Modeling43 Scaling Laws45 Simple Size Scaling45 Scaled Conductivity Testing46 Selecting the Type of Scaling47 Tank Size - Wall Effects47 Measurements47 Choosing Full-Scale or Scale-Model Tests47 Bibliography49 Chapter 5 - Atmospheric Testing49 Special Circumstances49 Limited Electrolyte49 Long Exposure Duration49 Orientation49 Wire-on-Bolt (CLIMAT) Test49 Advantages/Disadvantages50 Setup50 Measurements and Interpretation53 Plate Test53 Advantages/Disadvantages55 Setup55 Preparation of Plates56 Assembly and Exposure57 Measurements and Interpretation58 Washer Test58 Advantages/Disadvantages58 Setup58 Preparation of Washers60 Assembly and Exposure61 Measurements and Interpretation61 Special Considerations in Atmospheric Testing62 References62 Bibliography



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Lawson, H.H., Corrosion Testing Made Easy: Atmospheric Corrosion Test Methods, NACE, 1994. (Item # 37554)

Page Content

1 Chapter 1 - Introduction1 History of Atmospheric Testing1 Cost of Atmospheric Corrosion1 What is Atmospheric Corrosion?3 Common Means of Mitigation3 References5 Chapter 2 - Test Sites and Facility Hardware5 Classification of Atmospheres5 Site Selection and Preparation6 Hardware and Terminology11 References13 Chapter 3 - Test Site Instrumentation13 Typical Weather Instrumentation15 Additional Monitoring Equipment18 References21 Chapter 4 - Test Site Calibration21 Methods and Materials21 Corrosion Mapping22 References25 Chapter 5 - Test Samples and Preparation25 Sample Size and Specimen Preparation26 Sample/Material Identification28 Specimen Preparation28 Record Keeping29 Installation29 References33 Chapter 6 - Post Testing Procedures33 Removal and Storage33 Visual Evaluation34 Cleaning34 Mass Loss Determination35 Pit Evaluation35 Destructive Evaluation35 Other Evaluations35 Statistics35 Reporting36 References37 Chapter 7 - Measuring Atmospheric Corrosivity37 The CLIMAT Test37 Preparation, Testing, and Evaluation41 Other Attributes of the CLIMAT Test41 Other Procedures for Measuring Corrosivity of Test Sites42 References45 Chapter 8 - Special Testing Procedures45 Different Rack and Specimen Orientations46 Sheltering47 Measuring Galvanic Effects



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Page Content

49 Stress Corrosion Cracking in the Atmosphere51 Non-Standard Test Exposures53 References55 Chapter 9 - ISO Atmospheric Classifications55 Basis of Classifications55 Corrosivity Categories58 References59 Chapter 10 - Atmospheric Simulation Testing59 Cabinet Tests61 References63 Appendix - Planning, Instrumentation, and Evaluation of Atmospheric Corrosion Tests

Parts 1, 2, 3, and 4

*Sedriks, A.J., Corrosion Testing Made Easy: Stress Corrosion Cracking Test Methods, NACE, 1990. (Item # 37512)

Page Content

1 Chapter 1 - Introduction1 Stress Corrosion Cracking Terminology2 Constituents of a Stress Corrosion Cracking Test2 Selection of a Stress Corrosion Cracking Test4 Alloy Grain Orientation6 Residual Stresses7 Surface Condition8 Weldments11 Chapter 2 - Making and Using Uniaxially Loaded Tensile Specimens11 Specimen Preparation11 Constant Strain and Constant Load Tests13 Testing Procedure14 Assessment and Reporting of Results15 Slow Strain Rate Tests16 Definition of Parameters Used in Slow Strain Rate Testing16 Testing Procedure17 Assessment and Reporting of Results19 Chapter 3 - Making and Using Bent-Beam Specimens19 Two-Point Loaded Specimens20 Three-Point Loaded Specimens20 Four-Point Loaded Specimens21 Double-Beam Specimens21 Fully Supported Bent-Beam Specimens22 Testing Bent-Beam Specimens23 Assessment and Reporting of Results25 Chapter 4 - Making and Using U-Bend Specimens25 Specimen Preparation28 Testing Procedure29 Assessment and Reporting of Results



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Page Content

31 Chapter 5 - Making and Using C-Ring Specimens31 Specimen Preparation32 Stressing the Specimen33 Stressing With Strain Gages Attached33 Stressing Without Strain Gages33 Stress Considerations35 Testing Procedure35 Assessment and Reporting of Results37 Chapter 6 - Making and Using Precracked Cantilever Beam Specimens37 Terminology37 Ensuring Plane Strain Test Conditions39 Specimen Preparation41 Testing Procedure41 Determination of KISCC

