Guide to Requirements for Certification as a Senior Corrosion Technologist
STUDY GUIDE SENIOR CORROSION TECHNOLOGIST
We congratulate you on aspiring to be a NACE International Senior Corrosion Technologist. 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 Senior Corrosion Technologist Open-Book Examination….56 Answers to Sample Questions……………….…………………………..……..……68
1 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
Guide to Requirements for Certification as a Senior Corrosion Technologist
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.
2 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
Guide to Requirements for Certification as a Senior Corrosion Technologist
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 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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Guide to Requirements for Certification as a Senior Corrosion Technologist
Overview of the Professional Recognition Program Requirements for Certification Senior Corrosion Technologist 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 of several NACE International courses. Certification also requires signing a NACE International Attestation concerning professionalism. Requirements for Recertification All individuals who have held their certification for five 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.) 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 10. Only courses successfully completed within five years of the certification application being submitted to Headquarters will be accepted.
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Guide to Requirements for Certification as a Senior Corrosion Technologist
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 categories 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. However, each open-book examination is broken into timed sections solely for the convenience and comfort of the applicant. The examination must be completed in no more than two consecutive days. 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 Senior Corrosion Technologist is six months. Examinations may be taken at: NACE International Headquarters At examination sites that NACE International Headquarters, Areas, or Sections may organize from time to time.
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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Guide to Requirements for Certification as a Senior Corrosion Technologist
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 three members of the Application Review Board for review 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. 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
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Guide to Requirements for Certification as a Senior Corrosion Technologist
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 Senior Corrosion Technologist must be recertified every five 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. 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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Guide to Requirements for Certification as a Senior Corrosion Technologist
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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Guide to Requirements for Certification as a Senior Corrosion Technologist
Costs Certification fees in U.S. dollars include: Application processing fee (all categories) members - $100, nonmembers - $250 Note: Application processing fees are payable on each category of certification for which you apply. Senior Corrosion Technologist Examination fee: members and nonmembers: $125 ALL FEES ARE NONREFUNDABLE. Note 1: Return check service charge $25 Any 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. Senior Corrosion Technologist 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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Guide to Requirements for Certification as a Senior Corrosion Technologist
Parallel Path 1 - Senior Corrosion Technologist Basic Corrosion - An Introduction course PLUS One from Menu A* One from Menu B** 1 additional course from Menu A or B PLUS Designing for Corrosion Control course PLUS Chemical Treatment for Corrosion Control exam Parallel Path 2 - Senior Corrosion Technologist Corrosion Technician Certification PLUS One from Menu A* One from Menu B** 1 additional course from Menu A or B PLUS Designing for Corrosion Control course PLUS Chemical Treatment for Corrosion Control exam Parallel Path 3- Senior Corrosion Technologist Corrosion Technologist Certification PLUS 1 additional course from Menu A or B PLUS Designing for Corrosion Control course PLUS Chemical Treatment for Corrosion Control exam MENU A*
MENU B**
CP Level 1 Class & Certification CP Level 2 Class & Certification CP Level 3 Class & Certification
Basic Protective Coatings & Linings Advanced Protective Coatings & Linings Certified Coating Inspector
(Must meet work experience requirement) Only courses successfully completed within five years of the certification application being submitted to Headquarters will be accepted.
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Guide to Requirements for Certification as a Senior Corrosion Technologist
Work Experience The minimum requirements for acceptable work experience for Senior Corrosion Technologist are: Eight years corrosion work experience, including four years in responsible charge, OR Bachelor’s degree in physical sciences or engineering PLUS four years corrosion work experience in responsible charge “Acceptable work experience in responsible charge” is documented work experience in the field of corrosion which includes: (a) the investigation of corrosion causes and mechanisms, (b) the investigation, design and implementation of corrosion control procedures, or (c) the teaching of corrosion related science, any of which should be at a level of responsibility requiring initiative, technical ability, and independent judgment. The applicant need not be in administrative or supervisory control of the work, however, it is necessary that the applicant be in technical control and have technical responsibility. The distinguishing characteristic of one in “responsible charge” of work in the corrosion field should be the ability to deal creatively with a set of circumstances relating to corrosion and to deduce or synthesize a fruitful and safe course of action.
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Guide to Requirements for Certification as a Senior Corrosion Technologist
Overview of Senior Corrosion Technologist Examination This examination is an integral part of the certification program, being one of the requirements for certification as a NACE International Senior Corrosion Technologist. 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 Senior Corrosion Technologist. 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 Senior Corrosion Technologist. 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 Senior Corrosion Technologist.
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Guide to Requirements for Certification as a Senior Corrosion Technologist
Scope of Examination The open-book examination must be taken under proctored conditions previously outlined. The examination consists of four parts: Part I Part II Part III Part IV
Corrosion Science/Materials Selection & Design Corrosion Science/Cathodic Protection Corrosion Science/Coatings & Linings Corrosion Science/Environmental Treatment
It is expected that the answers will demonstrate a broad level of knowledge and experience in the candidate’s particular field, as well as, indicating a capability in the approach to the solution of corrosion problems outside his/her field. Detailed Overview Part I (2 hours) Corrosion Science/Materials Selection & Design Designed to exhibit a level of knowledge and understanding of corrosion science and specifically how it relates to material selection and design issues.
Part II (2 hours) Examination on Corrosion Science/Cathodic Protection Designed to test the applicants knowledge concerning the science and application of cathodic protection. Part III (2 hours) Examination on Corrosion Science/ Coatings and Linings Designed to assess the applicants knowledge of coatings and linings technology and how it is used in corrosion control. Part IV (2 hours) Examination on Corrosion Science and Environmental Treatment Designed to measure applicants knowledge of how corrosion control can be obtained by controlling the service environment.
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Guide to Requirements for Certification as a Senior Corrosion Technologist
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) Dillon, C.P., Corrosion Control in the Chemical Process Industries, Second Edition, MTI Publication, No. 45. (Item # 37938) Corrosion Data Survey - Metals Section, 6th Edition. (Item # 37519) Corrosion Data Survey, Nonmetals Section, 5th Edition. (Item # 37517) Fontana, M.G., Corrosion Engineering, Third Edition, McCraw-Hill, 1986. (Item # 37711) Metals & Alloys in the Unified Numbering System, Seventh Edition, SAE International and ASTM, 1993. (Item # 37731) Moniz, B.J., and Pollock, W.I., eds., Process Industries Corrosion: The Theory and Practice, NACE, 1986. (Item # 37521) Uhlig, H.H., Corrosion and Corrosion Control, An Introduction to Corrosion Science and Engineering, Third Edition, John Wyley & Sons, Inc., NY, 1985. (Item # 37707) *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 772188340, 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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Guide to Requirements for Certification as a Senior Corrosion Technologist
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 5 19
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Content Chapter 1 - General Corrosion of Metals General corrosion is corrosion that proceeds without appreciable localization of attack. Chapter 2 - Localized Corrosion Localized corrosion is defined as corrosive attack limited to a specific, relatively small surface area; the remaining area is largely unattacked. Chapter 3 - Galvanic Corrosion Galvanic corrosion occurs when a metal or alloy is electrically coupled to another, or to a conducting nonmetal in the same electrolyte. Chapter 4 - Environmental Cracking The 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. Chapter 5 - Erosion-Corrosion Cavitation and Fretting Surface damage by erosion, cavitation or fretting is often difficult to identify. There are features of each damage mode that make them subject to confusion. Chapter 6 - Intergranular Corrosion Intergranular corrosion consists of preferential attack at or adjacent to the grain boundaries of a metal or alloy. Chapter 7 - Dealloying Dealloying is a corrosion process whereby one constituent of an alloy is preferentially removed, leaving an altered residual structure. Chapter 8 - High Temperature Corrosion Performance It 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 3
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Content Chapter 1 - Scope and Language of Corrosion This chapter offers a general overview of corrosion and the reasons for studying it. A glossary of corrosion-related terms is included. Chapter 2 - Basics of Corrosion Corrosion reactions are presented in the most basic terms. The influence of various factors on the initiation and advancement of corrosion in aqueous systems is discussed. Chapter 3 - Metallurgy This chapter discusses the effects of metal structure, alloying elements, mechanical working, and heat treatment on corrosion behavior. Chapter 4 - Materials The properties of a wide variety of materials (alloys and nonmetals) are compared with regard to corrosion resistance and mechanical properties.
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Content Chapter 5 - Localized Corrosion Concentrated attack in the form of pitting, erosion, cavitation, fretting, deposition, corrosion, corrosion fatigue, and dealloying is presented in this chapter. Chapter 6 - Environmental Cracking The factors involved in stress corrosion, hydrogen embrittlement, and liquid metal embrittlement are defined, and the metals susceptible to attack in specific environments are enumerated. Chapter 7 - Inhibitors Anodic, 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. Chapter 8 - Corrosion by Water and Steam Factors 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. Chapter 9 - Cathodic Protection An easy-to-understand chapter on the present-day factors in practical cathodic protection practices and important design features. Chapter 10 - Underground Corrosion Certain 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. Chapter 11 - Atmospheric Corrosion This 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. Chapter 12 - Coatings The 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. Chapter 13 - High-Temperature Corrosion This 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. Chapter 14 - Testing and Inspection The 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. Chapter 15 - Design and Failure Analysis Some 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 1
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Content Chapter 1 - Introduction to Corrosion Introduction; 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. Chapter 2 - Corrosion as Related to Coatings Corrosion 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. Chapter 3 - Essential Coating Characteristics Coating Function; Essential Coating Properties; Additional Coating Properties; Types of Exposure. Chapter 4 - Coating Fundamentals Basic Coating Concepts; The Coating System; Basic Coating Formation; Coating Component Functions; Basic Coating Components Chapter 5 - Corrosion-Resistant Organic Coatings Natural Air-Oxidizing Coatings; Synthetic Oxidizing Coatings; Lacquers; Co-reactive Coatings; Heat-Condensing Coatings; 100% Solids Coatings. Chapter 6 - Corrosion-Resistant Zinc Coatings Protection by Zinc Coatings; Application of Zinc Coatings; Organic Zinc-Rich Coatings; Inorganic Zinc Coatings; Types of Zinc-Rich Coatings; Topcoating; Comparison Summary. Chapter 7 - Structural Design for Coating Use Principle of Design for Coating Use; Coating Problems Related to Design; Summary. Chapter 8 - The Substrate— —Importance to Coating Life Types of Substrates; Types of Contamination Chapter 9 - Surface Preparation Introduction; Types of Adhesion; Surface Preparation Objectives; Development of Techniques; Types of Contamination; Types of Surface Preparation; Concrete Surfaces; Other Influences on Surface Preparation Selection. Chapter 10 - Application of Coatings The 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. Chapter 11 - Coatings for Concrete Introduction; 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. Chapter 12 - Coating Selection Introduction; Consideration; Evaluating Operating Conditions; Compatibility; Substrate; Environment; Soil Problems; Internal Surface; Corrosive Conditions; Product
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Contamination; Coating Curing; Surface Preparation; Timing; Safety; Previous Experience; Coating Cost; Coating Properties; Summary.
