NOTICE: This standard has either been superseded and replaced by a new version or discontinued.

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Designation: G 4 – 95

Standard Guide for

Conducting Corrosion Coupon Tests in Field Applications1
This standard is issued under the fixed designation G 4; the number immediately following the designation indicates the year of original
adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A superscript
epsilon (e) indicates an editorial change since the last revision or reapproval.

1. Scope G 41 Practice for Determining Cracking Susceptibility of

1.1 This guide covers procedures for conducting corrosion Metals Exposed Under Stress to a Hot Salt Environment4
coupon tests in plant equipment under operating conditions to G 44 Practice for Evaluating Stress Corrosion Cracking
evaluate the corrosive attack upon engineering materials. It Resistance of Metals and Alloys by Alternate Immersion in
does not cover electrochemical methods for determining cor- 3.5 % Sodium Chloride Solution4
rosion rates. G 46 Practice for Examination and Evaluation of Pitting
1.1.1 While intended primarily for immersion tests, general Corrosion4
guidelines provided can be applicable for exposure of test G 47 Test Method for Determining Susceptibility to Stress-
coupons in plant atmospheres, provided that placement and Corrosion Cracking of High Strength Aluminum Alloy
orientation of the coupons is non-restrictive to air circulation. Products4
1.2 The values stated in SI units are to be regarded as the G 58 Practice for Preparation of Stress-Corrosion Test
standard. The values given in parentheses are for information Specimens for Weldments4
only. G 78 Guide for Crevice Corrosion Testing of Iron-Base and
1.3 This standard does not purport to address all of the Nickel-Base Stainless Alloys in Seawater and Other
safety concerns, if any, associated with its use. It is the Chloride-Containing Aqueous Environments4
responsibility of the user of this standard to establish appro- 3. Significance and Use
priate safety and health practices and determine the applica-
bility of regulatory limitations prior to use. See also 10.4.2. 3.1 Observations and data derived from coupon testing are
used to determine the average rate of corrosion and the type of
2. Referenced Documents attack (see Terminology G 15) that occur during the exposure
2.1 ASTM Standards: interval. The data may be used as part of an evaluation of
A 262 Practices for Detecting Susceptibility to Intergranu- potential materials of construction for use in similar service or
lar Attack in Austenitic Stainless Steels2 for replacement materials in existing facilities.
E 3 Practice for Preparation of Metallographic Specimens3 3.2 The data developed from this guide may also be used as
G 1 Practice for Preparing, Cleaning, and Evaluating Cor- guide lines to the behavior of existing plant materials for the
rosion Test Specimens4 purpose of scheduling maintenance and repairs.
G 15 Terminology Relating to Corrosion and Corrosion 3.3 Corrosion rate data derived from a single exposure
Testing4 generally do not provide information on corrosion rate change
G 16 Guide for Applying Statistics to Analysis of Corrosion versus time. Corrosion rates may increase, decrease, or remain
Data4 constant, depending on the nature of the corrosion products and
G 30 Practice for Making and Using U-Bend Stress Corro- the effects of incubation time required at the onset of pitting or
sion Test Specimens4 crevice corrosion.
G 36 Practice for Performing Stress-Corrosion Cracking
4. Limitations
Tests in a Boiling Magnesium Chloride Solution4
G 37 Practice for Use of Mattsson’s Solution of pH 7.2 to 4.1 Metal specimens immersed in a specific liquid may not
Evaluate the Stress Corrosion Cracking Susceptibility of corrode at the same rate or in the same manner as in equipment
Copper-Zinc Alloys4 in which the metal acts as a heat transfer medium in heating or
cooling the liquid. In certain services, the corrosion of heat-
1
exchanger tubes may be quite different from that of the shell or
This guide is under the jurisdiction of ASTM Committee G-1 on Corrosion of
Metals and is the direct responsibility of Subcommittee G01.12on In-Plant Corro- heads. This phenomenon also occurs on specimens exposed in
sion Tests. gas streams from which water or other corrodents condense on
Current edition approved Jan. 15, 1995. Published March 1995. Originally issued cool surfaces. Such factors must be considered in both design
as A224-39. Last previous edition G4-84.
2
Annual Book of ASTM Standards, Vol 01.03.
and interpretation of plant tests.
3
Annual Book of ASTM Standards, Vol 03.01. 4.2 Effects caused by high velocity, abrasive ingredients,
4
Annual Book of ASTM Standards, Vol 03.02.

