British Corrosion Journal

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Accelerated Atmospheric Corrosion Of Copper And

Copper Alloys

A. STERLING, A. ATRENS & I. O. SMITH

To cite this article: A. STERLING, A. ATRENS & I. O. SMITH (1990) Accelerated Atmospheric
Corrosion Of Copper And Copper Alloys, British Corrosion Journal, 25:4, 271-278, DOI:
10.1179/000705990799156391

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Accelerated atmospheric corrosion of copper and
copper alloys
A. STERLING The corrosion behaviour of a range of readily available commercial copper based alloys
A.ATRENS was examined in three accelerated atmospheric corrosion tests: acidified salt spray,
neutral salt spray at 80°C, and the GM (salt spray with thermal cycling) test. The
I. O. SMITH samples exposed to the G M test evinced very little corrosion. During exposure, the
weight of all the samples fluctuated in a random fashion, indicating that the corrosion
products were only partially adherent and became detached from the surface at random
times. The sequence of corrosion product formation on the specimen surfaces during
exposure to the neutral salt spray test was very similar to that observed on coppers
exposed to the atmosphere, indicating that this test can be used to give accelerated
indications concerning atmospheric corrosion in humid marine regions. Four 24 h
cycles of salt spray exposure are approximately equivalent to 1year's exposure to the
atmosphere. Alloying copper with phosphorus, tin, zinc, or silicon does not improve
atmospheric corrosion resistance. The alloy containing 30%Zn exhibited dezincijica-
tion. The nickel silvers exbibited corrosion rates in the neutral salt spray at 800C that
were lower by a factor of at least 13 than those of the high purity coppers. For six of the
alloys studied, the as received surface condition correlated with a slightly, but statisti-
cally significantly, higher corrosion rate, attributed to residual contaminants from
rolling.
Manuscript received 27 February 1987; in final form 25 October 1988. At the time the
work was carried out, the authors were in the Department of Mining and Metallurgical
Engineering, University of Queensland, St Lucia, Qld 4067, Australia. Dr Sterling is
now with Wilson Walton International, Mansfield, Qld and Dr Smith is with CRA
Advanced Technical Development, Connington, Western Australia.

INTRODUCTION EXPERIMENTAL PROCEDURE

The research presented in the present paper forms part of Test coupons
a wider investigation into the external corrosion of copper/ Details of the range of commercial alloys tested are given
brass automobile radiators. A standard radiator consists of in Table 1. Coupons, 100 x 75 mm in size, cut from rolled
a core connected to top and bottom header tanks. A sheet and drilled with a suspension hole, were stamped
typical core consists of about 50 parallel brass (often 70-30 with the appropriate alloy designation. Before testing,
brass) water channels, between which are cooling fins they were degreased in alcohol and washed in water, both
made from a finstock alloy that is essentially high purity processes being accompanied by rubbing with a rubber
copper containing 0·15 Sn. The service life of such radia-
%
stopper to remove any non-adherent material on the
tors can be limited in some geographical areas, for exam- surface.
ple in the south eastern regions of the USA, in Japan, and
in Australia, where they are exposed to an environment
Test methods
characterised by high temperatures, high humidity, and
Acidified salt spray
the presence of sea salt in the atmosphere. Failure modes
The testing conditions were as set out in ASTM
include rapid exterior corrosion of the cooling fins and
B287-1980, 'Standard method of acetic acid - salt spray
leaks in the water channels due to dezincification of the
(fog) testing', but with the temperature maintained at
brass. 50 ± 2°C. For this test, as well as for the other two tests,
The performance, corrosion mechanisms, and corrosion
the compressed air supply to the atomising nozzles was
products of a range of readily available commercial alloys
humidified in a saturation tower maintained 5 K above the
in three accelerated atmospheric corrosion tests has been
chamber temperature. This was done to prevent cooling of
studied. The tests used were:
the chamber and evaporation of water from the salt
(i) acetic acid salt spray
solution, thereby increasing its concentration. The pH of
(ii) neutral salt spray
the 50g1-1 NaCl spray solution was adjusted to 3·2±0·1
(iii) the GM test, which is designed to model the service
by the addition of glacial acetic acid. Analytical grade
environment of a radiator.
chemicals and distilled water were used. Specimens were
Direct prediction of service life is not expected from such
suspended vertically, by means of glass hooks; from cross-
accelerated tests, but they should provide the possibility of
members in the salt spray cabinet. The testing cycle lasted
quickly examining trends and ranking alloys.
24 h with the specimen exposed to the solution for 16 h
The scientific literature relating to accelerated atmos-
followed by washing and exposure to laboratory air for
pheric corrosion tests includes little in the way of analysis
8h.
of the corrosion products formed on copper alloys and
how these might influence the resulting corrosion rates.
The present study was carried out with this in mind. Neutral salt spray at BO°C
Consideration was also given to the influence of surface The testing conditions were as set out in ASTM
condition on corrosion rates, since it has been suggested1 Bl17-1979, 'Standard method of salt spray (fog) testing',
that the corrosion rates of as received copper alloys could but with the temperature maintained at 80 ± 5°C. The
be greater than those of carefully cleaned samples due to 50 g 1-1NaCl spray solution was maintained at pH 6·5-7·2.
the presence of residual surface contaminants from rolling. Analytical grade salt and distilled water were used. The