44 Reporting of Results47 Chapter 7 - Making and Using Precracked Wedge Opening-Loaded Specimens48 Specimen Preparation49 Relationship Between Crack Opening Displacement and KI

50 Testing Procedure52 Reporting of Results53 Chapter 8 - Measurement of Crack Velocities Using Precracked Specimens53 Variation of Crack Velocity with KI

54 Using the Compact Tension Specimen55 Determining Crack Velocity by Visual Observation56 Determining Crack Velocity from Crack Opening Displacement Measurements57 Determining Crack Velocity from Load Decrease Measurements58 Using the Double Cantilever Beam Specimen60 Using the Wedge Opening-Loaded Specimen with an Instrumented Bolt61 Using the Double Torsion Specimen64 Reporting of Results67 Chapter 9 - Making and Using Blunt Notched Specimens67 Definition of Parameters68 Using Plane Strain Blunt Notched Cantilever Beam and Compact Tension Specimens70 Using Other Blunt Notched Specimens71 Chapter 10 - Laboratory Environments for Stress Corrosion Testing71 Preparation and Control of Test Solutions72 Ambient Pressure-Ambient Temperature Tests72 Electrochemical Stimulation73 Specialized Tests73 Ambient Pressure-Elevated Temperature Tests75 Specialized Tests75 Elevated Pressure-Elevated Temperature Tests76 Static Autoclave Systems78 Refreshed Autoclave Systems81 Chapter 11 - Stress Corrosion Testing in Industrial and Natural Environments81 Testing in Industrial Plant Under Operating Conditions82 Testing in Seawater83 Testing in Atmospheric Environments



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*Verink, E.D., Corrosion Testing Made Easy: The Basics, NACE, 1993. (Item # 37538)

Page Content

1 Introduction: Corrosion Testing and Those Who Engage in It1 Before We Begin1 What Do Corrosion Research Technicians Do?1 Typical Activities of Corrosion Research Technicians3 Chapter 1 - General Operations and Laboratory Procedures5 Cleanliness and Good Housekeeping5 Contact With Spilled Chemicals7 Eye Protection7 Body Protection8 Handling Volatile Liquids and Gases10 Gas Masks and Respirators10 Cleaning up Spills11 Mercury11 Fire12 Ignition Sources14 Precautions Regarding Electrical Equipment14 Fire Extinguishers and Classes of Fires15 Resources for Further Study by the Corrosion Technician15 References17 Chapter 2 - Corrosion Technology17 Wet Corrosion17 General Corrosion or Uniform Corrosion18 Dealloying or Parting19 Galvanic Corrosion23 Pitting25 Concentration Cells25 Crevice Corrosion27 Occluded Cells27 Metal Ion Concentration Cells29 Intergranular Corrosion30 Erosion-Corrosion31 Cavitation 31 Environmental Cracking32 Stress Corrosion Cracking32 Hydrogen-Induced Cracking32 Liquid Metal Cracking32 Corrosion Fatigue33 Fretting Corrosion34 Fretting Corrosion Fatigue34 Influence of Paints and Other Coatings35 Microbiologically Influenced Corrosion35 Methods for Preventing and Controlling Wet Corrosion36 Dry Corrosion36 Corrosion Theory and Terminology36 Electrochemistry37 The Electrode37 The Auxilary Electrode37 The Electrochemical Cell



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Page Content

37 The Anode37 The Anion37 The Cathode37 The Cation38 The Test Electrode or Working Electrode38 Electrode Potential38 Corrosion Potential38 Polarization38 Overvoltage43 The Reference Electrode46 Control of Potential48 Passivity48 Resistance50 Electronic Resistance51 Ionic Resistance52 Polarization Resistance55 Current57 Faraday’s Law59 Cathodic Protection59 Anodic Protection60 References63 Chapter 3 - The Corrosion Research Laboratory64 Preparing Solutions66 Distinction Between Analytical and Equilibrium Concentrations66 Chemical Calculations and Computations66 Mass Percent67 Volume Percent67 Conversion of Mass Percent to Volume Percent68 Grades of Chemicals68 Reagent Analyzed or Reagent Grade68 Primary Standard68 Solutions and Reagents73 Removing Solid Materials from Containers74 Pouring Liquids from Bottles76 Pouring Liquids from Beakers and Other Containers76 Transferring Solutions from Pipettes and Medicine Droppers76 Mixing Solutions76 Pumps Used for Transferring Liquids78 Common Hazardous Chemicals79 Compressed Gases88 Leaking Cylinders90 Gas Regulators90 Bulk Liquids90 Glassware and Stoppers99 Handling Group Glass Surfaces101 Lubricating Stopcocks101 Storing Glassware102 Assembling Ground-Joint Glassware103 Plastic Equipment103 Cleaning Plastic Laboratory Ware