Copyright © ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959, United States.

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etc. (which may be emphasized in pipe elbows, pumps, etc.) films in corrosive environments. In many cases, there is no
may not be easily reproduced in coupon tests. acceptable method to remove the film without removing
4.3 The behavior of certain metals and alloys may be significant uncorroded metal. In these cases, the extent of
profoundly influenced by the presence of dissolved oxygen. It corrosion can best be measured as a mass gain rather than mass
is essential that the test coupons be placed in locations loss.
representative of the degree of aeration normally encountered
in the process. 5. Test Coupon Design
4.4 Corrosion products from the test specimens may have 5.1 Before the size, shape, and finish of test coupons are
undesirable effects on the process stream and should be specified, the objectives of the test program should be deter-
evaluated before the test. mined, taking into consideration any restrictions that might
4.5 Corrosion products from the plant equipment may dictate fabrication requirements. The duration, cost, confidence
influence the corrosion of one or more of the test metals. For level, and expected results affect the choice of the shape, finish,
example, when aluminum specimens are exposed in copper- and cost of the coupons.
containing systems, corroding copper will exert an adverse 5.1.1 Test coupons are generally fabricated into disks or
effect on the corrosion of the aluminum. On the contrary, rectangular shapes. Other shapes such as balls, cylinders, and
stainless steel specimens may have their corrosion resistance tubes are used, but to a much lesser extent.
enhanced by the presence of the oxidizing cupric ions. 5.1.2 Disks are normally made by one of three methods: (1)
4.6 The accumulation of corrosion products can sometimes by punching from sheet material, (2) by slicing from a bar, or
have harmful effects. For example, copper corroding in inter- (3) by trepanning by a lathe or mill. Punched disks are by far
mediate strengths of sulfuric acid will have its corrosion rate the least expensive and should be considered if material
increased as the cupric ion concentration in the acid increases. thickness is not a limitation. Some of the positive characteris-
4.7 Coupon corrosion testing is predominantly designed to tics of disks are: (1) the surface area can be minimized where
investigate general corrosion; however, other forms of corro- there is restricted space, such as in pipeline applications, (2)
sion may be evaluated with coupons. disks can be made inexpensively if a polished or machined
surface finish is not required, and (3) edge effects are mini-
4.7.1 Galvanic corrosion may be investigated by special
mized for a given total surface area. Some negative character-
devices that couple one coupon to another in electrical contact.
istics are: (1) disks are very costly to fabricate if a ground finish
It should be observed, however, that galvanic corrosion can be
and machined edges are required, (2) disks fabricated from
greatly affected by the area ratios of the respective metals.
sheet material result in a considerable amount of scrap mate-
4.7.2 Crevice or concentration cell corrosion may occur
rial, and (3) disks sliced from a bar present a surface orienta-
when the metal surface is partially blocked from the bulk
tion that can result in extensive end-grain attack. Using a bar is
liquid, as under a spacer. An accumulation of bulky corrosion
undesirable unless end-grain effects are to be evaluated.
products between coupons can promote localized corrosion of
5.2 Rectangular coupons are fabricated by either punching,
some alloys or affect the general corrosion rates of others. Such
shearing, or saw cutting. Punched coupons are the most
accumulation should be reported.
economical if the quantity is sufficiently high to justify the
4.7.3 Selective corrosion at the grain boundaries (for ex- initial die cost. Fabrication is more cost-effective for rectangu-
ample, intergranular corrosion of sensitized austenitic stainless lar coupons than for disks when ground finished and machined
steels) will not be readily observable in mass loss measure- sides are required, and they can be made using very few shop
ments and often requires microscopic examination of the tools. In some cases, rectangular coupons are more awkward to
coupons after exposure. mount.
4.7.4 Parting or dealloying is a condition in which one 5.3 Material availability and machinability also affect the
constituent is selectively removed from an alloy, as in the cost of producing all types of coupons. Before the shape and
dezincification of brass or the graphitic corrosion of cast iron. size are specified, the corrosion engineer should determine the
Close attention and a more sophisticated evaluation than a characteristics of the proposed materials.
simple mass loss measurement are required to detect this
phenomenon. 6. Test Specimens
4.7.5 Pitting corrosion cannot be evaluated by mass loss. It 6.1 The size and shape of test specimens are influenced by
is possible to miss the phenomenon altogether when using several factors and cannot be rigidly defined. Sufficient thick-
small test specimens since the occurrence of pitting is often a ness should be employed to minimize the possibility of
statistical phenomenon and its incidence can be directly related perforation of the specimen during the test exposure. The size
to the area of metal exposed. of the specimen should be as large as can be conveniently
4.7.6 Stress-corrosion cracking (SCC) may occur under handled, the limitation being imposed by the capacity of the
conditions of tensile stress and it may or may not be visible to available analytical balance and by the problem of effecting
the naked eye or on casual inspection. A metallographic entry into operating equipment.
examination (Practice E 3) will confirm this mechanism of 6.2 A convenient size for a standard corrosion coupon is 38
attack. SCC usually occurs with no significant loss in mass of mm (1.5 in.) in diameter and 3 mm (0.125 in.) in thickness with
the test coupon, except in some refractory metals. an 11 mm (0.438 in.) hole in the center of the round coupon.
4.7.7 A number of reactive metals, most notably titanium This size was arrived at as being the maximum size that could
and zirconium, develop strongly adherent corrosion product easily effect entry through a normal 38 mm nozzle. However,

