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IS 6009 (1970): Method for evaluation of results ofaccelerated corrosion test [MTD 24: Corrosion Protection]

Cr 2

ISr6009-1970 ( RePLTMled 1992)

Indian Standard METHOD FOR EVALUATION OF RESULTS

OF ACCELERATED CORROSION TESTS

( Fourth Reprht JANUARY 1998 )

UDC 620.197.6:620.199

BUREAU OF INDIAN STANDARDS MANAK BHAVXN, 9 BAHADUR SHAH ZAFAR MARC

NEW DELHI 110002

June 1971

IS : 6009 - 1970 ( RealIiiwd 1992 )

Indian Standard METHOD FOR EVALUATION OF RESULTS

OF ACCELERATED CORROSION TESTS

Metallic Finishes Sectional Committee, SMDC 23

Chairman Repenting

DR S. KRI~HNAMURTHY Indian Telephone Industries Ltd, Bangalore

Members DR S. N. ANANT NARAYAN International Nickel ( India ) Pvt Ltd, Bombay SHRI A. K. BHIMAN~ S. Mitra and Company, Bombay

SHRI H. C. SAMPAT ( AIfernatc ) SHRI K. G. CHANDRASHEKARAPPA Indian Telephone Industries Ltd, Bangalore SHRI AHINDRA CHATTERJEE Canning Mitra Phoenix Ltd, Bombay

SHRI S. V. KULKARNI ( Alternate ) SHRI D. K. CHARERJEE Sen-Raleigh Ltd, Asansol CHEMIST AND METALLURGIST, ICF, Ministry of Railways

PERAMBUR CHEMIST AND METALLURGIST-II,

RDSO, LUCKNOW ( Alternate ) SHRI KANTILAL T. DALAL Kohinoor Electra-Gilders, Bombay

SHRI JAYENDRA K. DALAL ( Alternate ) SHRI DILIP PAUL Guest, Keen, Williams, Ltd, Calcutta SHRI P. N. GANDHI The Indian Tube Company ( 1953 ) Ltd, Jamshedpur

SHRI P. MITRA ( Alternate ) GENERAL MANAGER, POSTS AND Directorate General of Posts & Telegraphs, Calcutta

TELEGRAPHS WORKSHOPS, CALCWITA

DEPUTY GENERAL MANAGER ( Alternafe ) SHRI K. J. JACOB Trivandrum Rubber Works Ltd, Trivandrum

SHRI K. K. SAMUEL ( Alternate ) SHRI M. N. KE~ARI Bharat Electronics Ltd, Bangalore

SWRI K. GURURAJA ( Alternate ) SHRI U. G. K. MENON Ministry of Defence ( R & D )

SHRI S. L. N. ACWARYULU (~Altemate ) SHRI B. K. MURTHY Indian Aluminium Company Ltd, Calcutta

SHRI N. GOPALKRISHNAN ( Alternate ) SHRI J. C. NANCIA Arim Metals Industries Pvt Ltd, Calcutta

SHRI S. K. NANGIA ( Alternate ) SHRI S. PANCHPAKESAN DR K. S. RAJAGOPALAN

T. I. Cycles of India., Madras Central Electrochemtcal Research Institute ( CSIR ),

Karaikudi SHRI B. A. SHENOI ( Alternate )

SHRI N. M. RAJU Hindustan Motors Ltd, Calcutta

( Continued on page 2 )

BUREAU OF INDfAN STANDARDS MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG

NEW DELHI 110002

IS:6009-1970

( Continued from page 1 )

Members Rcprescnting

&-IRIV.k'.~SWA~ Ministry of Defence ( DGI ) SHRI M. Y. BORKER ( Alternate)

REPRESENTATIVE Grauer & Weil ( India ) Ltd, Bombay &RI R. K. ROKADE The Premier Automobiles Ltd, Bombay

SHRI P. K. DE~HPANDE ( Al&mute) SHRI N. c. ROY Geep Flashlight Industries Ltd, Allahabad SHRI R. A. SHAH Ronuk Industries Ltd, Bombay

KUMARI MRIDULA A. SHAH ( Alternate ) SHRI A. SOUNDRARAJ Directorate General Ordnance Factories ( Ministry

of Defence ), Calcutta SHRI Y. S. TRWEDI ( Alternate )

( Bombay ) SHRI V. KRISHNAN ( Alternate )

( Calcutta ) SHRI D. 5. TANDON National Metallurgical Laboratory ( CSIR ),

SHRI C. D. VARGH=% SHRI R. K. SRWASTAVA,

Jamshedpur Hindustan Aeronautics Ltd, Bangalore

SI ( Ex-&cio Member ) Deputy Director ( Strut & Met )

Director General, II _

Secretary

SHRI S. L. BALI

Deputy Director ( Met ), IS1

2

IS:6009-1970

Indian Standard METHOD FOR EVALUATION OF RESULTS

OF ACCELERATED CORROSION TESTS

0. FOREWORD

0.1 This Indian Standard was adopted by the Indian Standards Institution on 22 December 1970, after the draft finalized by the Metallic Finishes Sectional Committee had been approved by the Structural and Metals Division Council.

0.2 In Indian Standards related to metallic coatings, accelerated corrosion tests, such as CASS, Corrodkote and Acetic Acid Salt Spray Test have been included. It has, therefore, become necessary to define acceptable levels of performance of coatings, other than those anodic to the basis metal, that have been subjected to accelerated corrosion tests.

0.3 This method is employed only on articles which have not already been rejected on simple inspection on the ground of the size or grouping of individual corrosion defects as required by the relevant Indian Standard.