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103 Sterilizing Plastic Laboratory Ware105 The Desiccator112 Measuring Temperature112 Liquid Thermometers114 Bimetallic Expansion Thermometers114 Thermistors114 Thermocouples115 Pyrometers115 Optical Pyrometers115 Single-Temperature Indicators115 Heating Chemicals115 Boiling Liquids119 Heating Organic Liquids120 Flameless Heating Devices123 Laboratory Hot Plates and Stirrers124 Other Means of Heating and Drying124 Measuring Pressure and Vacuum127 The Balance127 Rules for Proper Use129 Capacity and Precision132 Errors in Determining Mass133 Measuring pH133 pH and POH Theory133 The pH Meter137 Standardization Using Buffers139 Electrode Maintenance140 Filtration141 Filter Media141 Paper141 Membrane Filters141 Fritted Glassware144 Filtering Accessories144 Filter Supports144 Filter Aids145 Wash Bottles145 Operations Involved in Filtration147 Decantation147 Washing147 Transferring the Precipitate147 Gravity Filtration148 Vacuum Filtration149 Buchner Funnels149 Sintered Glass Crucibles150 Porous Porcelain and Monroe Crucibles151 Gravimetric Analysis152 Preparing the Crucible152 Filter Paper153 Cooling the Crucible to Constant Mass153 Volumetric Analysis154 Liter154 Titration



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154 Back Titration154 Standard Solution154 Primary Standard154 Equivalence Point154 Endpoint154 Titration Error154 Reading the Meniscus155 Typical Physical Changes During Volumetric Analysis155 Tools of Volumetric Analysis156 Volumetric Flasks156 Introducing a Standard156 Dilution to the Mark157 Pipettes160 Burettes162 Filling a Burette162 The Stopcock162 Titration164 Centrifugation166 Precautions167 Water for Laboratory Use169 Tubing Materials169 Synthetic and Natural Rubber Tubing Materials171 Tygon™ Tubing174 References174 Chapter 4 - Corrosion Testing175 Laboratory vs Field Tests175 Test Factors Associated Primarily with the Metal179 Test Factors Associated Primarily with the Environment180 Test Factors Involving Both the Metal and Its Environment181 Accelerated Tests of Corrosion Behavior181 Potentiodynamic Polarization Measurements184 Atmospheric Corrosion Tests184 Immersion Tests189 Tests in the Vapor Phase189 Tests with Relative Motion Between Specimen and Environment189 Rotating Disk Tests190 Flow Simulation Tests190 Jet Impingement Tests190 Paddle-Wheel Tests190 Venturi Tests190 Service Simulation Tests190 Spool Tests192 Environmental Cracking Tests197 Crevice Tests197 High-Temperature Oxidation (Dry Corrosion) Tests198 Discontinuous Methods of Assessing Reaction Rates199 Continuous Methods of Assessing Reaction Rates199 Mass Gain Method200 Gas Consumption Methods202 Characterizing Materials202 Size and Geometry of Specimens



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Page Content

203 Corrosiveness of the Environment204 Identifying Specimens204 Replicating Specimens204 Machining Specimens205 Handling Specimens206 Control Specimens206 Arranging Specimens for Testing206 Test Fixtures for Laboratory and Field Tests206 Duration of Tests206 References209 Chapter 5 - Observing and Assessing Test Results209 Planning the Work210 Data Recording and the Laboratory Notebook210 The Final Report211 Analytical Data211 Determinate Errors211 Indeterminate Errors211 Reporting Numerical Quantities211 Precision of Measurements211 Statistics212 Productivity and Efficiency212 Observations After Testing but Prior to Cleaning213 Cleaning Prior to Weighing213 Weighing215 Visual Examination215 Microscopic Observations216 Corrosion Rate Calculations216 Theoretical Weight Loss217 Preparing Specimens for Metallographic Examination218 Examining Oxides or Corrosion Products on Specimen Surfaces218 Sectioning Specimens222 Cleaning Specimens222 Mounting Specimens224 Grinding Specimens224 Rough Grinding224 Intermediate Grinding225 Polishing Techniques228 Metallographic Polishing Abrasives228 Diamond Dust229 Other Polishing Media229 Metallographic Polishing Cloths230 Preliminary Lapping Procedure230 Final Lapping Procedure231 Electrolytic Polishing231 Current-Voltage Relationship234 Safety Precautions240 Etching Specimens for Microscopic Examination241 Examining Specimens for Oxidation Experiments244 The Metallographic Microscope and Its Use244 The Principle of the Microscope245 Properties of Objective Lenses