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Content Chapter 13 - Coatings and Cathodic Protection Introduction; 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. Chapter 14 - Coating Failures Introduction; 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. Chapter 15 - Coating Repair and Maintenance Introduction; 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. Chapter 16 - Safe Application of Coatings and Linings Introduction; 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. Chapter 17 - Specifications Parts of a Specification; Types of Specifications; Areas of Specification; Appendix— Example of a Typical Specification. Chapter 18 - Inspection and Testing Variables Involved in Quality Control; Types of Coating Inspectors; What Should a Qualified Inspector Know; Areas of Coating Inspection; Inspection Equipment. Chapter 19 - Typical Coating Uses The 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 1 3 9 19 33 38 51 94 109 116 128 133 148 164 173 178
Content Chapter 1 - Preparing to be a Corrosion Engineer Chapter 2 - What is Corrosion? Chapter 3 - Coatings Chapter 4 - Cathodic Protection - How it works Chapter 5 - Criteria for Cathodic Protection Chapter 6 - Survey Methods and Techniques Chapter 7 - Instrumentation Chapter 8 - Ground Bed Design Chapter 9 - Cathodic Protection with Rectifiers Chapter 10 - Cathodic Protection with Galvanic Anodes Chapter 11 - Cathodic Protection with Other Current Sources Chapter 12 - Stray Current Electrolysis Chapter 13 - Construction Practices Chapter 14 - Maintenance Procedures Chapter 15 - Bacteriological Corrosion Chapter 16 - Economics
19 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
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Treseder, R.S., Baboian, R., and Munger, C.G., NACE Corrosion Engineers Reference Book, Latest Edition, NACE. (Item # 37523) Page
7 23 28 30 32 34 36 38 38 40 41 42 44 46 48 49 54 55 55 56 56 57 58 59 60 61 62 63 64 65 66 67 68 74 75 76 77 78 79
Content Glossary NACE Glossary of Corrosion-Related Terms Glossary of Corrosion-Related Acronyms Conversion Tables International System of Units (Sl) General Conversion Factors Temperature Conversions Stress Conversions Approximate Equivalent Hardness Numbers and Tensile Strengths for Steel Common Gage Series Used for Sheet Thickness Sheet Gage—Thickness Conversions Metric and Decimal Equivalents of Fractions of an Inch Physical and Chemical Data Physical Properties of Gases and Liquids Physical Properties of Elements Properties of Dry Saturated Steam—English Units Properties of Dry Saturated Steam—Sl Units Vapor Pressure of Water Below 100°C Dew Point of Moist Air Vapor Pressure vs Temperature for Volatile Compounds Approximate pH Values at 25°C Boiling Points vs Concentration of Common Corrosive Media pH Values of Pure Water vs Temperature Solubility of Gases in Water Solubility of Air in Water and Solvents Solubility of Water in Hydrocarbons Thermocouple Data Corrosion Testing Hypothetical Cathodic and Anodic Polarization Diagram Typical Cathodic and Anodic Polarization Diagram Hypothetical Cathodic and Anodic Polarization Plots for a Passive Anode Typical Standard Potentiostatic Anodic Polarization Plot Data for Tafel Equation Calculations Polarization Resistance Method for Determining Corrosion Rates Values for the Constant B for Polarization Resistance Method Standard Reference Potentials and Conversion Table Electrochemical Series Typical Potential-pH (Pourbaix) Diagram Standard Environments for Environmental Cracking Tests Specimen Types Used in Environmental Cracking Tests Planned Interval Corrosion Test Corrosion Rate Conversion Factors Densities of Common Alloys
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80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 95 96 97 98 98 99 100 101 102 103 104 104 105 106 108 109 109 110 110 111 112 113 114 117 118 119 120
Content
Atmospheric Corrosion Atmospheric Corrosion of Steel vs Time in an Industrial Atmosphere Corrosion Rates of Carbon Steel Calibrating Specimens at Various Locations Corrosion of Structural Steel in Various Environments Effect of Amount of Zinc on Service Life of Galvanized Sheet in Various Environments Development of Rust on Zinc- and Cadmium-Plated Steels in a Marine Atmosphere Atmospheric Corrosion of Zinc in Various Locations as a Function of Time Atmospheric Corrosion of Various Metals and Alloys Corrosion of Copper Alloys in Marine Atmospheres Relative Performance of Stainless Steels Exposed in a Marine Atmosphere Seawater and Cooling Water Corrosion Corrosion Factors for Carbon Steel in Seawater Zones of Corrosion for Steel Piling in Seawater Rates of General Wastage of Metals in Quiet Seawater Suggested Velocity Limits for Condenser Tube Alloys in Seawater Galvanic Series in Seawater Practical Galvanic Series The Major Constituents of Seawater Chemical Composition of Substitute Seawater Calculation of Calcium Carbonate Saturation Index (Langelier Index) Water Analysis Conversion Factors Common Groups of Algae Common Types of Bacteria Causing Slime Problems Microorganisms Commonly Implicated in Biological Corrosion Microbiocides Used in Cooling Water Systems Cathodic Protection Approximate Current Requirements for Cathodic Protection of Steel Design Criteria for Offshore Cathodic Protection Systems Effect of Applied Cathodic Current on Corrosion and Potential of Steel in Flowing Seawater Energy Capabilities and Consumption Rates of Galvanic Anode Materials in Seawater Consumption Rates of Impressed Current Anode Materials Platinum Consumption Rates for Cathodic Protection Anodes Resistance of Galvanic AnodesDwight’s Equation Typical Resistivities of Some Waters and Soil Materials Properties of Concentric Stranded Copper Single Conductors Temperature Correction Factors for Resistance of Copper Steel Pipe Resistance Alloy Pipe Resistance Corrosion of Galvanized Pipe in Various Soils Estimating Service Life of Galvanized Steel in Soils Process and Oil Industries Corrosion Caustic Soda Service Chart Alloys for Sulfuric Acid Service Alloys for Nitric Acid Service Alloys for Hydrochloric Acid Service Alloys for Hydrofluoric Acid Service Estimate of Sulfur Trioxide in Combustion Gas
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Page 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 136 138 139 140 141 148 152 153 154 156 158 160 162 164 165 166 168 170 171 172 174 176 178 180 184 186 187 188 188 189 189
Content Calculated Sulfuric Acid Dewpoint in Flue Gas Operating Limits for Steels in Hydrogen Service to Avoid Decarburization and Fissuring Combinations of Alloys and Environments Subject to Dealloying Liquid Metal Cracking Stress Corrosion Cracking Systems Hydrogen Degradation Potential Sulfide Stress Cracking Region as Defined by the 0.05 psia Criterion Maximum Temperature for Continuous Service in Dry Hydrogen Chloride and Chlorine Maximum Service Temperature in Air for Stainless Steels and Alloy Steels High Temperature Sulfidic Corrosion of Steels and Stainless Steels High Temperature H2S/H2 Corrosion of 5Cr-0.5Mo Steel High Temperature H2S/H2 Corrosion of Stainless Steels Ash Fusion Temperatures of Slag-Forming Compounds Distribution Ratio of Ammonia and Amines in Steam and Steam Condensate Oilfield Corrosion InhibitorsMolecular Structures Design Details to Minimize Corrosion Common Types of Scale Forming Minerals Chemical Cleaning Solutions for Specific Scales Components of Boiler Deposits Nondestructive Methods for Evaluating Materials Dimensions of Seamless and Welded Wrought Steel Pipe Standard Wall Steel PipeDimensions, Capacities, and Weights Metallic Materials Unified Numbering System for Metals and Alloys Common Names of UNS Alloys Comparable Alloy Designations Compositions and Typical Mechanical Properties Aluminum Alloys Copper Alloys Carbon and Low Alloy Steels Cast Irons Cast Heat Resistant Stainless Steels Cast Corrosion Resistant Stainless Steels Austenitic Stainless Steels Austenitic Stainless Steels (High Mn) Martinsitic Stainless Steels Ferritic Stainless Steels Duplex Stainless Steels Precipitation-Hardenable Stainless Steels Nickel Alloys CrMo Nickel Alloys Cobalt Alloys Refractory Alloys (Mo, Cb, Ta, W, Zr) Titanium Alloys Lead Alloys Magnesium Alloys Precious Metals (Au, Ag, Pt, Pd) Zinc Alloys
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API Grades of Casing and Tubing
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Page 192 192 192 193 194 196 197 198 200 201 202 205 206 207 208 209 210 211 211 212 213 214 218 220 222 223 224 230 234 236 238 240 242 243 244 245 246 246 247 248 250 251 252 253 254 255
Content Maximum Allowable Stress in Tension (ASME Code) Aluminum Alloys Copper Alloys Carbon and Low Alloy Steels Stainless Steels Nickel Alloys Titanium and Zirconium Alloys Creep Strength of Metals Temper DesignationsCopper Alloys Temper DesignationsMagnesium Alloys Temper DesignationsAluminum Alloys Melting Temperatures of Common Alloys Coefficients of Thermal Expansion of Common Alloys Iron-Carbon Equilibrium Diagram Critical Transformation Temperatures for Steels Temper and Radiation Color of Carbon Steel Annealing Temperatures for Austenitic Stainless Steels and Related Alloys Annealing Treatments for Ferritic Stainless Steels Annealing Temperatures and Procedures for Martensitic Stainless Steels Schoefer Diagram for Estimating Ferrite Content in Austenitic Fe-Cr-Ni Alloy Castings Delta Ferrite Content of Stainless Steel Weld Metals Overview of Joining Processes Preheat Temperatures for Welding Carbon and Low Alloy Steels Postweld Heat Treatment Requirements for Carbon and Alloy Steels Filler Metals Suitable for Welding Joints Between Dissimilar Austenitic Stainless Steels Electrodes and Filler Metals for Dissimilar Joints Between Nickel Alloys and Other Metals Nonmetallic Materials Typical Property Ranges for Plastics Properties of Elastomers Oxygen and Water Permeability in Plastic Films Polyethylene Line PipeDimensions and Properties PVC and CPVC Line PipeDimensions and Properties Reinforced Thermosetting Resin Line PipeDimensions and Properties Types of Portland Cement Chemical Requirements for Portland Cement Hydraulic Cements Chemical Resistant Mortars and Grouts Properties of Graphite and Silicon Carbide Properties of Glass and Silica Properties of High Temperature Refractories Typical Properties of Ceramic Bricks and Chemical Stoneware Protective Coatings Surface Preparation Standards Abrasive/Profile Comparative Chart Summary of SSPC Surface Preparation Specifications Comparative Maximum Heights of Profile Obtained with Various Abrasives Properties of Abrasives Protective Coating Classifications