Dr. Corros. J., 1990,Vol. 25, No.4 271

272 Sterling et al. Accelerated atmospheric corrosion of copper

Table 1 Alloy designations, specifications, and compositions

Related
Alloy Designation specifications Composition, wt-%

Tough pitch copper 101 AS 1566-110A; >99·9Cu-0·030

BS 2870, 2875-C101;
ASTM B152, B11
Phosphorus 102 AS 1566-122A; >99·9Cu-0·025P
deoxidised copper BS 2870, 2875-C106;
ASTM B152, B11
Cu-Sn finstock alloy 144 AS 1566-144D 99·8Cu-0·15Sn-0·02P
90-10 brass 203 AS 1566-220A; 90Cu-10Zn
BS 2870-CZ101;
ASTM B36
70-30 brass 207 AS 1566-260A; 70Cu-30Zn
BS 2870-CZ106;
ASTM B36
Phosphor bronze 523 AS 1566-518B; 95Cu-5Sn, trace P
BS 2870, 2875-PB102;
ASTM B103-C51000
Coinage bronze 548 AS 1566-404D 97Cu- 2·5Zn-0· 5Sn-0·03P
Silicon bronze 801 AS 1566-655A; 96Cu-3Si-1Mn
BS 2870, 2875-CS101;
ASTM B96-C65000
18% nickel silver 905 AS 1566-770B; Zn-55Cu-18Ni-0·2Mn
BS 2870-NS107;
ASTM B122-C77000
75-25 cupronickel 912 AS1566-713B 74·7Cu-25Ni-0·3Mn
12% nickel silver 926 AS 1566-757B; Zn-63Cu-12Ni-0·2Mn
BS 2870-NS104;
ASTM B122-C75700

specimen suspension and test cycle were identical to those
used in the acidified salt spray test.
GM test
This test requires controlled cycling between 38 and 85°C,
which was accomplished by mounting the specimens (at an
angle of 60° to the horizontal) on a radiator through which
warm or hot water was pumped as required. The test
requires the following 20 min cycle to be run continuously:
(i) 10 s salt spray (fog) while specimen is at 38°C
(ii) hold for 1 min at 38°C
(iii) increase temperature to 85°C and hold for 10 min
procedure was used for all samples, it is considered that
the comparisons made are valid.
After the completion of this first series of corrosion
tests, part of the corrosion products was removed from
each specimen and an X-ray powder diffraction pattern
was obtained using Cu Ka radiation. From the diffraction
patterns, the identities of the corrosion products were
determined and the relative concentration of each was
calculated assuming a linear relationship between concen-
tration and X-ray peak intensity. The percentage error
consequent on this, the simplest possible assumption, is
unlikely to be greater than 20 %
•