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it is also convenient for larger size nozzle entries as well as for amount of oxides on the surface can vary as well. Also, surface
laboratory corrosion testing. A convenient standard coupon for finishes are difficult to apply to edges that have been distorted
spool-type racks measures 25 by 50 by 3 mm (1 by 2 by 0.125 by punching or shearing. Since the primary requirement is
in.) or 50 by 50 by 3 mm (2 by 2 by 0.125 in.). A round coupon usually to determine the corrosion resistance of the material
of 53 by 3 mm (2 by 0.125 in.) or 55 by 1.5 mm (2 by 0.062 itself, a clean metal surface is most often used. The purpose of
in.) is sometimes employed. These last three measure about the test dictates the required finish of the coupon. For instance,
0.005 dm2 in surface area. for water treating applications, relative changes of weights of
6.3 Other sizes, shapes, and thicknesses of specimens can be coupons are usually compared to optimize inhibitor additions.
used for special purposes or to comply with the design of a The coupon are generally punched or sheared and finished by
special type of corrosion rack. Special coupons should be blasts with glass beads. This is one of the most economical
reduced to a few in number in preliminary tests; special ways of preparing coupons. Manufacturing variables in coupon
coupons should be employed to consider the effect of such preparation that can be removed reasonably should be elimi-
factors of equipment construction and assembly as heat treat- nated. A standard surface finish facilitates the comparison of
ment, welding, soldering, and cold-working or other mechani- results among test samples.
cal stressing. 7.2 Some of the available finishes are:
6.4 Since welding is a principal method of fabricating 7.2.1 Mill finish (pickled, bright annealed, or shot blasted),
equipment, welded coupons should be included as much as 7.2.2 Electrolytic polished, (Note that electrolytic polishing
possible in the test programs. can produce a surface layer enriched in some alloying elements
6.4.1 Aside from the effects of residual stresses, the main while depleted in others. For example, chromium is enriched
items of interest in a welded coupon are the corrosion on stainless surfaces and sulfur is depleted.)
resistance of the weld bead and the heat affected zone. 7.2.3 Blasted with sand or steel shot, (Note that blasting
Galvanic effects between weld metal and base metal can also many metals with sand can cause embedded sand particles and
be evaluated. The weld and heat affected zone regions are steel shot can cause surface contamination with iron or iron
relatively small; therefore, welded coupons should be made oxide. Glass beads are better, but not if broken pieces are
slightly larger than the normal size coupon when possible, for allowed to be used in the blasting.)
example, 50 mm by 75 mm (2 in. by 3 in.). The optimum 7.2.4 Sanded with abrasive cloth or paper,
method of welding coupons is to join the two halves using a 7.2.5 Machine finished, and
single vee or double vee groove with full penetration and 7.2.6 Passivation with nitric acid to remove surface iron
multiple passes. Double vee joint preparation is used for very contamination and other chemical cleaning methods used, for
thick samples. Machining the weld flush is optional, depending example, after welding.
on how closely the sample will be examined afterward (see 7.3 The surface finish most widely used is produced by
practice G58). sanding with an abrasive cloth or paper. Sanding removes the
6.4.2 The welding process and number of passes influence mill scale and oxides as well as other defects in the material
the heat input and, consequently, the width and location of the such as scratches, pits, etc., that can produce misleading results
heat affected zone. For example, gas tungsten arc welding has when the data are being analyzed.
lower heat input than oxygen fuel welding and causes a 7.3.1 A 120 grit finish is generally acceptable and is readily
narrower heat affected zone, which is also closer to the weld produced without the need for specialized equipment. Other
bead. surface finishes may be obtained through the appropriate use of
abrasive papers and cloth. In order to prevent metallurgical
7. Preparation of Test Specimens changes that could affect the corrosion resistance, the test
7.1 Controversy exists as to whether the test coupon edges sample should be cooled during fabrication. Wet sanding is one
should be machined. The cold-worked area caused by shearing method of preventing specimens from heating up. In many
or punching coupons can provide valuable information on alloy cases, it is necessary to begin sanding with coarse abrasives
susceptibility to stress corrosion cracking. Also, the ability to and progressively move to finer abrasives.
compare information among coupons of different materials can 7.3.2 Clean polishing belts should be used to avoid contami-
be affected by the amount of cold work performed on the nation of the metal surface, particularly when widely dissimilar
material. Therefore, the decision to machine test coupons and metals are being finished. For example, a belt used to sand
to test coupons with/without the residual stresses associated brass should not be used to sand aluminum. Particles of one
with cold work should be made on a case-to-case basis. metal could become imbedded in the other, resulting in
7.1.1 The depth of cold work associated with punching and erroneous data.
shearing operations typically extends back from the cut edge to 7.4 Test specimens should be cleaned and the initial mass
a distance equal to the coupon thickness. Removal of the cold determined (see Practice G 1).
worked areas can be performed by grinding or careful machin- 7.5 A pre-exposure inspection of test specimens should be
ing the coupon edges. conducted in order to identify any pits, mechanical scratches,
7.1.2 Ideally, the surface finish of the test coupon should be or residual surface treatment artifacts that could influence the
identical with the surface finish of the material to be used for corrosion behavior of the specimen.
equipment fabrication. However, this is often difficult because
the finish on materials varies between mills, between sheet and 8. Number of Test Specimens
plate and even between heat treatments. The mill scale and the 8.1 In general, at least duplicate specimens should be tested.