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Page 256 257 258 259 260 261 262 263 264 266 267 268 270 270 271 272 276 278 279 280 282 284 288 289 290 291 292 294 296 300 301 301 305 306 306 307 307 309 309 309 311 312 312 312 313
Content Alkyd CoatingsProperties Solvent Dry LacquersProperties Epoxy CoatingsProperties 100% Solids CoatingsProperties Urethane CoatingsProperties Heat-Condensing CoatingsProperties Coalescent-Emulsion CoatingsProperties Zinc CoatingsSummary of Properties Zinc CoatingsProperties Compatibility of Coating Materials with Various Primers Resistant Properties of Binders for Coatings Properties of Generic Coatings for Atmospheric Service Temperature Limits of Coatings Radiation Toleration of Coatings Coefficient of FrictionSlip Factors for Various Coatings and Surface Finishes Chemical Resistance of Coatings for Immersion Service Typical Physical Properties of Coatings for Concrete Dry Film Thickness of Coatings as a Function of Solids Content and Coverage Rate Effect of pH on Corrosion of Zinc in Aerated Aqueous Solutions Rust Preventives Pressure Loss in Hose Approximate Square Feet per Linear Foot and per Ton for Different Steel Members Surface Area per Ton of Steel for Various Types of Construction Square Feet of Area and Gallon Capacity per Foot of Depth in Cylindrical Tanks Properties of Flammable Liquids Used in Paints and Lacquers Do’s and Don’ts for Steel Construction to be Coated Surface Finishing of Welds in Preparation for Lining Standards Standards Organizations Metallic Materials SpecificationsAPI, ASTM, CSA Nonmetallic Materials SpecificationsAPI, ASTM, AWWA Nonmetallic Materials StandardsASTM Protective Coatings NACE, ASTM, SSPC Pipeline CoatingsNACE, ASTM, AWWA, CSA, DIN Metallic and Anodic CoatingsASTM Cathodic ProtectionNACE, ASTM Atmospheric CorrosionASTM Oil ProductionNACE, API Oil ProductsASTM Automotive, AircraftASTM Process and Power IndustriesNACE, ASTM, API GeneralNACE, ASTM ElectrochemistryASTM Localized CorrosionASTM Erosion, Wear, and AbrasionASTM Environmental CrackingASTM
25 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
Guide to Requirements for Certification as a Senior Corrosion Technologist
Boyer, H.E., and Gall, T.L., eds., ASM Handbook: Volume 13, Corrosion, ASM International, Metals Park, OH. (Item # 37714) Page 15 17 18 29 37 45 50 56 61 77 79 80 104 123 136 145 191 193 197 204 212 229 231 234 239 242 245 283 291 303 311 314 316 319 321 338 344 369 375 377 380 383 389 396 399
Content Fundamentals of Corrosion Introduction Thermodynamics of Aqueous Corrosion Kinetics of Aqueous Corrosion Effects of Environmental Variables on Aqueous Corrosion Effects of Metallurgical Variables on Aqueous Corrosion Fundamentals of High-Temperature Corrosion in Molten Salts Fundamentals of High-Temperature Corrosion in Liquid Metals Fundamentals of Corrosion in Gases Forms of Corrosion Introduction General Corrosion Localized Corrosion Metallurgically Influenced Corrosion Mechanically Assisted Degradation Environmentally Induced Cracking Corrosion Testing and Evaluation Planning and Preparation of Corrosion Tests In-Service Monitoring Simulated Service Testing Laboratory Testing Evaluation of Uniform Corrosion Evaluation of Pitting Corrosion Evaluation of Galvanic Corrosion Evaluation of Intergranual Corrosion Evaluation of Exfoliation Corrosion Evaluation of Stress-Corrosion Cracking Evaluation of Hydrogen Embrittlement Evaluation of Corrosion Fatigue Evaluation of Crevice Corrosion Evaluation of Erosion and Cavitation Evaluation of Microbiological Corrosion Interpretation and Use of Corrosion Test Results Designing to Minimize Corrosion Materials Selection Design Details to Minimize Corrosion Corrosion of Weldments Corrosion Economic Calculations Corrosion Protection Methods Fundamentals of Corrosion Protection Aqueous Solutions Cleaning for Surface Conversion Phosphate Conversion Coatings Chromate Conversion Coatings Aluminum Anodizing Organic Coatings & Linings
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Electroplated Coatings
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Content Hot Dip Coatings Porcelain Enamels Chemical-Setting Ceramic Linings CVD/PVD Coatings Thermal Spray Coatings Anodic Protection Cathodic Protection Corrosion Inhibitors for Oil and Gas Production Corrosion Inhibitors for Crude Oil Refineries Control of Environmental Variables in Water Recirculating Systems Surface Modification Corrosion of Specific Alloy Systems Carbon Steels Alloy Steels Stainless Steels Cast Irons Cast Steels Aluminum and Aluminum Alloys Copper and Copper Alloys Nickel-Base Alloys Cobalt-Base Alloys Titanium and Titanium Alloys Zirconium and Hafnium Niobium and Niobium Alloys Tantalum Magnesium and Magnesium Alloys Zinc Tin and Tin Alloys Lead and Lead Alloys Noble Metals Beryllium Uranium and Uranium Alloys Powder Metallurgy Materials Cemented Carbides Metal Matrix Composites Amorphous Metals Electroplated Hard Chromium Brazed Joints Clad Metals Corrosion in Specific Industries and Environments Marine Corrosion Nuclear Power Industry Fossil Fuel Power Plants Automotive Industry Aircraft Industry Aerospace Industry Electronics Industry Telephone Cable Plants Chemical Processing Industry
28 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
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Page 1186 1221 1226 1232 1262 1288 1293 1299 1311 1317 1324 1336 1367 1371
Content Pulp and Paper Industry Brewery Industry Pharmaceutical Industry Petroleum Production Operations Petroleum Refining and Petrochemical Operations Pipelines Mineral Industry Structures Metal Processing Equipment Batteries and Fuel-Cell Power Sources Metallic Implants and Prosthetic Devices Dental Alloys Emission-Control Equipment Metric Conversion Guide
Nathan, C.C., Corrosion Inhibitors, NACE, 1973. (Item # 37515) Page 1 7 28 42 55 61 76 89 95 96 98 100 102 114 126 148 156 173 190 196 220 224 228 236 240 245
Content Scope and Importance of Inhibitor Technology Theoretical Aspects of Corrosion Inhibitors and Inhibition Methods of Evaluation and Testing of Corrosion Inhibitors Corrosion Inhibitors in Refineries and Petrochemical Plants Part 1 Part 2 - Control of Fouling Corrosion Inhibitors in Petroleum Production Primary Recovery Corrosion Inhibition in Secondary Recovery Control of Internal Corrosion of Pipelines Carrying Refined Petroleum Products Control of Internal Corrosion of Pipelines Carrying Crude Oil Inhibition of Natural Gas Pipelines Inhibition of Tanks and Other Structures Handling Crude Petroleum Inhibition of Tankships Transporting Refined Petroleum Products Controlling Corrosion in Petroleum Drilling and in Packer Fluids Inhibitors for Potable Water Inhibition of Cooling Water Inhibitors in Desalination Systems Inhibitors in Acid Systems Application of Inhibitors in Automobiles and Their Environment Inhibitors in Organic Coatings Inhibition and Corrosion Control Practices for Boiler Waters Inhibitors for Temporary Protection Part 1 - Oil and Grease Coatings Part 2 - Vapor Phase Corrosion Inhibitors Microbiological Corrosion and Its Control Controlling Corrosion in Pulp and Paper Mills Inhibition of Aluminum Inhibition of Corrosion From Caustic Attack
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Application of Inhibitors in Miscellaneous Environments
30 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
Guide to Requirements for Certification as a Senior Corrosion Technologist
Atkinson, J.T.N., and Van Droffelaar, H., Corrosion and Its Control: An Introduction to the Subject, NACE, 1994, Second Edition. (Item # 37552) Page 1 23 37 47 67 83 105 125 141 149 165 179 195 203 219 263 289 311
Content Chapter 1 - Electrochemical Background for Corrosion Chapter 2 - Electrochemistry of Corrosion Cells Chapter 3 - Metallurgical Aspects of Corrosion and Its Control Chapter 4 - The Corrosion Product as a Factor in Corrosion Control Chapter 5 - Oxidation and High Temperature Corrosion Chapter 6 - Synergistic Modes of Attack Chapter 7 - Control Measures - Modification of the Environment Chapter 8 - Control Measures - Protective Coatings Chapter 9 - Control Measures - Action at the Design State Chapter 10 - Corrosion Economics Chapter 11 - Corrosion Testing Chapter 12 - Detecting and Monitoring Corrosion Chapter 13 - Regulations and Specifications Chapter 14 - Safety and the Corrosion Engineer Chapter 15 - Engineering Materials Chapter 16 - Stainless Steels Chapter 17 - Failure Analysis Chapter 18 - Computers in the Practice of Corrosion
Gellings, P.J., Introduction to Corrosion Prevention and Control, Delft University Press, 1985. Page 1 1 2 3 4 5 5 6 6 8 8 9 11 13 16 21 22 23 24 26 26 28
Content Chapter 1 - Definition and Importance of Corrosion Definition of Corrosion Importance of Corrosion Corrosion Resistance and Materials Selection General Plan of the Book References Problems Chapter 2 - The Driving Force for Corrosion Reactions Introduction Thermodynamics of Oxidation Reactions Reactions in Solution Electrochemical Cells Electrodes and Electrode Potentials Electrochemical Series and Their Applications Potential-pH Diagrams Limitations of Thermodynamic Consideration Summary References Problems Chapter 3 - The Rates of Electrochemical Reactions Introduction Polarization Diagrams
31 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
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Page 29 30 32 33 35 36 37 37 39 41 45 47 49 51 54 58 59 59 59 63 66 67 69 73 77 81 82 82 83 83 83 85 85 88 89 91 92 97 101 102 102 103 105 106 109 112 113 113 114
Content Polarization of Single Polarization Charge-Transfer Polarization Diffusion Polarization Passivity and Polarization Summary Problems Chapter 4 - Rates of Electrochemical Corrosion Reactions Introduction Polarization Diagrams for Polyelectrodes Corrosion in Acid Solutions Corrosion in Neutral Solutions: ‘Oxygen Corrosion’ Influence of Electrolyte Resistivity on Corrosion Rate Bimetallic Corrosion Cathodic Protection Passivity Problems Chapter 5 - Characteristic Forms of Electrochemical Corrosion Introduction Rusting and Atmospheric Corrosion of Iron and Steel Pitting Corrosion Crevice Corrosion and Deposit Attach Selective Dissolution Intercrystalline Corrosion Stress Corrosion Cracking and Corrosion Fatigue Erosion and Cavitation Corrosion. Impingement Attack Fretting Corrosion Concluding Remarks References Chapter 6 - Prevention and Control of Electrochemical Corrosion Introduction Obtaining and Using Corrosion Data Protective Coatings Metallic Coatings Inorganic Non-metallic Coatings Organic Coatings Temporary Corrosion Preventives Designing Against Corrosion The Economics of Corrosion Control References Chapter 7 - High Temperature Oxidation and Its Control Introduction Kinetic Equations for High Temperature Oxidation Parabolic Oxidation Rate of Parabolic Oxidation Prevention and Control of High Temperature Oxidation Dew Point Corrosion References Problems Epilogue: How to Prevent or Control Corrosion