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Page Content

246 Numerical Aperture246 Resolving Power247 Vertical Resolution247 Curvature of the Field247 Microscope Eyepieces249 Making Measurements Within the Microscope249 Care of Optical Parts250 Photomicrography250 Surface Analytical Techniques250 Scanning Auger Microprobe252 Scanning Electron Microscopy (SEM)254 X-ray Diffraction (XRD)255 X-ray Photoelectron Spectroscopy (XPS, ESCA)256 Electron Probe Microanalysis (EMP)257 Energy Dispersive X-ray Spectroscopy (EDS)257 References265 Appendix A - ASTM Standards and Specifications for Corrosion Testing269 Appendix B - Selected NACE Standards273 Appendix C - Greek Alphabet275 Appendix D - Temperature Conversions277 Appendix E - Melting Points and Atomic Weights of Elements279 Appendix F - Standard Symbols and Constants281 Appendix G - Derived Units of the International System283 Appendix H - Length Conversion Factors285 Appendix I - Area Conversion Factors285 Appendix J - Force Conversion Factors287 Appendix K - Volume and Capacity Conversion Factors289 Appendix L - Mass Conversion Factors291 Appendix M - Pressure/Stress Conversion Factors293 Appendix N - Energy/Work and Power Conversion Factors295 Appendix O - Elements Present in Solution in Sea Water297 Appendix P - Surface Areas and Volumes



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Sample Questions - Corrosion Technician Open-book Examination

Exercise I Circle the letter that corresponds with the answer of your choice for each question. The passing score on this quiz is 11.

1. Polluted air is more corrosive than clean air.a. Trueb. False

2. Salt water is more corrosive than fresh water.a. Trueb. False

3. Corrosion is the deterioration of a substance (usually a metal) or its properties because of a reaction with its environment. a. Trueb. False

4. Electrons are negatively charged.a. Trueb. False

5. An ion is a neutral atom.a. Trueb. False

6. The cathode is an electrode where oxidation reactions occur. a. Trueb. False

7. Passivity is due to formation of a surface film which acts as a barrier to further corrosion. a. Trueb. False

8. Metallic ions may plate out on cathodic surfaces (as opposed to anodic surfaces). a. Trueb. False

9. Moisture promotes corrosion by acting as an electrolyte. a. Trueb. False



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10. Corrosion rates generally increase when temperature increases. a. Trueb. False

11. Electrochemical reactions can occur without the transfer of electrons.a. Trueb. False

12. Electrons are said to be a. Positively charged particles b. Negatively charged particles c. Neutral particles d. Varies depending on specific conditions

13. Corrosion always results in the deposition of metal at thea. Cathode b. Anode c. Both a and b d. Neither a nor b

14. ? allows electronic current to flow from anode to cathode. a. Anode b. Cathode c. Electrolyte d. Metallic path

15. Factors influencing corrosion in liquid environments includea. Chemistry of system b. Flow rate of liquid c. Temperature of liquid d. All of the above



41



Exercise II

Circle the letter that corresponds with the answer of your choice for each question. The passing score on this quiz is 11.

1. Nearly all metals exhibit crystalline structures.a. Trueb. False

2. Thermoplastic materials become and remain pliable whenever heated. a. Trueb. False

3. Thermoset materials harden and remain hard after one exposure to heat. a. Trueb. False

4. Plastics are generally not prone to "cold flow" or "creep." a. Trueb. False

5. Metals conduct electricity through the flow of ions. a. Trueb. False

6. Plastics are subject to corrosion by oxidation.a. Trueb. False

7. Plastics may deteriorate due to continued polymerization.a. Trueb. False

8. Concrete may corrode.a. Trueb. False

9. Reinforcing steel in concrete does not present a corrosion risk. a. Trueb. False

10. Water used to make concrete should be free of chemical contaminants. a. Trueb. False



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11. ? tend to leach calcium from concrete.a. Soft waters b. Hard waters c. Sea waters d. Alkaline waters

12. A chemical substance which, when added to an environment, decreases the rate of attack by that environmenta. Galvanic cathodeb. Galvanic anodec. Corrosion inhibitord. Electrolyte

