Astm stp 585 1975

ATMOSPHERIC CORROSION INVESTIGATION OF ALUMINUMCOATED, ZINC-COATED, AND COPPERBEARING STEELWIRE AND WIRE PRODUCTS (A TWELVE YEAR REPORT) Sponsored by Committee A-5 on Corrosion of Iron and Steel Prepared by V I Kelley ASTM SPECIAL TECHNICAL PUBLICATION 585 Listprice $5.50 04-585000-02 AMERICAN SOCIETY FOR TESTING AND MATERIALS 1916 Race Streett Philadelphia, Pa 19103 BY AMERICANSOCIETYFOR TESTING AND MATERIALS1975 Library of Congress Catalog Card Number: 75-3831 NOTE The Society is not responsible, as a body, for the statements and opinions advanced in this publication Printed in Gibbsboro, N.J April 1975 STP585-EB/Apr TABLE OF C O N T ~ T S PAGE Foreword Brief Summary of Results Acknowledgements Scope of A-5 and Authorization The Test Program lO The Test Plan 12 Table - Exposure Sites 15 Description of Test Specimens 19 Table - Process Description - Preparation of 20 Test Wires Table - Base Metal Analyses 22 Coating Weights - General 26 Coating Analyses and Photomicrographs Table - Mechanical Properties 27-43 45 Table - Description of Aluminum Wire Materials and ASTM Specifications 48 Relationship of Aluminum vs Zinc Coating 50 The Results 51 Table - Unfabricated Wire 53 Table - Farm Field Fence 55 Table - Barbed Wire 60 Table - Chain Link Fence 64 Table i0 - Wire Strand 70 Table ii - Wire Test Abbreviation & Symbols 72 (Continued) Copyright 1975 by A S T M International www.astm.org 1975 TABLE OF CONTENTS (Continued) PAGE Table 12 - A l u m i n u m Coated - Average Corrosion Rates By Product and Location 75 Table 13 - Zinc Coated - Average Corrosion Rates By Product and Location Fig through 13 - Comparison 76 of Corrosion Rates - Zinc and A l u m i n u m Coated-by-Location 79-84 Breaking Strength Loss 85 Table 14 - Breaking Loads 86 Sugary 88 FOREWORD Committee A-5 on Corrosion of Iron and Steel was organized in 1907, to investigate the corrosion of iron and steel In 1908, the Committee sponsored its first atmospheric exposure of metalliccoated wires to evaluate their corrosion resistance Since that date, there have been a considerable number of test programs involving wire, sheet and hardware In June 1959, the Advisory Committee on Corrosion authorized Committee A-5 on Corrosion of Iron and Steel to conduct atmospheric corrosion tests of aluminum coated wire and wire products at seven ASTM sites in the United States (See Map on Next Page) and an eighth site in Warrington, England The responsibility for the latter site was assumed by Eylands Whitecross Limited For comparative purposes bare copper-bearing steel wire and zinc-coated steel wire and fabricated wire products were included in the testing program (Continued) B FOREWORD (Continued) COLeGE.PA.J) ~ L E / (40~ NEWARK KEARNY, 44'N74~ W)N,J REYE$,CALIF~ • (POINT ~ O ~ N - 122o 57' W ) MANHATTAN,KANSAS (39eI2'N - 96 ~ 35'W ) KURE BEACHt N.C (34O00N - Tl'o54'W) BRAZO$ RIVER FREEPORT, TEX AS ( N - gs~ ) M A P - LOCATION OF TEST SITES IN THE UNITED STATES BRIEF SUMMARY OF RESULTS The Warrington, England test site is located at 53 ~ 24.2' N latitude and ~ 34.5' W longitude The Newark-Kearny site where the specimens are now exposed has been in existence since July 2, 1970 At the time of original exposure in 1961 they were in Newark, N.J which has an industrial atmosphere The moving of the test site and specimens was necessitated by a request from the owner, who needed the area for expanding facilities The wire and wire products specimens were exposed at the seven U.S sites in the spring and summer of 1961 and at Warrington, England on March l, 1964 There were 340 unfabricated tensile test specimens exposed at each of four sites To date, 27 have been removed and tested Wire products specimens (field fence, barbed wire, chain link fence and wire strand) were exposed at all eight sites The range of zinc coatings-hot dipped was 0.36 to 2.81 oz per sq ft of surface area The electroplated zinc coating range was 0.87 to 2.98 The hot dipped aluminum-coated specimens ranged from 0.27 to 0.63 oz per sq ft and the aluminum powder metallurgy clad ranged from 1.76 to 4.54 oz per sq ft of surface The initial rust corrosion rates of aluminum coated unfabricated wire varied from 0.032 oz per sq ft per year at Kure Beach 800' lot to 0.061 oz per sq ft per year at Warrington The initial rust corrosion rate (CIR) at State College shows