32 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
Guide to Requirements for Certification as a Senior Corrosion Technologist
Hack, H.P., Corrosion Testing Made Easy : Galvanic Corrosion Test Methods, NACE, 1993. (Item # 37537) Page 1 1 2 2 2 2 4 4 5 6 7 9 10 11 11 11 13 13 13 14 14 14 14 15 15 16 16 17 17 17 18 18 19 19 19 19 20 21 22 22 23 24 25 25 26
Content Chapter 1 - Introduction The Nature of Galvanic Corrosion Galvanic Corrosion Testing Galvanic Corrosion Theory The Importance of Theory Electricity and Corrosion Determining the Rate of Corrosion Current vs Corrosion - Faraday’s Law Current vs Potential The Galvanic Couple Complicating Factors References Bibliography Chapter 2 - Factors to Consider When Testing Making the Test Resemble Reality Materials Environment Composition Dissolved Gases Minor Constituents Conductivity Organics Bio-Constituents Temperature Flow Atmospheric Variables Geometry Specifics for the Forms of Corrosion Duration of Test Replication References Bibliography Chapter 3 - Laboratory Testing Standardized Tests Accelerated Tests Common Issues Mounting and Electrical Connection Gasketed Mounting Rod Mounting Partial Immersion Wall Mounting Epoxy Mounting Press-Fit Mounting Full Immersion Other Mounting Methods
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Connecting the Wire Solution Volume
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Page 28 28 33 36 36 36 37 38 39 39 41 41 41 42 42 42 42 42 42 43 43 45 45 46 47 47 47 47 49 49 49 49 49 49 49 50 50 53 53 55 55 56 57 58 58 58 58 60 61
Content Basic Tests Galvanic Series Galvanic Couple Test Polarization Tests Galvanostatic Test Potentiostatic Test Potentiodynamic Test Preexposure References Bibliography Chapter 4 - Component Testing and Scale Modeling Full-Scale Components Advantages Disadvantages Conducting Full-Scale Component Tests Geometry Initial Conditions - History of Surface Operating Cycle Measurements Scale Modeling Scaling Laws Simple Size Scaling Scaled Conductivity Testing Selecting the Type of Scaling Tank Size - Wall Effects Measurements Choosing Full-Scale or Scale-Model Tests Bibliography Chapter 5 - Atmospheric Testing Special Circumstances Limited Electrolyte Long Exposure Duration Orientation Wire-on-Bolt (CLIMAT) Test Advantages/Disadvantages Setup Measurements and Interpretation Plate Test Advantages/Disadvantages Setup Preparation of Plates Assembly and Exposure Measurements and Interpretation Washer Test Advantages/Disadvantages Setup Preparation of Washers Assembly and Exposure Measurements and Interpretation
35 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
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Page 61 62 62
Content Special Considerations in Atmospheric Testing References Bibliography
Lawson, H.H., Corrosion Testing Made Easy: Atmospheric Corrosion Test Methods, NACE, 1994. (Item # 37554) Page 1 1 1 1 3 3 5 5 5 6 11 13 13 15 18 21 21 21 22 25 25 26 28 28 29 29 33 33 33 34 34 35 35 35 35 35 36
Content Chapter 1 - Introduction History of Atmospheric Testing Cost of Atmospheric Corrosion What is Atmospheric Corrosion? Common Means of Mitigation References Chapter 2 - Test Sites and Facility Hardware Classification of Atmospheres Site Selection and Preparation Hardware and Terminology References Chapter 3 - Test Site Instrumentation Typical Weather Instrumentation Additional Monitoring Equipment References Chapter 4 - Test Site Calibration Methods and Materials Corrosion Mapping References Chapter 5 - Test Samples and Preparation Sample Size and Specimen Preparation Sample/Material Identification Specimen Preparation Record Keeping Installation References Chapter 6 - Post Testing Procedures Removal and Storage Visual Evaluation Cleaning Mass Loss Determination Pit Evaluation Destructive Evaluation Other Evaluations Statistics Reporting References
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Page 37 37 37 41 41 42 45 45 46 47 49 51 53 55 55 55 58 59 59 61 63
Content Chapter 7 - Measuring Atmospheric Corrosivity The CLIMAT Test Preparation, Testing, and Evaluation Other Attributes of the CLIMAT Test Other Procedures for Measuring Corrosivity of Test Sites References Chapter 8 - Special Testing Procedures Different Rack and Specimen Orientations Sheltering Measuring Galvanic Effects Stress Corrosion Cracking in the Atmosphere Non-Standard Test Exposures References Chapter 9 - ISO Atmospheric Classifications Basis of Classifications Corrosivity Categories References Chapter 10 - Atmospheric Simulation Testing Cabinet Tests References Appendix - Planning, Instrumentation, and Evaluation of Atmospheric Corrosion Tests Parts 1, 2, 3, and 4
37 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
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*Sedriks, A.J., Corrosion Testing Made Easy: Stress Corrosion Cracking Test Methods, NACE, 1990. (Item # 37512) Page 1 1 2 2 4 6 7 8 11 11 11 13 14 15 16 16 17 19 19 20 20 21 21 22 23 25 25 28 29 31 31 32 33 33 33 35 35 37 37 37 39 41 41 44
Content Chapter 1 - Introduction Stress Corrosion Cracking Terminology Constituents of a Stress Corrosion Cracking Test Selection of a Stress Corrosion Cracking Test Alloy Grain Orientation Residual Stresses Surface Condition Weldments Chapter 2 - Making and Using Uniaxially Loaded Tensile Specimens Specimen Preparation Constant Strain and Constant Load Tests Testing Procedure Assessment and Reporting of Results Slow Strain Rate Tests Definition of Parameters Used in Slow Strain Rate Testing Testing Procedure Assessment and Reporting of Results Chapter 3 - Making and Using Bent-Beam Specimens Two-Point Loaded Specimens Three-Point Loaded Specimens Four-Point Loaded Specimens Double-Beam Specimens Fully Supported Bent-Beam Specimens Testing Bent-Beam Specimens Assessment and Reporting of Results Chapter 4 - Making and Using U-Bend Specimens Specimen Preparation Testing Procedure Assessment and Reporting of Results Chapter 5 - Making and Using C-Ring Specimens Specimen Preparation Stressing the Specimen Stressing With Strain Gages Attached Stressing Without Strain Gages Stress Considerations Testing Procedure Assessment and Reporting of Results Chapter 6 - Making and Using Precracked Cantilever Beam Specimens Terminology Ensuring Plane Strain Test Conditions Specimen Preparation Testing Procedure Determination of KISCC Reporting of Results
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Page 47 48 49 50 52 53 53 54 55 56 57 58 60 61 64 67 67 68 70 71 71 72 72 73 73 75 75 76 78 81 81 82 83
Content Chapter 7 - Making and Using Precracked Wedge Opening-Loaded Specimens Specimen Preparation Relationship Between Crack Opening Displacement and K I Testing Procedure Reporting of Results Chapter 8 - Measurement of Crack Velocities Using Precracked Specimens Variation of Crack Velocity with KI Using the Compact Tension Specimen Determining Crack Velocity by Visual Observation Determining Crack Velocity from Crack Opening Displacement Measurements Determining Crack Velocity from Load Decrease Measurements Using the Double Cantilever Beam Specimen Using the Wedge Opening-Loaded Specimen with an Instrumented Bolt Using the Double Torsion Specimen Reporting of Results Chapter 9 - Making and Using Blunt Notched Specimens Definition of Parameters Using Plane Strain Blunt Notched Cantilever Beam and Compact Tension Specimens Using Other Blunt Notched Specimens Chapter 10 - Laboratory Environments for Stress Corrosion Testing Preparation and Control of Test Solutions Ambient Pressure-Ambient Temperature Tests Electrochemical Stimulation Specialized Tests Ambient Pressure-Elevated Temperature Tests Specialized Tests Elevated Pressure-Elevated Temperature Tests Static Autoclave Systems Refreshed Autoclave Systems Chapter 11 - Stress Corrosion Testing in Industrial and Natural Environments Testing in Industrial Plant Under Operating Conditions Testing in Seawater Testing in Atmospheric Environments
*Verink, E.D., Corrosion Testing Made Easy: The Basics, NACE, 1993. (Item # 37538) Page 1 1 1 1 3 5 5 7 7 8 10
Content Introduction: Corrosion Testing and Those Who Engage in It Before We Begin What Do Corrosion Research Technicians Do? Typical Activities of Corrosion Research Technicians Chapter 1 - General Operations and Laboratory Procedures Cleanliness and Good Housekeeping Contact With Spilled Chemicals Eye Protection Body Protection Handling Volatile Liquids and Gases Gas Masks and Respirators
39 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
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Cleaning up Spills
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Page 11 11 12 14 14 15 15 17 17 17 18 19 23 25 25 27 27 29 30 31 31 32 32 32 32 33 34 34 35 35 36 36 36 37 37 37 37 37 37 37 38 38 38 38 38 43 46
Content Mercury Fire Ignition Sources Precautions Regarding Electrical Equipment Fire Extinguishers and Classes of Fires Resources for Further Study by the Corrosion Technician References Chapter 2 - Corrosion Technology Wet Corrosion General Corrosion or Uniform Corrosion Dealloying or Parting Galvanic Corrosion Pitting Concentration Cells Crevice Corrosion Occluded Cells Metal Ion Concentration Cells Intergranular Corrosion Erosion-Corrosion Cavitation Environmental Cracking Stress Corrosion Cracking Hydrogen-Induced Cracking Liquid Metal Cracking Corrosion Fatigue Fretting Corrosion Fretting Corrosion Fatigue Influence of Paints and Other Coatings Microbiologically Influenced Corrosion Methods for Preventing and Controlling Wet Corrosion Dry Corrosion Corrosion Theory and Terminology Electrochemistry The Electrode The Auxilary Electrode The Electrochemical Cell The Anode The Anion The Cathode The Cation The Test Electrode or Working Electrode Electrode Potential Corrosion Potential Polarization Overvoltage The Reference Electrode Control of Potentia