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If possible, in cases in which confidence limits are required for 10.2.1 A flat bar rack is usually made of rigid material, such
corrosion rate measurement, then somewhere between 5 and 10 as 6 mm (.0250 in.) thick plate, and is approximately 25 mm (1
replicates should be run, depending on the scope of the in.) wide by 305 mm (12 in.) long. With a few mounting holes
program. The confidence level can be established by the at one end, a flat bar rack is capable of supporting several
procedures shown in Guide G 16. The duplicate samples specimens. The other end is attached in the process location
should be widely separated on the test rack rather than adjacent either by welding, bolting, or clamping. See Fig. 1.
to one another. The results for the samples should also be 10.2.2 A spool rack, with adjustable end plates, can be used
reported separately. to mount up to 36 coupons. Typical racks are approximately
305 mm (12 in.) long with 15 mm (0.625 in.) spacing between
9. Identification of Test Specimens
coupons. With the support bars on the sides, the rack can be
9.1 Although it may be necessary in special instances to handled without touching the coupons. The rack can be easily
notch the edge of the specimens for identification, it is mounted by strips that are attached to the top and bottom.
preferable that they be stamped with a code number. The These strips can be welded, bolted, or clamped in place. See
stamped number has an additional advantage in that, should a Fig. 2.
specimen show a preferential attack at the stamped area, a
10.2.3 A pipeline rack is designed to fit between the flanges
warning is given that the material is susceptible to corrosion
in a pipeline. It can also be used at a nozzle. Because of the
when cold worked. It is also possible in some instances to
cantilever support and pipe diameter, the number of coupons
detect stress-corrosion cracking emanating from the stamped
that can be mounted on this system is restricted. Design
areas. Note, however, that although the presence of such
modification can be made in order to increase the number of
localized attacks is a positive indication, absence of attack is
coupons. A potential problem with the pipeline rack is the flow
not a guarantee of immunity from attack in operating equip-
restriction in the pipeline. See Fig. 3.
ment.
10.3 One of the most common reasons for the failure of test
10. Test Rack Design and Test Location racks is selecting fasteners that do not resist the environment.
10.1 The purpose of the rack is to support test coupons in Since the bolting hardware is usually highly stressed and
the process environment at the proper location and orientation. contains crevices, corrosive attack on fasteners can occur
To accomplish this, the corrosion engineer should first deter- rapidly. Another common reason for failure is defective weld-
mine the number, size, and spacing of the coupons to be tested ing of the test rack components or of the test rack to the vessel.
and then establish the proper location and orientation of the Full-penetration welds should be used, and the area to be
rack. With this accomplished, the type of rack can be selected. welded should be thoroughly cleaned. Fatigue failures caused
10.1.1 Coupons are usually electrically isolated from one by equipment vibration or high flow rates is another leading
another and the rack unless special effects, such as galvanic cause of rack failures. With proper design, a rack can be built
corrosion, are under study. Insulation is achieved by sleeving that will eliminate these failures.
all metal parts in contact with the coupons and separating the 10.3.1 Problems caused by failure of a mounting system
coupons with washers. The sleeves and washers should be also should be considered in designing the test rack. In many
made from a nonconductive material such as polytetrafluoro- cases, such as with agitated vessels, pumps, etc., a loose test
ethylene (PTFE) fluorocarbon or ceramic material. rack could do extensive damage. (Test racks should be inserted
10.2 The rack should be as simple as possible, but it also after the pumps to prevent damage to the impeller in case of
should be sturdy and constructed of materials resistant to the rack failure.)
test environment. Bolts should be spot welded or double nuts 10.4 Retractable coupon holders overcome the greatest
used to prevent loosening during exposure. Occasionally an limitation of most forms of coupon testing, which is the need
insulated bolt is all that is necessary to suspend the test to shut down in order to remove the test rack from the process.
specimens. Handling this assembly requires a few more pre- The arrangement consists of a 50 mm (2 in.) or larger nozzle
cautions than some other mounting systems but is cost effective that is fitted with a fully opening gate or plug valve. The
in many instances. Another method is to suspend the test rod-shaped coupon holder is contained in a retraction chamber,
coupons by an insulated wire. This system can be used in a which is flanged to the valve, and is fitted additionally with a
storage tank or other nonagitated vessels; for example, as used drain valve (see Fig. 3). The other end of the retraction
in chemical cleaning operations. chamber contains a packing gland through which the coupon