the lighter weight aluminum coated wires (0.27 to 0.37 osf) with a corrosion rate of 0.035 oz per sq ft per year, whereas the higher weight aluminum coated wires (0.43 to 0.63 osf) averages 0.056 oz per sq ft per year The only site reporting complete rust corrosion was Warrington, England Strengthwise-there have only been specimens of aluminum coated wire tested and both of these were from Warrington The data are insufficient to generalize The details concerning the test data are included in this paper by V I Kelley They were approved by Committee A - The committee is pleased to have this paper appear as an ASTM Special Technical ~ulletin ACKNOWLEDGEMENTS The writer wishes to acknowledge and extend thanks to the following people who helped with information or personally encouraged the compilation of this document: G W Bowdren - Public Service Gas and Electric Co S K C o b u r n - U S Steel Corp T O Hodges - Kansas State University R N Johnson - U S~ Steel Corp V P Pearson - Inland Steel Co Laury Peters - Bethlehem Steel Corp E E Ramn - Ohio Edison Co - Chnm of A-5 J H R i g o - U S Steel Corp Bernard Ryan - Eylands - Whitecross, Limited C E Shoemaker - Bethlehem Steel Corp G J Tyler - State of N.J., Dept of Environmental Protection Table 13 - Average Corrosion Rates to Initial Rusting (CIR) (ounces of coating per square foot per year) for each Zinc-coated product exposed at each location ZINC - COATED UnfabriLocation Chain cared Field Barbed Wire Fence Wire P All Link Wire Fence Strand Average Products Brazos River~ Tex a O 148 o.42o 0.189 C O.252 Kure Beach, N.C (80') a 0.226 b O 419 f 0.376 o.135 0.289 Kure Beach, N.C (800') O.lO4 0.124 o.158 o.285 c 0.168 C c C Manhattan, Kans a O 166 d 0.204 g 0.237 0.143 0.183 a o.o91 0.169 0.181 0.143 0.146 State College, Pa 0.063 0.055 0.073 c 0.064k Warrington, Eng e 0.194 0.253 o.54o o.3oo 0.171 o.294 h 0.132 0.152 o.283 0.261 0.148 n Newark, Kearny, N.J o.167 Point Reyes, Calif All Locations, Average m a No specimens exposed b Specimen No 24 scrapped in 1973 c Insufficient data for averaging d Scrapped specimens 24 & 25 in 1970 e Exposed in 1964 f Specimen No 27 scrapped in 1971 gscrapped specimens 27 & 28 in 1970 h Highest average (CIR) Location 76 (Continued) Copyright by ASTM Int'l (all rights reserved); Fri Jan 23:26:46 EST 2016 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized TABLE 13 (Continued) k Lowest average (CIR) Location m Highest a v e r a g e (CIR) Product n Lowest average (CIR) Product PResults are averages of line wires and barbs 77 Copyright by ASTM Int'l (all rights reserved); Fri Jan 23:26:46 EST 2016 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized It is of interest to note that the aluminum coated products (Table 12) range from a high of 0.060 oz of coating per sq compared to a low of 0.042 at Point Reyes ft per year at Brazos River Also, note that the highest product was chain link fence with an average of 0.063 compared to the lowest average of 0.045 for field fence In review of the zinc coated products (Table 13), it is found that it ranges from an average of 0.294 oz of coating per sq ft per year at Warrington, England to a low average of 0.064 at State College and that the highest average product is barbed wire at 0.283 and the lowest average product is wire strand at 0.148 Excluding State College, the average (CIR) by locati~, for zinc coated products is 3.1 to 5.6 times the average (CIR) of the aluminum coated wire products By product comparison, the zinc coated products are 2.6 to 6.0 times the average (CIR) of the aluminum coated products A graphic comparison of the corrosion rates to initial rusting (CIR), average, for the unfabricated wire and wire products, zinc versus aluminum-coated, by location is illustrated in Figures through 13 ~he average CIR value is given in ounces per square foot of coating per year average of all products at the particular location is shown at the right of each graph The most significant observation is the relative equality of both zinc and aluminum at State College, Pa Copyright by ASTM Int'l (all rights reserved); Fri Jan 23:26:46 EST 2016 Downloaded/printed by University of Washington (University of Washington) pursuant to License Agreement No further reproductions authorized The 0.600 5 -0.500 0.450 O 0.400 r O N 0.350 IJ.I ::D _1 0.300 0.250 (J i,i m 0.200