(iv) cool to 38°C and hold at this temperature to end of

20 min period.
First series of tests
The first series of tests was designed to monitor corrosion
behaviour, and to determine how it changed with time, in
each of the accelerated corrosion tests. The coupons were
examined, cleaned, dried, and weighed after each 24 h
cycle of exposure. The cleaning procedure consisted of
washing in water while rubbing with a rubber stopper, so
removing loose deposits and corrosion products, but leav-
ing any adherent corrosion products. This procedure was
considered to have minimal effect on subsequent corrosion
behaviour. The specimens were photographed, in colour,
periodically to record the pattern of corrosion products
and how this pattern changed with number of exposure
cycles. Subsequently, the specimens were sectioned and
examined microscopically to determine the degree of non-
uniform corrosion in terms of intercrystalline corrosion,
dezincification, and pitting. Sectioning was done at
random and a section of the order of 20-30 mm in length
was examined. The maximum depth of pitting attack was
measured on these sections as the distance between the pit
bottom and the specimen surface. Such measurements do
not in~lude any contribution from general corrosion of the
sample. This procedure does not allow for the possible
existence of extremely deep pits elsewhere on the surface,
but· since pitting is a statistical process and the same
Second series of tests
The second series of corrosion tests was designed to
measure corrosion penetration over 10 cycles of exposure
to 80°C neutral salt spray. The specimens were either
cleaned as described previously (designated as received)
or acid cleaned for 5 min in 5%HzS04 followed by rubbing
with a rubber stopper under flowing water to remove the
surface oxide (designated acid cleaned). The weight in this
condition (before exposure to the environment) is desig-
nated Wbefore' After exposure to 10 cycles of neutral salt
spray at 80°C, the specimens were washed, acid cleaned,
washed, dried, and weighed, to give Wafter' Separate
experiments were also carried out to measure the mass of
material removed by acid cleaning a previously cleaned
specimen ~ w. The weight loss due to exposure to the
environment studied ~ W is given by
~ W = Wbefore - Wafter - ~ W (1)
RESULTS AND DISCUSSION
First series of tests
The weight change results for the specimens exposed to
acidified salt spray, neutral salt spray, and the GM test are
given in Tables 2-4 respectively. The results are presented
in detail to draw attention to the considerable spread in
the weight changes. In fact, the results for all the speci-
mens in all three tests display no discernible pattern, but

Br. Corros. J., 1990, Vol. 25, NO.4

 Sterling et al. Accelerated atmospheric corrosion of copper 273

Table 2 Weight change per cycle during exposure to acidified salt spray, mg

Alloy

Cycle 101 102 144 203 207 523 548 801 905 912 926

1 -61·0 -70·4 -4·6 -17·9 +1·3 -12·1 -40·1 -6·5 -12·0 -16·7 -29·1
2 -159·6 -98·1 -7·4 -1·8 +4·6 -13·0 -10·9 -1'8 -2·8 -28·8 -13·4
3 -23·2 -64·4 -18·6 0·0 +5·4 -24·4 -24·4 +4·4 -2·4 -14·6 -7·7
4 -7·3 -24·7 -23·0 -3·5 +4'1 -6·9 -7·9 -2·9 -2·4 -16·6 -8·1
5 -1·7 -8·2 -5·9 -2·4 +6·1 -11·3 -0·6 +5·7 +0·8 -28·2 -6·4
6 -6·3 -42·0 -8·6 +20·7 +10'8 -33·2 -24·6 +23·9 -3·0 -57·2 -7·2
7 -11·8 -40·2 -16·1 +5·1 +3·8 -27·1 -16·2 -25·6 -8·7 -27·5 -13·7
8 +7·2 -11·6 -1·5 +4·9 '+2·4 -21·5 -5·6 +7·7 -4·6 -21·4 -7·2
9 +6·4 +4·7 +0·9 +12·5 +4·5 -17·4 -13·0 +30·6 -5·4 -35·6 -5·0
10 -32·2 -6·1 -39·5 +9·2 +1·8 -6·0 -13·9 -10·2 -4·4 -52·7 -8·6
11 -3·0 -3·9 -3·5 +6·3 +3·7 -45·1 -8·2 -30·2 -4·0 -27·6 -10·0
12 -17·9 -25·5 -13·5 -5·9 +5·6 -9·6 -14·7 -46·7 -8·4 -37·0 -9·9
13 -2·1 -23·0 -3·8 +6·6 +2·1 -18·3 -22·6 -46·5 -5·4 -31·1 -12·5
14 -0·3 -22·3 -47·4 -3·0 -0·9 -28·8 -26·3 -23·7 -7·4 -26·2 -12·7
15 +0·4 -16·7 -4·6 +7·5 +4·3 -0·2 -17·4 +4·6 -0·7 -36·7 -9·0
16 +0·8 -13·1 -0·4 +6·4 +5·0 -15·0 -17·5 -8·4 -6·7 -22·3 -14·7
Total -311·6 -465·5 -197·5 +51·7 +64·6 -289·9 -241·3 -125·6 -77·5 -480·2 -175·2