FIG. 1 Flat Bar Rack

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FIG. 2 Typical Spool Rack

holder passes. The test coupons are mounted on the rod in the 10.5 Selection of the process location is critical to obtaining
extended position and are then drawn into the retraction meaningful data. The three basic process locations are (see Fig.
chamber. The chamber is bolted to the gate or plug valve, 4): (1) immersed stagnant, for example, the boot of the filter
which is then opened up to allow the coupons to be moved into where deaerated conditions, solid settlements prevail, (2)
the operating environment. The sequence is reversed to remove immersed flowing, for example, in piping where aeration, gas
the coupons and the process is cleared from the retraction and solids entrainment, and turbulence or velocity exert effects,
chamber before disconnecting it to access the coupons. See (3) splash, waterline, or liquid level where the conditions
Fig. 4. simulate partial immersion or spray. When calculating corro-
10.4.1 All components of retractable coupon holders must sion rates, the test time is not reduced to compensate for partial
be suitably corrosion resistant and fabricated to standards that immersion conditions.
comply with the equipment design code. The consequences of 10.6 In certain situations, process conditions (in addition to
a process leak must be carefully considered. Retractable the three basic locations) must be considered. For example:
coupon holders are best considered in low pressure systems,
10.6.1 Velocity effects should be considered if the coupons
that is, 1 MPa (about 150 psi) or less. However, commercially
are laid out flat and parallel to the flow. If the coupons are
available probes and retrieval tools are available for service in
arranged any other way, they tend to shield one another from
systems up to 20 MPa (3000 psi).
the turbulence. The location of the coupons is critical in
NOTE 1—Caution: In using retractable coupon holders on-line with simulating the turbulence experienced, for example, at a pipe
either hot, pressurized fluids or hazardous fluids, or both, the possibility of wall.
a serious leak (or blowout) at the packing gland must be considered and
appropriate precautions taken. Provisions should be made to purge and
10.6.2 Condensation (dew point or cold finger) effects
dispose of the process fluid from the cavity where the specimens are held should be considered. The coupons represent a different mass
before they are removed from the system. Restraining devices must be effect from a pipe, vessel wall, tube sheet, tube, etc. It may be
used when removing specimens while the internal system is pressurized. necessary to expose several sets of coupons in a line to

