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The Futility and Folly of Seeking the Accelerated Corrosion Holy Grail

The Futility and Folly of Seeking the Accelerated Corrosion Holy Grail
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Since the dawn of mankind, or at least since the advent of the very first accelerated corrosion cabinet, it has been the goal of coatings evaluators to develop an accelerated corrosion testing protocol which reflects the real world of corrosion in totality. There have been passionate arguments promoting one or another testing protocol while demonizing others, but that one protocol has yet to be developed to everyone’s satisfaction. 

Product Number: 41215-885-SG
Author: Carl W. Reed, Kat Coronado
Publication Date: 2015
Industries: Coatings , Corrosion Monitoring and Control , Coatings and Linings
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Since the dawn of mankind, or at least since the advent of the very first accelerated corrosion cabinet, it has been the goal of coatings evaluators to develop an accelerated corrosion testing protocol which reflects the real world of corrosion in totality. There have been passionate arguments promoting one or another testing protocol while demonizing others, but that one protocol has yet to be developed to everyone’s satisfaction. While the simplistic notion of one accelerated corrosion testing protocol is appealing, it is naïve to believe this Holy Grail is actually attainable. Mother Nature, in her divine wisdom, simply will not allow it. In the natural world, there are literally millions of variables that affect the composition and rate of corrosion. Distilling these variables into a few and packaging them into the proverbial accelerated box is not possible. It is therefore incumbent on the industry to back away from such futility and folly and embrace the variations that real world corrosion has to offer by understanding what corrosion is, what is important about corrosion and its measurement, and how to deal with it from a coatings point of view. This paper will look at the history of accelerated corrosion testing and some popular accelerated corrosion protocols. Also, mechanisms of corrosion and the variables that affect the corrosion process will be discussed, especially as they relate to testing protocols. And finally, the role of coatings in accelerated corrosion testing and the variability encountered in the different test protocols will be examined.

Since the dawn of mankind, or at least since the advent of the very first accelerated corrosion cabinet, it has been the goal of coatings evaluators to develop an accelerated corrosion testing protocol which reflects the real world of corrosion in totality. There have been passionate arguments promoting one or another testing protocol while demonizing others, but that one protocol has yet to be developed to everyone’s satisfaction. While the simplistic notion of one accelerated corrosion testing protocol is appealing, it is naïve to believe this Holy Grail is actually attainable. Mother Nature, in her divine wisdom, simply will not allow it. In the natural world, there are literally millions of variables that affect the composition and rate of corrosion. Distilling these variables into a few and packaging them into the proverbial accelerated box is not possible. It is therefore incumbent on the industry to back away from such futility and folly and embrace the variations that real world corrosion has to offer by understanding what corrosion is, what is important about corrosion and its measurement, and how to deal with it from a coatings point of view. This paper will look at the history of accelerated corrosion testing and some popular accelerated corrosion protocols. Also, mechanisms of corrosion and the variables that affect the corrosion process will be discussed, especially as they relate to testing protocols. And finally, the role of coatings in accelerated corrosion testing and the variability encountered in the different test protocols will be examined.

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A previous paper presented by the authors at SSPC 2015 demonstrated the futility and folly of attempting to use accelerated corrosion testing as a tool for predicting real world corrosion performance. The effect of corrosion was shown to be governed by the type of ions and the concentration of oxygen in the corrosion environment. By understanding these two factors, accelerated corrosion testing can, however, be used as an indicator of performance which may be encountered in the real world. 
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