0.4 For the purpose of rounding off, rules as described in IS : 2-1960* shall be applicable.

1. SCOPE

1.1 This standard specifies a rating system that provides a means of defining levels of performance of coatings, other than those anodic to the basis metal, that have been subjected to accelerated corrosion tests. This method takes into account only corrosion of the basis metal.

2. DEFINITIONS

2.0 For the purpose of this standard, the following definitions shall apply.

2.1 Significant Surfacea - In general, significant surfaces are those surfaces that are visible and subjected to wear or corrosion or both, or surfaces on which the coating is otherwise functionally necessary. The designation of the significant surfaces shall be agreed upon by the manufacturer and the purchaser, and may be indicated

*Rules for rounding off numerical values ( rcviscd ).

3

IS : 6009 - 1970

on the drawings. The surfaces on which a controlled deposit ordinarily cannot be obtained, such as holes, recesses, angular bases, are normally exempt from the requirements for significant surfaces, unless they are specifically designated as such. When such areas are designated as significant surfaces and the thickness requirements are to be met, the manu- facturer and the purchaser shall recognize the necessity for either thicker deposits on the more accessible surfaces or special rackmg. Special racks may involve the use of conforming, auxiliary, interior, or bipolar electrodes.

NOTE-Significant surfaces generally may be defined as those parts of the visible surface that can be touched with a sphere of diameter either 20 mm or as agreed upon by the manufacturer and the purchaser.

2.2 Corrosion Spot - A surface corrosion defect at which the coating is penetrated as indicated by the appearance of basis metal, corrosion products or lifting of the coating. Discolouration or other surface defects, which do not penetrate the coating, do not count as corrosion spots. The size of a corrosion spot is the area of the penetration through the coating and no that of associated staining.

3. SAMPLING

3.1 The batch should be sampled in the manner required by the relevant specification. The total significant surface area of the sample should be in excess of 5 000 mm2.

3.2 If the individual articles forming the sample have a signilicant surface area smaller than 5 000 mm2, the sample for assessment should comprise a sufficient number of individual articles to obtain a total significant surface area equal to or greater than this area.

3.3 If the rating number required by the relevant specification is > 8, the total signiscant surface area of the sample should exceed 10 000 mm*.

4. EXAMINATION OF SAMPLE AFTER TEST

4.1 The sampIe should be examined in its condition at the end of the test or after rinsing in running water, if i, is necessary to remove the residue of the test medium. Corrosion products may be removed subsequently, to enable the size of individual corrosion spots to be assessed.

4.2 For the purpose of evaluation, divide the area of the significant surface of the sample hypothetically into squares of 5 mm size. This is easily done by placing a graticule, made of fully flexible transparent pIastics material, on the sample so as to give the most favourable result, that is, the highest rating.

4.3 Count the number ( N) of 5 mm squares in the significant area of the sample and the number ( n ) of such squares containing one or more

4

IS : 6009 - 1970

corrosion spots. When evaluating the total area of sample, squares more than half occupied should be counted as full squares and those less than half occupied should be ignored. 4.4 If a spot appears to lie in more than one square, it should be counted only once in the evaluation, but cracks traversing more than one square should be counted for each square entered.

5. SUITABILITY OF.SAMPLES FOR EVALUATION

5.1 If ten or more corrosion spots can be included in any two adjacent 5 mm squares, or any spots are present of area greater than 2.5 mmz, the sample shall be considered unsuitable for assessment. traversing more than one 5 mm square,

For long cracks the sample shall be considered

unsuitable for assessment if the area of the crack in any one square exceeds 2.5 mms. 5.2 If the sample consists of more than one individual article, and gross differences in the degree of corrosion are evident between these- individual articles, the sample shall be considered unsuitable for assessment.

6. INITIAL RATING NUMBER

6.1 Determine the frequency of the spots as a percentage from the expression:

Frequency = 100 x + ( see 4.3 )

table: Allocate a rating number to the sample according to the following

Frequency, Percent Rating .Number

10*

9* 8* 7 6 5 4 3

2 1 0

0 (no corrosion spots)

Over 0 up to 0.25

Over O-25 ,, ,, 05 Over @5 up to 1

Over 1 ,, ,, 2

Over 2 ,, ., 4 Over 4 ,, ,, 8 Over 8 ,, ,, 16 Over 16 ,, ,, 32

Over 32 ,, ,, 64 Over 64

+&3 33.

IS:690991970

7. REDUCTION CONCEWATIO? OF?%&O&T%OTSF% Lkii%i ARTICLES

7.1 Samples Comprising Individual Articles with Areas for Assess- ment Greater than 2 509 mm - Find the 50 x 50 mm area showing the greatest number of corrosion spots. Count the number of 5 mm squares in this area which are occupied by corrosion spots. Reduce the.initial rating obtained by the method ,given in 6 by one unit for each ten squares thus obtained.

8. EXAMPLES FOR THE RATING SYSTEM

Total number of 5 mm squares in sample area Number of squares containing corrosion spots Percentage of squares containing corrosion spots Rating number from table ( $88 6 )

= 400 -_ 48 = 12 = 3

Greatest number of squares with corrosion spots in any area of 50 x 50 mm (see 7 ) = 17

Final rating number = 3 - g

=3--(roundedoff) -_ 1

Exam@ 2

Total number of 5 mm squares in sample area = 400 Number of squares containing corrosion spots = 1 Percentage of squares containing corrosion spots c 025

Rating number from table ( se8 6 ) e3 9 Greatest number of squares with corrosion spots

in any area of 50 X 50 mm ( $68 7 ) -_ 1

Final rating number =9-o= g

6

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