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FIG. 3 Pipe Insertion Rack

determine the optimum condition that duplicates condensation 12. Initial Coupon Measurements
in the equipment.
12.1 After the coupon has been cut to size and the final
10.6.3 The effects of heat transfer (for example, when the
surface finish applied (if other than mill finish), it should be
tube wall is heated) are impossible to duplicate with conven-
cleaned in an organic solvent and the mass determined to the
tional coupons.
nearest 0.1 mg on an analytical balance. The total surface area
11. Selection of Materials for Evaluation is also determined to an accuracy of 6 1 %. These measure-
ments are filed for later use in the corrosion rate calculations.
11.1 The following materials, at least, should be considered
for inclusion as controls: 12.2 During fabrication, each coupon should be stamped
11.1.1 The material currently used in the process equipment with a code number for identification. The record of the details
in which the test is being run or in the equipment of interest. of the test exposure (dimensions, weight, location, method of
11.1.2 A material that would be expected to incur the type of mounting, location on rack, etc.) should be kept in a perma-
corrosion of immediate concern, for example, stress corrosion, nent, bound log book. Responsibility for properly maintaining
cracking, pitting, crevice corrosion, and the records in this log book throughout the test should be
11.1.3 One or more materials likely to be resistant to the specifically assigned to one individual.
environment. 12.3 For coupons of materials that cannot be stamped (for

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FIG. 4 Retractable “Slip-In” Coupon Holder

example, too hard or brittle), a system of notches can be used 15. Removal of Specimens from Test
to identify individual coupons. Notches may be formed by 15.1 The condition and appearance of the holder and speci-
filing or grinding. mens after removal from equipment should be noted and
13. Installation of Specimen Holder recorded. In removing the specimens from the holder, exercise
care to keep them in proper sequence relative to each other so
13.1 The location of the test specimens in the operating that any specimen may be identified from the original record of
equipment will be governed by the information that is desired. its position on the holder. That is important if corrosion has
This may require tests at more than one location in the same been so severe that identification marks have been removed.
piece of equipment, such as below the level of the test liquid, 15.2 A record should be made of the appearance and
at the level of the liquid, or in the vapor phase. adhesion of any coatings or films on the surface of the
13.2 It is desirable to have the specimen holder securely specimens after washing. It may be desirable to photograph the
fixed in place. The preferred position of the holder is with the specimens. Color photographs may be of value. Samples of any
long axis horizontal so as to prevent drippage of corrosion products or films resulting from corrosion may be preserved for
products from one specimen to the other. Preferably, the future study.
specimen should be so placed that any flow of liquid will be
against the edges of the specimens. The same condition of 16. Cleaning and Weighing of Test Specimens
agitation of the liquid should then be encountered by all
specimens. 16.1 Specimens should be cleaned as soon as possible after
removal from test.
14. Duration of Exposure 16.2 The procedures for cleaning and weighing specimens
14.1 The duration of exposure may be based on known rates are described in Practice G 1.
of deterioration of the materials in use. More often, it is
governed by the convenience with which plant operations may 17. Examination of Specimen Surface
be interrupted to introduce and remove test specimens. In many 17.1 The specimen should be carefully examined using
tests, some materials may show little or no attack while other low-power magnification as needed for type and uniformity of
materials may be completely destroyed. In general, the dura- surface attack such as etching, pitting, dealloying or parting,
tion of the test should be as long as possible, commensurate tarnishing, filming, scaling, etc. If pitting is observed, the
with the resistance of the materials under test. In special cases, number, size and distribution, and the general shape and
the duration may be established in regard to some specific uniformity of the pits should be noted (see Practice G 46). The
phase of the operation, for example, to study corrosion in one maximum and minimum depth of the pits can be measured
step of a batch process. Possible changes in the rate of with a calibrated microscope or by the use of the depth gage.
corrosion may be studied either by successive exposures or by Photographs of the cleaned specimens will serve as an excel-
the installation of several sets of specimens at the same time, lent record of the surface appearance.
which can be removed one set at a time at different intervals. 17.2 Detection of certain effects, such as stress corrosion
The minimum duration of the test in hours is approximately 50, cracking, dealloying, or intergranular attack, will require low-
divided by the expected corrosion rate expressed in millimetres power microscopic examination. However, in some cases,
per year (or 2000 divided by the corrosion rate in mils per higher resolution and magnification examinations may be
year). It is desirable to run the test with various time intervals necessary. This could include, but is not limited to, scanning
so that the changes in corrosion rate with exposure time can be electron microscopy or high-power optical microscopy, or
evaluated. both, of metallographically prepared specimens. Mass loss is