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Content Passivity Resistance Electronic Resistance Ionic Resistance Polarization Resistance Current Faraday’s Law Cathodic Protection Anodic Protection References Chapter 3 - The Corrosion Research Laboratory Preparing Solutions Distinction Between Analytical and Equilibrium Concentrations Chemical Calculations and Computations Mass Percent Volume Percent Conversion of Mass Percent to Volume Percent Grades of Chemicals Reagent Analyzed or Reagent Grade Primary Standard Solutions and Reagents Removing Solid Materials from Containers Pouring Liquids from Bottles Pouring Liquids from Beakers and Other Containers Transferring Solutions from Pipettes and Medicine Droppers Mixing Solutions Pumps Used for Transferring Liquids Common Hazardous Chemicals Compressed Gases Leaking Cylinders Gas Regulators Bulk Liquids Glassware and Stoppers Handling Group Glass Surfaces Lubricating Stopcocks Storing Glassware Assembling Ground-Joint Glassware Plastic Equipment Cleaning Plastic Laboratory Ware Sterilizing Plastic Laboratory Ware The Desiccator Measuring Temperature Liquid Thermometers Bimetallic Expansion Thermometers Thermistors Thermocouples Pyrometers Optical Pyrometers Single-Temperature Indicators
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Heating Chemicals
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Page 115 119 120 123 124 124 127 127 129 132 133 133 133 137 139 140 141 141 141 141 144 144 144 145 145 147 147 147 147 148 149 149 150 151 152 152 153 153 154 154 154 154 154 154 154 154
Content Boiling Liquids Heating Organic Liquids Flameless Heating Devices Laboratory Hot Plates and Stirrers Other Means of Heating and Drying Measuring Pressure and Vacuum The Balance Rules for Proper Use Capacity and Precision Errors in Determining Mass Measuring pH pH and POH Theory The pH Meter Standardization Using Buffers Electrode Maintenance Filtration Filter Media Paper Membrane Filters Fritted Glassware Filtering Accessories Filter Supports Filter Aids Wash Bottles Operations Involved in Filtration Decantation Washing Transferring the Precipitate Gravity Filtration Vacuum Filtration Buchner Funnels Sintered Glass Crucibles Porous Porcelain and Monroe Crucibles Gravimetric Analysis Preparing the Crucible Filter Paper Cooling the Crucible to Constant Mass Volumetric Analysis Liter Titration Back Titration Standard Solution Primary Standard Equivalence Point Endpoint Titration Error
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Page 154 155 155 156 156 156 157 160 162 162 162 164 166 167 169 169 171 174 174 175 175 179 180 181 181 184 184 189 189 189 190 190 190 190 190 190 192 197 197 198 199 199 200 202 202 203 204 204 204
Content Reading the Meniscus Typical Physical Changes During Volumetric Analysis Tools of Volumetric Analysis Volumetric Flasks Introducing a Standard Dilution to the Mark Pipettes Burettes Filling a Burette The Stopcock Titration Centrifugation Precautions Water for Laboratory Use Tubing Materials Synthetic and Natural Rubber Tubing Materials Tygon™ Tubing References Chapter 4 - Corrosion Testing Laboratory vs Field Tests Test Factors Associated Primarily with the Metal Test Factors Associated Primarily with the Environment Test Factors Involving Both the Metal and Its Environment Accelerated Tests of Corrosion Behavior Potentiodynamic Polarization Measurements Atmospheric Corrosion Tests Immersion Tests Tests in the Vapor Phase Tests with Relative Motion Between Specimen and Environment Rotating Disk Tests Flow Simulation Tests Jet Impingement Tests Paddle-Wheel Tests Venturi Tests Service Simulation Tests Spool Tests Environmental Cracking Tests Crevice Tests High-Temperature Oxidation (Dry Corrosion) Tests Discontinuous Methods of Assessing Reaction Rates Continuous Methods of Assessing Reaction Rates Mass Gain Method Gas Consumption Methods Characterizing Materials Size and Geometry of Specimens Corrosiveness of the Environment Identifying Specimens Replicating Specimens Machining Specimens
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Handling Specimens
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Page 206 206 206 206 206 209 209 210 210 211 211 211 211 211 211 212 212 213 213 215 215 216 216 217 218 218 222 222 224 224 224 225 228 228 229 229 230 230 231 231 234 240 241 244 244 245 246 246 247
Content Control Specimens Arranging Specimens for Testing Test Fixtures for Laboratory and Field Tests Duration of Tests References Chapter 5 - Observing and Assessing Test Results Planning the Work Data Recording and the Laboratory Notebook The Final Report Analytical Data Determinate Errors Indeterminate Errors Reporting Numerical Quantities Precision of Measurements Statistics Productivity and Efficiency Observations After Testing but Prior to Cleaning Cleaning Prior to Weighing Weighing Visual Examination Microscopic Observations Corrosion Rate Calculations Theoretical Weight Loss Preparing Specimens for Metallographic Examination Examining Oxides or Corrosion Products on Specimen Surfaces Sectioning Specimens Cleaning Specimens Mounting Specimens Grinding Specimens Rough Grinding Intermediate Grinding Polishing Techniques Metallographic Polishing Abrasives Diamond Dust Other Polishing Media Metallographic Polishing Cloths Preliminary Lapping Procedure Final Lapping Procedure Electrolytic Polishing Current-Voltage Relationship Safety Precautions Etching Specimens for Microscopic Examination Examining Specimens for Oxidation Experiments The Metallographic Microscope and Its Use The Principle of the Microscope Properties of Objective Lenses Numerical Aperture Resolving Power Vertical Resolution
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Page 247 247 249 249 250 250 250 252 254 255 256
257 257 265 269 273 275 277 279 281 283 285 285 287 289 291 293 295 297
Content Curvature of the Field Microscope Eyepieces Making Measurements Within the Microscope Care of Optical Parts Photomicrography Surface Analytical Techniques Scanning Auger Microprobe Scanning Electron Microscopy (SEM) X-ray Diffraction (XRD) X-ray Photoelectron Spectroscopy (XPS, ESCA) Electron Probe Microanalysis (EMP)
Energy Dispersive X-ray Spectroscopy (EDS) References Appendix A - ASTM Standards and Specifications for Corrosion Testing Appendix B - Selected NACE Standards Appendix C - Greek Alphabet Appendix D - Temperature Conversions Appendix E - Melting Points and Atomic Weights of Elements Appendix F - Standard Symbols and Constants Appendix G - Derived Units of the International System Appendix H - Length Conversion Factors Appendix I - Area Conversion Factors Appendix J - Force Conversion Factors Appendix K - Volume and Capacity Conversion Factors Appendix L - Mass Conversion Factors Appendix M - Pressure/Stress Conversion Factors Appendix N - Energy/Work and Power Conversion Factors Appendix O - Elements Present in Solution in Sea Water Appendix P - Surface Areas and Volumes
Dillon, C.P., Corrosion Control in the Chemical Process Industries, Second Edition, MTI Publication, No. 45. (Item # 37938) Page 1 1 1 2 4 15 15 17 19 20 20
Content Chapter 1 - Introduction Purpose Cost of Corrosion Methodology Resources Section I - Fundamental Factors Chapter 2 - Basic Considerations Safety and Reliability Cost Environmental Aspects Energy Consideration Materials Conservation
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Page 23 23 23 25 29 32 42 43 45 45 46 46 47 50 55 55 55 69 69 74 77 83 83 90 93 93 95 96 98 101 101 105 105 105 107 111 111 114 121 123 123 124 131 133 134 136 136
Content Chapter 3 - Factors in Materials Selection Cost Physical Properties Mechanical Properties Codes and Regulations Fabrication Characteristics Corrosion Characteristics Amenability to Corrosion Control Chapter 4 - Materials Selection Procedures Materials Considerations Materials-Environment Interactions Specific Equipment Procedures and Communications Conclusion Section II - Corrosion Factors Chapter 5 - Corrosion Mechanisms Definition Electrochemistry of Metallic Corrosion Chapter 6 - Corrosion and Metallurgical Phenomena Corrosion Phenomena Metallurgical Phenomena Chapter 7 - Sensitization and Weld Decay Chapter 8 - Environmental Cracking Metallic Materials Plastics Chapter 9 - Corrosion Testing Materials Factors Materials Characteristics Laboratory Tests Field Tests Corrosion Coupons Coupon Evaluation Section III - Materials Chapter 10 - Light Metals Structure of Metals Magnesium Aluminum and Its Alloys Chapter 11 - Iron and Steel Cast Irons Steels Numbering Chapter 12 - Stainless Steels Nature of Stainless Steel Types of Stainless Steel Stainless Castings Chapter 13 - High-Performance Nickel-Rich Alloys Superaustenitics High-Nickel Austenitics Ranking Alloys
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Page 139 139 142 145 145 147 147 149 149 151 152 155 155 160 163 163 173 175 183 183 184 187 189 194 197 202 204 207 209 209 210 211 214 217 217 218 220 220 221 224 227 228 231 233 239 239 256
Content Chapter 14 - Nickel and Its Alloys Nickel Alloys Chromium-Bearing Alloys Chapter 15 - Lead, Tin and Zinc Lead and Its Alloys Tin Zinc Chapter 16 - Copper and Its Alloys Copper Brass Bronze Chapter 17 - Reactiver, Refractory and Noble (Precious) Metals Reactive and Refractory Metals Noble (Precious) Metals Chapter 18 - Nonmetallic Materials Plastics Rubber and Elastomers Other Nonmetallic Materials Section IV - Corrosive Environments Chapter 19 - Corrosion by Water and Steam Water Chemistry Scaling Indices Corrosion of Steel by Water Types of Waters Boilers, Steam and Condensate Cooling-Water Systems Microbiologically Influenced Corrosion (MIC) Behavior of Materials Special Information Sources Chapter 20 - Corrosion by Soil Types of Corrosion Factors in Soil Corrosion Behavior of Specific Materials Corrosion Control Chapter 21 - Atmospheric Corrosion Types of Corrosion Controlling Factors Types of Atmospheres Corrosion Control Specific Materials Special Problems Chapter 22 - Oxidizing Acids Nitric Acid Chromic Acid Concentrated Sulfuric Acid and Oleum Chapter 23 - Reducing Acids Inorganic Acids Organic Acids
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Page 263 263 267 267 269 272 273 273 276 277 277 283 283 283 285 285 287 291 291 292 292 293 295 295 296 296 296 298 301 301 302 303 303 306 306 311 311 312 312 317 317 318 320 320 320 322