appear to be random - even in respect of gains or losses in
weight. The weight losses during each GM test (Table 4)
were much less than those measured during exposure to
the other two environments. This is simply a reflection of
the fact that the exposure conditions during the GM test
are milder than those in the other two tests.
The weight change results reflect two different pro-
cesses: weight increases as corrosion products are formed
at the specimen surface, but decreases as non-adherent
corrosion products are detached from the surface. The fact
that the weight change per cycle is random with no
discernible pattern indicates that the corrosion products
are only partially adherent and that variable amounts of
corrosion products are detached from the surface at
random. This implies that the corrosion products are at
best only partially protective, and moreover implies that
weight change data cannot be used to predict corrosion
rate.
The maximum depths of pitting following exposure to
acidified salt spray and to neutral salt spray, recorded in
Table 5, show a fairly close correlation between the
behaviour of the alloys in the two environments. Phosphor
bronze (523), coinage bronze (548), and 75-25 cupro-
nickel (912) showed the least pitting attack with maximum
penetration in the range 0-8 ~m. Medium penetration in
the range 11-18 ~m was observed for 12% nickel silver
(926), 18% nickel silver (905), phosphorus deoxidised
copper (102), tough pitch copper (101), and eu-Sn fin-
stock alloy (144), although both nickel silvers showed no
measurable pitting penetration after exposure to the
neutral salt spray. The alloys with the highest pitting
penetration, in the range 21-80 ~m, were 90-10 brass
(203), silicon bronze (801), and}0-30 brass (207). The 70-
30 brass was the only alloy to exhibit dezincification.
There is no apparent pattern of pitting susceptibility with
alloy composition. The corrosion products and the appear-
ances of the specimens were quite different for the three
accelerated atmospheric corrosion tests, as detailed below.
Acidified salt spray test
The corrosion products and their concentrations produced
during exposure to acidified salt spray are given in Table 6,

Table 3 Weight change per cycle during exposure to neutral salt spray at 80°C, mg