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often used to evaluate intergranular corrosion (see Practices does not guarantee the immunity of equipment to failure.
A 262). 18.3 Pitting can occur on an unshielded metal surface and
17.3 A distinction should be made between localized corro- can lead to failure of equipment displaying a low general
sion occurring under the insulating spacers and occurring on corrosion rate. Pitting can occur in passive type materials such
the boldly exposed surface. As previously noted, corrosion at as some grades of aluminum and stainless steel; it may also
or under the insulating spacers is an indication of susceptibility affect some copper base and nickel base alloys. The environ-
of the material to crevice corrosion (see Guide G 78) in the ment usually contains an aggressive ion, such as chloride,
specific environment. Pitting on the surface is indicative of the which is made more aggressive if the conditions are oxidizing.
pitting tendency of the environment on the boldly exposed Pitting can occur on usually nonpassive metals, such as steel,
surfaces of the specific alloy and specimens to be evaluated. if, for example, a filming inhibitor breaks down locally.
17.4 In the case of pitting of the specimen, the mass loss is 18.3.1 Pitting test data should include a measurement of the
of little value and the study of the number, size, and distribu- maximum pit depth during the test period and it should
tion of the pits will be of much more importance. Sometimes encompass a description of the following characteristics of the
pitting is initiated but is self-healing and stops. (Additional pit: (1) shape—jagged, circular, elongated, (2) section—
information is provided in Practice G 46.) shallow, deep, rounded, conical, undercut, and (3) amount—
17.5 If an alloy is known to be susceptible to localized superficial, scattered, profuse, isolated.
corrosion on a microscale, such as the phenomenon of inter- 18.4 Guidelines for evaluating pitting are contained in
granular corrosion in stainless steel, dezincification in brass, or Practice G 46. The statistical nature of pitting indicates that it
stress-corrosion cracking of any kind, the specimen should be is more likely to occur within large coupons and on the surface
bent after the previously outlined examination is completed, finish of the test coupon. Therefore, evaluation of pitting must
and any cracks that develop on the surface noted. Use caution use the largest practical size coupon and a standardized surface
when bending materials susceptible to hydrogen embrittle- finish and preparation technique.
ment. The results should be compared with those obtained on 18.5 Properly conceived laboratory tests (see, for example,
similar bend tests on unexposed specimens from the same lot Practices G 30, G 36, G 37, G 41, G 44, and Test Method G 47,
of material. Metallographic examination (Practice E 3) is also etc.) are valuable tools for investigating factors affecting stress
a useful means of characterizing these phenomena. corrosion cracking of engineering alloys. However, in-plant
17.6 The behavior of the coupons in galvanic couples can be corrosion tests for stress corrosion cracking susceptibility come
compared with that of corresponding insulated specimens closer to representing the environmental variables that could
exposed at the same time, and any galvanic effects can be affect alloy behavior in service. The limitations of both
observed. In a galvanic couple, the corrosion on one coupon laboratory tests and in-plant corrosion should be recognized.
will be accelerated while the other will be decelerated. As For example, simple exposure of stressed specimens in an
mentioned earlier, such tests are only qualitative, as the extent operating flow stream may not take heat transfer, if present in
of the galvanic corrosion is influenced by the area ratio service, into account.
between the anodic and cathodic members of the galvanic
couple, the relative potential difference between the dissimilar 19. Report
metals, and the solution conductivity. The results will apply 19.1 In reporting results of corrosion tests, the conditions of
directly only to assemblies in which the ratio of areas used in the test should be described in complete detail with special
making the tests is similar to the ratio of areas anticipated in the attention being given to the following:
fabricated assembly. 19.1.1 Corrosive medium and concentration,
19.1.2 Type of equipment in which test was made,
18. Localized Corrosion 19.1.3 Process carried out in the operating equipment,
18.1 Metals often perform differently in aerated versus 19.1.4 Location and configuration of specimens in the
nonaerated environments, depending on how strongly oxygen operating equipment,
reduction (cathodic depolarization) controls the cathodic reac- 19.1.5 Temperature of corrosive media (maximum, mini-
tion. The presence of other oxidizers, such as ferric or cupric mum, or average),
ions, also can have an effect. Other factors that can affect 19.1.6 Oxidizing or reducing nature of corrosive media,
crevice corrosion behavior include, for example, crevice 19.1.7 Amount and nature of aeration and agitation of
former material and size, the resulting gap produced by corrosive media,
tightening, and the area ratio of the shield to exposed surfaces. 19.1.8 Duration and type of test (if equipment was operated
Some variables influence the initiation of attack while others intermittently during the tests, the actual hours of operation
may impact both initiation and propagation. In process equip- should be stated as well as the total time of the test),
ment containing crevices, such as under gaskets or scale 19.1.9 Surface condition of specimen (mill finished, pol-
deposits, variable corrosion behavior may occur. ished, machined, pickled, 120 grit, etc.)
18.2 Several types of crevice corrosion spacers can be 19.2 The form of corrosion that is documented should be
substituted for the normal flat washer to study crevice corro- reported, together with any observations on corrosion products
sion in more detail (see Guide G 78). Coupons should be or scales. The extent of each corrosive form should be
photographed to document the location and overall affected quantified as described in 16.
area of crevice attack. Although the presence of crevice 19.2.1 Penetration damage should be expressed in millime-
corrosion on test coupons is a positive indication, its absence tres and corrosion rates in millimetres per year (mm/y) for