Content Chapter 24 - Carbon Dioxide Specific Materials Chapter 25 - Hydrogen Sulfide Corrosivity Specific Materials Pyrophoric Products Chapter 26 - Corrosion by Chlorine Specific Materials Storage and Handling Chapter 27 - Corrosion in Alkaline Environments Sodium Hydroxide Potassium Hydroxide Calcium Hydroxide Alkaline Salts Chapter 28 - Ammonia and Its Compounds Ammonia and Ammonium Hydroxide Amines Chapter 29 - Corrosion by Salts Neutral Salts Acid Salts Alkaline Salts Oxidizing Salts Chapter 30 - Hydrogen Phenomena Slow Strain Rate Embrittlement Hydrogen Blistering Hydrogen-Assisted Cracking High-Temperature Effects Practical Guidelines Chapter 31 - High-Temperature Phenomena Metal Behavior Internal Stability Surface Stability High-Temperature Corrosion Effects of Alloying Elements Heat-Resistant Alloys Chapter 32 - Effects of Mercury Amalgamation Environmental Cracking Accelerated Corrosion Section V - Elements of Corrosion Control Chapter 33 - Corrosion Control Change of Material Change of Environment Anticorrosion Barriers Electrochemical Techniques Design Considerations Special Features in Heat Exchanger Design
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Page 329 329 330 330 330 331 332 333 334 335 339 339 339 340 341 342 342 343 343 345 346 346 365 365 369 371 371 371 377 378 381 381 384 386 387
Content Chapter 34 - Introduction to Economic Comparisons Return on Investment Compound Interest Annual Cost or Savings Present Worth and Annual Cost Discounting Depreciation Discounted Cash Flow and PWAT PWAT and Annual Costs Use of Annual Cost Calculations Chapter 35 - Corrosion Inhibitors Definition Electrochemistry Aqueous Systems Refrigeration Brines Acids Acid-Gas Scrubbing Systems Nonaqueous Environments Other Considerations Chapter 36 - Paints and Coatings Temporary Rust Preventatives Paints and Coatings Chapter 37 - Anti-Corrosion Barriers Metallic Barriers Nonmetallic Barriers Chapter 38 - Cathodic Protection Definition Principles Design and Application Specialty Applications Chapter 39 - Inspection and Failure Analysis Inspection Failure Analysis Preventive and Predictive Maintenance Documents and Data/Information Retrieval
Corrosion Data Survey - Metals Section, 6th Edition. (Item # 37519) Page i i iii iii iv iv insert
Content Introduction How to Use the Survey Sources of Data NACE References Additional References Acknowledgments Key to Data Table
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Page insert 1 139 155 171 173 174 175 175 175 176 177 178 180 182 184
Content Identification and Nominal Analyses of Metals and Alloys Section 1 - Main Tables Section 2 - Short Tables Section 3 - High Temperature Tables Section 4 - Graphs Operating Limits to Steels in Hydrogen Service to Avoid Decarburization & Fissuring Time for Incipient Attack of Carbon Steel in Hydrogen Service Hydrogen Sulfide vs. Low Chromium Steels Phosphoric Acid vs. Type 316 Steels Carbon Steels vs. 3000 ppm Hydrogen Sulfide in 5% Sodium Chloride Caustic Soda Service Graph Mixed Acids Graph Carbon Monoxide Graph Hydrochloric Acid Graph Hydrofluoric Acid Graph Sulfuric Acid Graph
*Corrosion Data Survey, Nonmetals Section, 5th Edition. (Item # 37517) Page v 1i 1 401 441 494
Content Introduction Index to Corrosives Aqueous Solutions of Industrial Chemicals Industrial Gases and Their Aqueous Solutions Beverages, Extracts, Foods, Insecticides, Medicines, and Miscellaneous Worksheets: Corrosion Data Survey Nonmetals Section
Fontana, M.G., Corrosion Engineering, Third Edition, McCraw-Hill, 1986. (Item # 37711) Page 1 1 3 4 5 5 9 9 12 12 13 14 14 19 21
Content Chapter 1 - Introduction Cost of Corrosion Corrosion Engineering Definition of Corrosion Environments Corrosion Damage Classification of Corrosion Future Outlook Chapter 2 - Corrosion Principles Introduction Corrosion Rate Expressions Electrochemical Aspects Electrochemical Reactions Polarization Passivity
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Page 23 23 24 26 26 27 28 28 32 36 38 38 39 39 41 41 45 46 46 48 50 51 51 53 59 59 63 64 66 69 70 71 72 73 73 74 76 78 83 85 86 86 88 88 89 89 90
Content Environmental Effects Effect of Oxygen and Oxidizers Effects of Velocity Effect of Temperature Effects of Corrosive Concentration Effect of Galvanic Coupling Metallurgical and Other Aspects Metallic Properties Economic Considerations Importance of Inspection New Instrumentation Study Sequence Chapter 3 - Eight Forms of Corrosion Uniform Attack Galvanic or Two-Metal Corrosion EMF and Galvanic Series Environmental Effects Distance Effect Area Effect Prevention Beneficial Applications Crevice Corrosion Environmental Factors Mechanism Combating Crevice Corrosion Filiform Corrosion Pitting Pit Shape and Growth Autocatalytic Nature of Pitting Solution Composition Velocity Metallurgical Variables Evaluation of Pitting Damage Prevention Intergranular Corrosion Austenitic Stainless Steels Weld Decay Control for Austenitic Stainless Steels Knife-Line Attack Intergranular Corrosion of Other Alloys Selective Leaching Dezincification: Characteristics Dezincification: Mechanism Dezincification: Prevention Graphitization Other Alloy Systems High Temperatures
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Page 91 92 95 97 98 100 100 102 104 105 109 112 114 116 117 123 124 126 136 138 139 143 143 144 144 145 149 151 153 153 153 155 156 157 158 158 162 165 167 169 171 174 174 176 181 184 184 185 186
Content Erosion Corrosion Surface Films Velocity Turbulence Impingement Galvanic Effect Nature of Metal or Alloy Combating Erosion Corrosion Cavitation Damage Fretting Corrosion Stress Corrosion Crack Morphology Stress Effects Time to Cracking Environmental Factors Metallurgical Factors Mechanism Multienvironment Charts Classification of Mechanisms Methods of Prevention Corrosion Fatigue Hydrogen Damage Characteristics Environmental Factors Hydrogen Blistering Hydrogen Embrittlement Prevention Fracture Mechanics Chapter 4 - Corrosion Testing Introduction Classification Purpose Materials and Specimens Surface Preparation Measuring and Weighing Exposure Techniques Duration Aeration Cleaning Specimens After Exposure Temperature Standard Expressions for Corrosion Rate Galvanic Corrosion High Temperatures and Pressures Erosion Corrosion Crevice Corrosion Intergranular Corrosion Huey Test for Stainless Steels Streicher Test for Stainless Steels Warren Test
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Page 186 187 189 191 192 194 198 200 202 204 206 207 212 215 216 218 219 219 220 220 220 222 224 224 225 226 236 239 239 240 243 244 244 245 245 248 251 253 256 259 259 263 263 265 265 269 269 269 269
Content Pitting Stress Corrosion NACE Test Methods Slow-Strain-Rate Tests Linear Polarization AC Impedance Small-Amplitude Cyclic Valtammetry Electronic Instrumentation In Vivo Corrosion Paint Tests Seawater Tests Miscellaneous Tests of Metals Corrosion of Plastics and Elastomers Presenting and Summarizing Data Nomograph for Corrosion Rates Interpretation of Results Chapter 5 - Materials Mechanic Properties Other Properties Metals and Alloys Cast Irons High-Silicon Cast Irons Other Alloy Cast Irons Carbon Steels and Irons Low-Alloy Steels Stainless Steels Aluminum and Its Alloys Magnesium and Its Alloys Lead and Its Alloys Copper and Its Alloys Nickel and Its Alloys Zinc and Its Alloys Tin and Tin Plate Cadmium Titanium and Its Alloys Refractory Metals Noble Metals Metallic Glasses Metallic Composites Nonmetallics Natural and Synthetic Rubbers Other Elastomers Plastics Thermoplastics Fluorocarbons Acrylics Nylon Chlorinated Polyether Polyethylenes
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Page 270 270 270 270 271 271 271 271 271 272 272 272 274 274 276 277 278 278 278 280 280 281 281 282 292 292 292 294 294 300 302 304 304 309 315 315 317 317 319 320 321 322 323 324 326 327 327 328 328
Content Polypropylene Polystyrene Rigid Polyvinyl Chloride (PVC) Vinyls Other Thermoplastics Thermosetters Epoxies Phenolics Polyesters Silicones Ureas Laminates and Reinforced Plastics Other Nonmetallics Ceramics Carbon and Graphite Wood Chapter 6 - Corrosion Prevention Materials Selection Metals and Alloys Metal Purification Nonmetallics Alteration of Environment Changing Mediums Inhibitors Design Wall Thickness Design Rules Cathodic and Anodic Protection Cathodic Protection Anodic Protection Comparison of Anodic and Cathodic Protection Coatings Metallic and Other Inorganic Coatings Organic Coatings Corrosion Control Standards Failure Analysis Chapter 7 - Mineral Acids Sulfuric Acid Steel Cast Iron Chemical Lead High-Silicon Cast Iron Durimet 20 Nickel-Molybdenum and Nickel-Molybdenum-Chromium Alloys Combined Iscorrosion Chart Conventional Stainless Steels Monel, Nickel, Inconel, and Ni-Resist Copper and Its Alloys Other Metals and Alloys
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Page 329 334 334 336 337 337 338 342 345 346 346 347 349 350 350 351 352 352 353 356 357 357 357 359 360 360 369 372 373 378 381 383 384 386 392 398 402 405 405 407 413 414 414 416 427 434 439 439 440
Content Summary Chart Equipment at Ambient Temperatures Sulfuric Acid Plant Equipment Nonmetallics Nitric Acid Stainless Steels Class 1 Materials Class 2 Materials Class 3 Materials Mixed Acids Hydrochloric Acid Class 1 Metals and Alloys Class 2 Metals and Alloys Class 3 Metals and Alloys Aeration and Oxidizing Agents Nonmetallic Materials Hydrogen Chloride and Chlorine Hydrofluoric Acid Aqueous Hydrofluoric Acid Anhydrous Hydrofluoric Acid Fluorine Phosphoric Acid Materials of Construction Miscellaneous Chapter 8 - Other Environments Organic Acids Alkalies Atmospheric Corrosion Seawater Fresh Water High-Purity Water Soils Aerospace Petroleum Industry Biological Corrosion Human Body Corrosion of Metals by Halogens Corrosion of Automobiles Nuclear Waste Isolation Liquid Metals and Fused Salts Solar Energy Geothermal Energy Sewage and Plant-Waste Treatment Pollution Control Coal Conversion Pulp and Paper Industry Dew Point Corrosion Corrosion Under Insulation Electronic Equipment
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Page 441 443 443 443 444 445 445 445 446 447 452 454 456 458 459 461 462 463 469 474 482 482 482 483 485 487 492 495 495 497 499 499 502 505 505 505 505 507 511 513 516 518 519 520 520 524 529 529 534