Alloy

Cycle 101 102 144 203 207 523 548 801 905 912 926

1 -32·3 -72·8 -1·3 +33·5 +35·7 -63·3 +24·6 +18·3 +20·0 +14·1 -+16·2
2 +8·4 -4·6 +21·4 +19·2 +25·8 -51·9 -23·5 +27·1 +4·9 +10·1 +11·5 .
3 +7'8 +5·7 +0·8 +10·6 +4·8 -28·5 -2·9 . +5·4 +4·4 +8·9 -1·0
4 +7·6 +6·9 +6·3 +3·6 +13·0 -7·2 +3·5 +8·1 +2·2 -2·2 +4·8
5 -9·2 -10·1 +11·8 +8·6 +9·7 -94·6 +13·3 +33·3 +10·2 +3·4 +7·5
6 -21·8 -150·8 +16·8 +41·9 +14·9 -27·4 +5·0 +17·9 +0·3 +2·0 +2·8
7 -3·9 -6·2 -143·4 -0·2 -5·2 -18·8 +1·5 +4·3 +1·6 +0·6 +1·7
8 +1·9 -0·5 -15·3 +8·2 +4·1 -87·7 +4·8 +9·5 +0·7 +1·4 -1·0
9 +8·1 -0·8 -4·4 +12·8 +8·9 -27·6 +6·8 +7·5 +4·1 +2·4 -0·3
10 +3·3 +7·5 -0·1 +0·3 +7·9 -57·2 +7·1 +9·4 +2·0 +2·2 -0·2
11 +4·7 -9·0 +1·2 +16·5 +3·7 -37·2 +2·7 +9·2 -0·7 -0·9 -1·3
12 +6·6 +12·9 +6·9 +2·0 +11·1 -52·0 +3·5 +12·6 +1·3 +1·4 +5·7
13 +2·5 -0·3 +7·2 -7·9 -0·3 -71·7 +3·3 +5·2 -2·9 -1·3 -8·9
14 +14~4 +9·7 +10·0 +6·9 +4·7 -26'3 +8·7 +17·3 +1·5 +1·3 +4·0
15 +13·5 +5·3 +7·2 +8·2 +6·8 -21·4 +15·8 +6·6 +0·7 +1·9 +7·1
16 -4·7 -18·1 -4·7 -3·4 +12·0 -63·2 -14·8 +9·8 +0·4 +0·5 -0·5
17 +10·9 -6·9 -7·2 +17·8 -0'8 -12·9 +5·5 +2·6 +0·8 -0·3 -0·4
18 +17·0 +15·5 +19·5 +13·6 +15·0 -53·7 +4·5 +7·8 +1·6 +2·1 +1·4
19 -6·7 +8·7 -15·2 +5·9 -6·7 -32·6 -42·1 +7·7 -1·7 -1·4 -1·6
Total +27·1 -207·9 -82·5 +218·1 +165·1 -835·2 +27·3 +219·4 +51·2 +46·2 +47·5