8
 G4
uniform or general corrosion (see Practice G 1). An evaluation variability of the environment, and the nature of the corrosion
based on mass loss is also sometimes used when corrosion has process. Accordingly, it is impossible to provide a general
been substantially uniform in distribution over the surface of statement that will apply to all circumstances. In general,
specimens; it is expressed as mass loss per square meter per however, a variation of 6 20 % from the mean would be
day (g/m2/day). The use of mass loss data to estimate corrosion considered normal, while a variation of 6 50 % might be
penetration will be subject to error to the extent to which expected in some circumstances.
nonuniform distribution of corrosion and changes of corrosion 20.2 The ability of coupons to simulate the performance of
rate with time occur.
the materials of construction of a process plant is largely
19.2.2 The depth of pitting or crevice corrosion should be
dependent on the design of the program and the understanding
reported to the nearest 0.01 mm (0.0005 in.) for the test period
of the corrosive process involved. A well-designed coupon
and not interpolated or extrapolated to thousandths of an inch
per year or any arbitrary period. The size, shape, and distribu- program should give results that correlate to the existing
tion of the pits should be noted. The surface area of the materials of construction within the limits mentioned in 20.1.
specimen and the area of the crevices should be recorded if
crevice corrosion occurs. The maximum depth of crevice 21. Keywords
corrosion that exists beneath the coupon spacer must be 21.1 corrosive coupons; forms of corrosion; general corro-
reported. sion rate; in-plant exposures; localized attack; specific size and
20. Accuracy of Results surface conditions; test duration; test racks
20.1 The reproducibility of plant corrosion tests is depen-
dent on a number of factors, including the alloys tested, the

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