_STP_585-1975.pdf

ATMOSPHERIC CORROSION INVESTIGATION OF ALUMINUM-COATED,ZINC-COATED,AND COPPER-BEARING STEEL WIRE 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 List price$5.50 04-585000-02 AMERICAN SOCIETY FOR TESTING AND MATERIALS 1916 Race Streett Philadelphia,Pa.19103?9 BY AMERICAN SOCIETY FOR TESTING AND MATERIALS 1975 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 TABLE OF CONTTS Foreword Brief Summary of Results Acknowledgements Scope of A-5 and Authorization The Test Program The Test Plan Table 1-Exposure Sites Description of Test Specimens Table 2-Process Description-Preparation of Test Wires Table 3-Base Metal Analyses Coating Weights-General Coating Analyses and Photomicrographs Table 4-Mechanical Properties Table 5-Description of Aluminum Wire Materials and ASTM Specifications Relationship of Aluminum vs.Zinc Coating The Results Table 6-Unfabricated Wire Table 7-Farm Field Fence Table 8-Barbed Wire Table 9-Chain Link Fence Table i0-7 Wire Strand Table ii-Wire Test Abbreviation&Symbols(Continued)Copyright?9 1975 by ASTM International www.astm.org STP585-EB/Apr.1975 PAGE 3 5 7 8 lO 12 15 19 20 22 26 27-43 45 48 50 51 53 55 60 64 70 72 TABLE OF CONTENTS(Continued)PAGE Table 12-Aluminum Coated-Average Corrosion Rates-By Product and Location 75 Table 13-Zinc Coated-Average Corrosion Rates-By Product and Location 76 Fig.8 through 13-Comparison of Corrosion Rates-Zinc and Aluminum 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 metallic-coated 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)LE/NEWARK KEARNY,N,J.(40 44N-74 W)POINT REYE$,CALIF(58 O N-122 o 57 W)MANHATTAN,KANSAS(39eI2N-96 35W)KURE BEACHt N.C.(34O00N-Tlo54W)BRAZO$RIVER FREEPORT,TEX AS(28053.N-gs)MAP-LOCATION OF TEST SITES IN THE UNITED STATES 4 BRIEF SUMMARY OF RESULTS The Warrington,England test site is located at 53 24.2 N latitude and 2 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 7 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.5 Strengthwise-there have only been 2 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-5.The committee is pleased to have this paper appear as an ASTM Special Technical ulletin.6 ACKNOWLEDGEMENTS The writer wishes to acknowledge and extend thanks to the following people who helped with