Content Liquid-Metal Embrittlement or Cracking Hydrogen Peroxide Rebar Corrosion Bolting Statue of Liberty Chapter 9 - Modern Theory—Principles Introduction Thermodynamics Free Energy Cell Potentials and the EMF Series Applications of Thermodynamics to Corrosion Electrode Kinetics Exchange Current Density Activation Polarization Concentration Polarization Combined Polarization Mixed-Potential Theory Mixed Electrodes Passivity Mechanisms of the Growth and Breakdown of Passive Films Chapter 10 - Modern Theory—Applications Introduction Predicting Corrosion Behavior Effect of Oxidizers Velocity Effects Galvanic Coupling Alloy Evaluation Corrosion Prevention Anodic Protection Noble-Metal Alloying Corrosion Rate Measurements Tafel Extrapolation Linear Polarization Chapter 11 - High-Temperature Corrosion Introduction Mechanisms and Kinetics Piling-Bedworth Ratio Electrochemical and Morphological Aspects of Oxidation Oxide Defect Structure Oxidation Kinetics Effect of Alloying Catastrophic Oxidation Internal Oxidation High-Temperature Materials Mechanical Properties Oxidation Resistance Other Metal-Gas Reactions Decarburization and Hydrogen Attack Corrosion of Metals by Sulfur Compounds at High Temperatures
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541
Hot Corrosion of Alloys
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Metals & Alloys in the Unified Numbering System, Seventh Edition, SAE International and ASTM, 1993. (Item # 37731) Page v vi
1 47 95 99 107 121 129 145 183 199 207 225 235 247 271 279 311
315 321 325 331 339 349 379 385 391 397 405
Content Introduction to the Unified Numbering System Index to US Designations by Base Elements Listing of UNS Numbers Assigned to Date, with Description of Each Material Covered and References to Documents in Which the Same or Similar Materials are Described Axxxxx Number Series - Aluminum and Aluminum Alloys Cxxxxx Number Series - Copper and Copper Alloys Exxxxx Number Series - Rare Earth and Similar Metals and Alloys Fxxxxx Number Series - Cast Irons Gxxxxx Number Series - AISI and SAE Carbon and Alloy Steels Hxxxxx Number Series - AISI and SAE H-Steels Jxxxxx Number Series - Cast Steels (Except Tool Steels) Kxxxxx Number Series - Miscellaneous Steels and Ferrous Alloys Lxxxxx Number Series - Low Melting Metals and Alloys Mxxxxx Number Series - Miscellaneous Nonferrous Metals and Alloys Nxxxxx Number Series - Nickel and Nickel Alloys Pxxxxx Number Series - Precious Metals and Alloys Rxxxxx Number Series - Reactive and Refractory Metals and Alloys Sxxxxx Number Series - Heat and Corrosion Resistant Steel (Including Stainless), Valve Steels and Iron-Base “Superalloys” Txxxxx Number Series - Tool Steels, Wrought and Cast Wxxxxx Number Series - Welding Filler Metals Zxxxxx Number Series - Zinc and Zinc Alloys Cross Index of Commonly Known Documents Which Describe Materials Same as or Similar to Those Covered by UNS Numbers AA (Aluminum Association) Numbers ACI (Steel Founders Society of America) Numbers AISI (American Iron and Steel Institute) including SAE (Society of Automotive Engineers) Numbers (Carbon and Low Alloy Steels) AMS (SAE/Aerospace Materials Specification) Numbers ASME (American Society of Mechanical Engineers) Numbers ASTM (American Society for Testing and Materials) Numbers AWS (American Welding Society) Numbers Federal Specification Numbers MIL (Military Specification) Numbers SAE (Society of Automotive Engineers) “J” Numbers Index by Common Trade Designations
61 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
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Moniz, B.J., and Pollock, W.I., eds., Process Industries Corrosion: The Theory and Practice, NACE, 1986. (Item # 37521) Page
1 11 21 31 45 67 85 123 171 191
205 215 227 243 259 265 275 287 297 311 315 353 367
373 405 415 427 445 461 479 503 529 545
Content Basics Phenomena Forms of Corrosion Electrochemical Principles of Corrosion Environmental Cracking Hydrogen Effects on Steel High Temperature Corrosion Testing Field Coupon Corrosion Testing Field Applications of Electrochemistry Evaluation Tests for Intergranular Corrosion Overviews Corrosion in Petroleum Refineries Corrosion in the Pulp and Paper Industry Environments Waters Cooling Water Treatment Boiler Feedwater and Steam Condensate Microbiologically Influenced Corrosion Acids Sulfuric Acid Nitric Acid Hydrochloric Acid and Hydrogen Chloride Hydrochfluoric Acid and Hydrogen Fluoride Organic Acids Others Alkalies and Hypochlorites Ammonia Halogens Sulfur Compounds - Low Temperature Sulfur Compounds - High Temperature Metals Ferrous Carbon and Low Alloy Steels Weathering Steels Austenitic Stainless Steels Ferritic and Duplex Stainless Steels High Temperature Wrought Alloys Nonferrous Nickel Copper Titanium Zirconium Tantalum and Niobium
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Page
Content
551
Aluminum Others
567
573 577 589 603 639 649 661 681 695 703 711
721 727 739 759 769 775 783 821 835 845 851
Cladding and Overlay Nonmetals Polymers FRP Design Thermoplastics Elastomeric Linings Protective Coatings Ceramics Types of Ceramics Acid Brick Linings Refractories Others Glass Glass-Lined Steel Carbon and Graphite Wood Equipment and Practice Equipment Materials Standards Vessel Design Welding Corrosion Under Thermal Insulation Corrosion from Process Modifications Practice Nondestructive Testing Failure Analysis Equipment Cleaning Field Identification of Metals Appendix A - Comparison of Stainless Steel and Nickel Alloys Appendix B - NACE Glossary of Corrosion Related Terms
63 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
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Uhlig, H.H., Corrosion and Corrosion Control, An Introduction to Corrosion Science and Engineering, Third Edition, John Wyley & Sons, Inc., NY, 1985. (Item # 37707) Page 1 6 16 35 60 90
123
165 178 187 210 217 233 245 250 263 278 297 327 341 358 361 371 375 389 392 404
Content Chapter 1 - Definition and Importance Chapter 2 - Electrochemical Mechanisms Chapter 3 - Corrosion Tendency and Electrode Potentials Chapter 4 - Polarization and Corrosion Rates Chapter 5 - Passivity Chapter 6 - Iron and Steel Aqueous Environments Metallurgical Factors Chapter 7 - Effect of Stress Cold Working Stress Corrosion Cracking Hydrogen Cracking Radiation Damage Corrosion Fatigue Fretting Corrosion Chapter 8 - Atmospheric Corrosion of Iron and Other Metals Chapter 9 - Corrosion of Iron and Other Metals In Soils Chapter 10 - Oxidation and Tarnish Chapter 11 - Stray-Current Corrosion Chapter 12 - Cathodic Protection Anodic Protection Chapter 13 - Metallic Coatings Chapter 14 - Inorganic Coatings Chapter 15 - Organic Coatings Chapter 16 - Inhibitors and Passivators Chapter 17 - Treatment of Water and Steam Systems Chapter 18 - Alloying for Corrosion Resistance; Stainless Steels Chapter 19 - Copper and Copper Alloys Chapter 20 - Aluminum and Magnesium Chapter 21 - Lead Chapter 22 - Nickel and Nickel Alloys Chapter 23 - Cobalt and Cobalt Alloys Chapter 24 - Titanium, Zirconium, and Tantalum Chapter 25 - Silicon—Iron and Silicon—Nickel Alloys Chapter 26 - Problems Appendix
64 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
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Sample Questions - Senior Corrosion Technologist Open-Book Examination Part I – excerpts from Corrosion Science/Materials Selection Design 1.
A corrosion inhibitor is a substance which, when added to an environment, decreases the rate of attack by the environment. a. True b. False
2.
Corrosion always results in the deposition of metal at the a. Cathode b. Anode c. Both a and b d. Neither a nor b
3.
Sea water is more corrosive than fresh water? a. True b. False
4.
A chemical substance which, when added to an environment, decreases the rate of attack by that environment. a. Galvanic cathode b. Galvanic anode c. Corrosion inhibitor d. Electrolyte
5.
An ion is a neutral atom. a. True b. False
6.
In seawater, which of the following metals is anodic with respect to steel? a. Copper b. Titanium c. Zinc d. Type 304 Stainless Steel
7.
Corrosion rates generally increase when temperature increases. a. True b. False
65 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
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8.
Electrode potentials are sensitive to a. Temperature b. Presence of depolarizers c. Both a and b d. Neither a nor b
9.
Nearly all metals exhibit crystalline structures. a. True b. False
10.
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
11.
Metals conduct electricity through the flow of ions. a. True b. False
12.
Which of the following is not an electrochemical cell? a. b. c. d.
A galvanic corrosion cell An active/passive cell A thermogalvanic cell None of the above
13.
Water used to make concrete should be free of chemical contaminants. a. True b. False
14.
Crevice corrosion a. 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
15.
Hydrogen induced cracking may occur at cathodes. a. True b. False
66 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
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16.
Sacrificial coatings a. 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
17.
Passivating inhibitors cause a shift in cathode potential, causing the cathode to become more positive. a. True b. False
18.
Corrosion detection is used for a. Safety b. Cost effectiveness c. Both a and b d. Neither a nor b
19.
Oxidizing anodic inhibitors require the presence of oxygen. a. True b. False
20.
Silicates and phosphates are common oxygen scavengers. a. True b. False
67 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
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Sample Questions - Senior Corrosion Technologist Open-book Examination Exercise II –excerpts from Corrosion Science/Cathodic Protection 1.
According to the classic definition of cathodic protection, the object is to polarize a. anodic areas b. cathodic areas c. both a and b d. neither a or b
2.
In a basic corrosion cell, the electrode having the greatest tendency to give up electrons is the cathode. a. True b. False
3.
Half cell potentials measured at the structure-to-electrolyte boundary are influenced by: a. Surface chemistry b. Concentration of metal ions c. Flow of electric current to or from the structure d. All of the above
4.
Polyphase powered cathodic protection rectifiers are more efficient than single phase units. a. True b. False
5.
Which material is not a common impressed current anode: a. graphite b. high silicon iron c. platinum clad titanium d. aluminum
6.
All cathodic protection systems require an external power source to drive the required current. a. True b. False
7.