13. Pourbaix diagrams predict the potential of metals in environments with varying pH. a. Trueb. False

14. Passivity of a metal can be enhanced by alloying it with a more active metal.a. Trueb. False

15. Martensitic alloys containa. Up to 30% chromium b. 18% chromium, 8% nickel c. Additions of Ni, Mo, and Cu in amounts from 50-94% d. 12-17% chromium



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Exercise III


1. In seawater, which of the following metals is anodic with respect to steel?a. Copperb. Titaniumc. Zincd. Type 304 Stainless Steel

2. Which of the following is not an electrochemical cell? a. A galvanic corrosion cellb. An active/passive cellc. A thermogalvanic celld. None of the above

3. Stress corrosion cracking is usually accompanied by significant metal loss. a. Trueb. False

4. Stress corrosion cracking is a cathodic phenomenon. a. Trueb. False

5. Hydrogen induced cracking may occur at cathodes.a. Trueb. False

6. Hydrogen induced cracking occurs when molecular hydrogen evolves as a gaseous cathodic reaction product without penetrating the metal substrate. a. Trueb. False

7. Conversion of atomic hydrogen to molecular hydrogen may be inhibited by arsenic compounds. a. Trueb. False

8. Sulfide stress cracking may be encountered where wet H2S is present. a. Trueb. False



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9. Liquid metal embrittlement may occur if a metal is stressed in tension while in contact with an active liquid metal. a. Trueb. False

10. Cathodic protection may contribute to hydrogen damage in metals. a. Trueb. False

11. Cathodic protection may be helpful in controlling cavitation corrosion.a. True b. False

12. Crevice corrosiona. Occurs most commonly on film-protected metals b. Occurs where free access to environment is restricted c. Both a and b d. Neither a nor b

13. Filiform corrosion may occura. Beneath coatings b. Within coatings c. Above coatings d. All of the above

14. Electrode potentials are sensitive toa. Temperature b. Presence of depolarizers c. Both a and b d. Neither a nor b

15. In a galvanic couple, which of the following is likely to promote the most rapid corrosion reaction? a. Large cathode area, small anode area b. Small cathode area, large anode area c. Polarized cathode d. Cathodic protection



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Exercise IV


1. Oxidizing anodic inhibitors require the presence of oxygen.a. Trueb. False

2. Silicates and phosphates are common oxygen scavengers.a. Trueb. False

3. Inhibitors may be added to coatings.a. Trueb. False

4. Cathodic protection can control corrosion.a. Trueb. False

5. Concrete is generally resistant to acidic environments. a. Trueb. False

6. Corrosion control at the design stage must be planned.a. Trueb. False

7. A corrosion inhibitor is a substance which, when added to an environment, decreases the rate of attack by the environment. a. Trueb. False

8. Passivating inhibitors cause a shift in cathode potential, causing the cathode to become more positive. a. Trueb. False

9. Ohmic inhibitors increase resistance of electrolyte circuit by formation of a film on the metal surface.a. Trueb. False



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10. Ohmic inhibitors may affect the entire surface of the metal.a. Trueb. False

11. Approximate cathodic protection current requirements for bare steel in moving seawater are a. Less than 1 mA/M2

b. 10-30 mA/M2 c. 55-85mA/M2 d. 100-160 mA/M2

12. A cathodically protected structure may be coated primarily toa. Reduce the area exposed to the electrolyte b. Prevent polarization c. Improve appearance d. Increase cathodic protection current requirements

13. Sacrificial coatingsa. Corrode instead of a steel substrate b. Act as a barrier between the substrate and the corrosive medium c. Both a and b d. Neither a nor b

14. Corrosion detection is used fora. Safetyb. Cost effectivenessc. Both a and bd. Neither a nor b

15. When a quantity of inhibitor is periodically added to a closed system, the ? technique is in use. a. Continuous injection b. Batch treatment c. Squeeze treatment d. None of the above



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Answers to Sample Questions

Exercise I Exercise II Exercise III Exercise IV

1. a2. a3. a4. a5. b6. b7. a8. a9. a10. a11. b12. b13. d14. d15. d

1. a2. a3. a4. b5. b6. a7. a8. a9. b10. a11. a12. c13. b14. a15. d

1. c2. d3. b4. b5. a6. b7. a8. a9. a10. a11. a12. c13. a14. c15. a

1. b2. b3. a4. a5. b6. a7. a8. b9. a10. a11. d12. a13. c14. c15. b



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