Usually the best choice of cathodic protection design for an un-isolated, bare piping system is a. distributed galvanic anodes b. point-type impressed current c. point-type galvanic anodes d. distributed impressed current
68 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
Guide to Requirements for Certification as a Senior Corrosion Technologist
8.
Attenuation along the anode header cable may be a significant factor in the design of an impressed current distributed anode system. a. True b. False
9.
Calculate the service life of a galvanic anode system which is supplying 540 milliamperes of current and consists of six (6) 14.5 kg (32 lb.) anodes at 6 meter (20 feet) spacings. Assume an output capacity of 1100 ampere-hours/kg. a. 7.2 years b. Less than one year c. 20.2 years d. 23.5 years
10.
The first step in designing an impressed current cathodic protection system is to size the D.C. output of the rectifier to be used. a. True b. False
11.
The Wenner four pin method is the test method commonly used to calculate: a. b. c. d.
Cathodic polarization Soil resistivity Current attenuation None of the above
12.
An advantage of an impressed current cathodic protection system is the availability of larger driving voltages, thereby providing flexibility of current output. a. True b. False
13.
Estimate the resistance to earth of an anode bed 48.8 meters (160 feet) long in 6,000 ohmcm soil consisting of 9 prepackaged impressed current anodes installed vertically on 6 meter (20 feet) centers. Each anode is 0.203 m (8 inch) diameter by 2.13 meters (7 feet) long. The bottom of each anode will be installed to a depth of 4.6 meters (15 feet) below grade. a. 4.68 ohms b. 2.34 ohms c. 1.27 ohms d. 3.43 ohms
14.
If a piping system is not isolated from other underground metallic structures, the amount of current required to protect that piping will be less than if it were isolated. a. True b. False
69 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
Guide to Requirements for Certification as a Senior Corrosion Technologist
15.
Which of the following is true of a galvanic anode cathodic protection system? a. Structure is protected where current leaves the structure b. Relies upon the natural difference in potential between two dissimilar metals to cause protection current to flow c. Protective currents flow from the cathode through the soil to the pipe d. Are used on large bare structures because of the galvanic anode system high current output
16.
Cathodic protection system design life should be equal to structure design life. a. True b. False
17.
Calculate the total current needed to protect: 6,363.6 square meters (68,500 sq. ft.) of pipeline surface area Coating efficiency of 70% Soil resistivity of 10,000 ohm-cm Design current density of 21.5 mA/square meter a. 0.75 amps b. 41.0 amps c. 20.6 amps d. 68.5 amps
18.
Knowledge of the presence of high strength steels in the structure to be protected is of importance to the cathodic protection design engineer. a. True b. False
19.
The Wenner "four pin method" can be used to measure the resistivity of the environment for a deep well anode. a. True b. False
20.
An impressed current cathodic protection system is operating at 10 volts and 15 amperes. The total circuit resistance a. cannot be identified with the data available b. is 0.66 ohms c. is 0.06 ohms d. can be changed by turning the rectifier up
70 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
Guide to Requirements for Certification as a Senior Corrosion Technologist
Sample Questions - Senior Corrosion Technologist Open-book Examination Exercise III- excerpts from Corrosion Science/Coatings and Linings 1.
Coal tar enamel coatings are usually applied with film thickness of 10 mils (250 microns) or less. a. True b. False
2.
An epoxy emulsion coating uses water as a a. Diluent b. True solvent c. Pigment d. Catalyst
3.
Thermoplastic coating materials soften and become fluid each time they are heated. a. True b. False
4.
A pigment is a. A "discrete particulate solid" used to give specific decorative or protective properties to a coating b. The liquid base of a coating c. Used to make a solution of resin, which may dry to form a film d. One of a family of mono-ethyl-ethers
5.
Thermoset coating materials soften and become fluid each time they are heated. a. True b. False
6.
The main binder ingredient in coatings which cure by oxidation is a. MEK peroxide b. Vegetable or fish oils c. Cobalt, lead, and manganese compounds d. Silicone
7.
An asphalt or coal tar enamel is a liquid solution in volatile solvent. a. True b. False
71 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
Guide to Requirements for Certification as a Senior Corrosion Technologist
8.
Solvent-based inorganic zinc-rich coatings require a. A final bake at temperatures between 400° F (205° C) and 550° F (232° C) to cure b. Between 50%-90% relative humidity to cure c. Presence of organic solvent vapor to cure d. All of the above
9.
Furan coatings are highly elastic and resilient. a. True b. False
10.
The type of coating, which would probably be most adversely affected by being stored in freezing temperatures, would be a. Chlorinated rubber b. Epoxy emulsion c. Alkyd d. Two-component epoxy e. Most modern protective coatings are not affected by age and have almost unlimited shelf life. a. True b. False
11.
12.
Saponification is most likely to occur if environment. a. An alkyd b. A chlorinated rubber c. An epoxy (two-component) d. A baked phenolic
?
13.
Moisture-cured urethane coatings require the addition of water to the base coating before application to ensure complete curing. a. True b. False
14.
Zinc rich coatings generally contain a. 20%-30% b. 100% c. 75%-95% d. 50%-75%
15.
Chlorinated rubber coatings cure primarily by solvent evaporation. a. True b. False
?
coating is exposed to an alkaline
zinc dust by weight in the dry film.
72 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
Guide to Requirements for Certification as a Senior Corrosion Technologist
16.
The condensation curing mechanism occurs a. When the base resin is activated by heat, a catalyst, or some other means, to form long chain molecules b. As a function of oxidative cross-linking c. When two inorganic molecules combine with a molecule of water to form a stable cross-linked film d. When two molecules react, forming a new bond and giving off a molecule of water
17.
Coatings, which cure by oxidation, should be applied as thickly as possible so that a skin forms at the coating's surface. a. True b. False
18.
In some coating formulations, digestion, or "sweat in" time is necessary to ensure a. The combination of base and converter of a chemically cured coating have become compatible b. Removal of amine blush c. Complete cure of the coating prior to application d. Fisheyes
19.
An advantage of water-borne coatings such as acrylics and latex emulsion is that they may be applied in the rain. a. True b. False
20.
The three general types of coatings are: a. Organic zinc-rich, inorganic zinc-rich, zinc-rich epoxy b. Galvanic, inhibitive, barrier c. Oxidative, coalescent, polymerized d. None of the above
73 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
Guide to Requirements for Certification as a Senior Corrosion Technologist
Sample Questions - Senior Corrosion Technologist Open-book Examination Exercise IV-excerpts from Corrosion Science and Environmental Treatment. 1.
It is usually less expensive to control corrosion at the design stage. a. True b. False
2.
The service environment includes a. both atmospheric and immersion conditions. b. galvanic corrosion effects. c. oxygen content and pH d. all conditions which can affect the corrosion of the candidate materials. e. consideration of protective coating performance.
3.
The most efficient form of controlling corrosion is to include corrosion control in the design process. a. True b. False
4.
The dissolved gas which most commonly controls the rate of corrosion in solution is a. carbon dioxide. b. hydrogen. c. oxygen. d. hydrogen sulfide. e. nitrogen.
5.
Allowing for complete drainage is as important in structures as it is in fluid handling and storage systems. a. True b. False
6.
Welded joints are usually desirable from the standpoint of corrosion because a. welded joints are stronger than bolted or riveted joints. b. they offer the possibility of a joint free from crevices. c. the weld metal can be cathodic to the base material. d. welds can be easily stress relieved. e. there are fewer components to corrode.
7.
The galvanic series for any environment is the same as for seawater. a. True b. False
8.
Steels a. b. c. d. e.
contain more carbon than cast irons. cannot be cast. contain less than 5% of alloying elements. contain nickel and chromium for improved corrosion resistance. can be given a wide variety of properties through heat treatment.
74 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
Guide to Requirements for Certification as a Senior Corrosion Technologist
9.
The effects of localized corrosion are usually difficult to evaluate during design. a. True b. False
10.
The use of inhibitive additives a. is seldom used today due to environmental constraints. b. is dangerous as too much inhibitor will usually result in accelerated corrosion. c. requires periodic monitoring and control of the inhibitor addition. d. is ineffective in recirculating systems. e. can be effectively monitored only by periodic chemical analysis of the service environment.
11.
It is usually more common to eliminate galvanic corrosion through design than to determine and evaluate its impact. a. True b. False
12.
Stress corrosion cracking a. occurs more frequently due to residual stress than to applied loads. b. is almost always transgranular. c. occurs primarily in metals which are otherwise essentially immune to corrosion. d. are usually discovered during periodic system inspections. e. occur primarily from applied compressive stress.
13.
In low resistivity environments, the output from a sacrificial anode will be higher than in a high resistivity environment. a. True b. False
14.
External corrosion of ships is controlled a. through the use of cathodic protection. b. through the use of corrosion resistant materials. c. through the use of metallic cladding. d. through the combined use of coatings and cathodic protection. e. through the use of anodic protection.
15.
Tolerance of corrosion rather than elimination of corrosion is often the key to successful design. a. True b. False
16.
Operation and maintenance of impressed current cathodic protection systems is a. of little concern in impressed current cathodic protection systems as the anodes are not consumed in supplying current. b. an important factor in the success of their operation. c. required only if there has been construction in the vicinity. d. beyond the capability of most field personnel. e. required infrequently as continuous supply of current is not necessary for effective protection.
75 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
Guide to Requirements for Certification as a Senior Corrosion Technologist
17.
It is usually easy to change operating conditions after the design stage. a. True b. False
18.
When stiffeners are required in a tank or vessel a. they should be made of a material more cathodic than the tank or vessel material. b. they should be isolated for the tank or vessel wall to prevent galvanic attack. c. they should be vented to prevent overpressure. d. they should be located on the outside of the tank or vessel whenever possible. e. they should be made of a material more resistant to corrosion than the tank wall.
19.
Sensitization in austenitic stainless steels can be eliminated by a. reduction in the nickel and chromium content of the alloy. b. heating the alloy between 800 and 1500 degrees F. c. passivation. d. post-weld heat treatment (assuming that there is a weld). e. all of the above.
20.
The most important design features of corrosion-resistant structures are a. the absence of crevices and features which trap and hold water. b. the selection and use of highly corrosion resistant materials. c. the avoidance of horizontal and sloped surfaces. d. the avoidance of dissimilar metals and large anode/small cathode galvanic cells. e. the elimination of residual stress and heavy metal contamination.
76 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
Guide to Requirements for Certification as a Senior Corrosion Technologist
Answers to Sample Questions
Exercise I
Exercise II
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
a d a c b c a c a a b d a c a c b c b b
b b d a d b d a c b b a b b b b b a b b
Exercise III
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
b a a a b b b b b b b a b c a d b a b b
Exercise IV
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
a d a c a b b e a c a a a d a b b d d a
77 NACE International Certification Program © NACE International, 1999, 2001 January, 1999 November 2001