Br. Corros. J., 1990, Vol. 25, NO.4

274 Sterling et al. Accelerated atmospheric corrosion of copper

Table 4 Weight change per cycle during exposure to GM test, mg

Alloy

Cycle 101 102 144 203 207 523 548 801 905 912 926

1 +2·0 +1·5 +0·6 -0·6 +3·4 +2·9 -4·8 +0·6 +1·7 -3·5 +2·0
2 -0·8 -0·5 -0·9 +3·3 -0·7 -3·2 +3·6 -0·9 -5·2 +1·9 -6·3
3 +1·3 +1·4 +1·1 -1·6 +1·6 +5·0 +4·0 +0·6 +1·7 -2·2 +6·9
4 -0·1 -0·4 +0·2 +2·4 -0·1 +0·0 -10·1 +0·1 +1·8 +1·1 -3·7
5 +1·4 +1·0 +2·3 +3·2 +2·1 -1·0 +13·8 +2·2 -0·3 +0·7 +4·8
6 -0·6 -1·0 +0·0 -3·1 -0·6 +2·9 -4·1 -1·2 +0·3 -1·4 -5·9
7 +0·6 +0·2 +1·0 +3·5 +1·3 +1·0 +5·5 +3·9 +0·6 +0·6 -0·4
8 -0·4 -0·6 +0·6 -0·9 +0·5 +3·7 +0·2 +1·1 -0·5 -0·7 +4·6
9 +1·0 +1·3 +1·5 +5·7 +2·3 -1·6 +3·5 +2·3 -6·8 +2·7 -6·3
10 -1·7 -1·6 -1·7 -1·2 -0·9 +2·8 -5·8 +0·3 +4·6 -3·3 +5·3
11 +0·4 +0·4 +0·9 +2·2 +1·0 +2·5 -1·7 +1·2 +1·6 +0·2 -0·3
12 +1·9 +3·2 +3·3 -0·6 +2·0 +2·6 -1·0 +1·5 -2·3 -1·8 -4·3
13 -0·6 +0·4 +0·4 +0·0 +0·3 -2·0 -2·6 +1·1 -1·5 +0·5 +7·7
14 +1·0 +0·0 +0·2 +7·2 +0·4 +6·5 +8·7 +1·0 +9·3 +3·5 +4·0
15 -0·4 +0·1 +0·0 +0·6 +0·3 +0·8 +0·5 +0·6 +0·0 -0·3 -0·2
16 -0·4 -0·2 -0·5 +0·7 -0·1 +0·0 +0·5 +1·0 -0·1 -0·3 +0·0
17 +0·6 -0·4 +0·8 +1·0 +1·5 +1·9 +0·2 +0·3 +0·2 +0·4 +0·2
18 -0·4 -0·1 -0·3 +0·5 +0·3 +1·0 +0·6 +1·1 -0·1 -0·1 +0·5
19 -0·1 +0·1 -0·1 +0·4 +0·2 +1·0 +0·1 -0·2 +0·1 +0·0 -0·3
20 -0·9 -0·3 +0·0 +0·1 +0·2 +1·0 +0·6 +1·4 -0·6 -0·5 -0·3
21 +0·5 +0·9 +0·5 +0·7 +0·9 +1·2 +0·6 +0·8 +0·1 +0·4 -0·1
22 -0·7 -0·6 -0·5 -0·1 -0·5 +1·2 -0·2 -0·3 -0·3 -0·4 -0·5
23 +0·5 +0·4 +0·7 +0·7 +1·0 +0·8 +0·8 +1·2 +0·2 +0·2 +0·5
24 +0·1 +0·5 +0·3 +0·7 +1·0 +1·1 +0·8 +1·6 +0·3 +0·2 +0·4
25 +0·4 +0·5 +0·4 +0·0 +0·1 +1·4 +0·1 +0·1 -0·3 +0·0 -0·6
26 +0·5 +0·4 +0·5 +0·6 +0·5 +1·7 +0·9 +0·9 +0·1 +0·3 +0·2
27 -0·1 +0·5 +0·2 +0·1 +0·6 +1·5 +0·6 +0·6 -0·3 -0·1 -0·3
28 -0·2 +0·1 +0·3 +0·7 +0·2 +0·0 +0·5 +0·6 +0·5 +0·3 +0·4
29 +0·2 +0·4 +0·3 +0·3 +1·1 +1·4 +0·5 +0·7 -0·2 -0·2 +0·0
30 +0·5 +0·6 +0·7 +0·4 +0·6 +1·5 +1·1 +1·0 +0·3 +0·4 +0·3
31 +0·0 +0·1 +0·1 -0·1 +0·2 +0·4 +0·4 +0·4 -0·3 -0·5 -0·6
32 +0·4 +0·3 +0·4 +0·7 +0·8 +1·1 +0·9 +1·5 +0·3 +0·3 +0·4
33 +0·5 +0·5 +0·6 +0·0 +0·7 +1·2 +1·0 +0·8 -0·2 +0·1 +0·0
34 +0·2 -0·1 -0·4 +0·3 +0·2 +0·3 +0·4 +1·2 +0·0 -0·2 -0·1
35 -0·2 +0·3 +0·1 +0·5 +0·8 +1·1 +0·1 +0·8 -0·1 +0·4 +0·1
Total -6·3 +10·1 +13·7 +28·4 +23·2 +43·7 +30·2 +29·9 +4·6 -2·3 -8·1

which also lists the major alloy components: copper, products contaInIng cuprous oxide (CuzO) and basic
nickel, and zinc. Due to insufficient corrosion product on copper chlorides. The majority of the basic copper chlor-
some of the samples, grouping of corrosion product was ide was of the form of CuClz.3(Cu(OH)z), but there were
carried out for very similar alloys where it would be also other forms which included CuiOH)6Clz.3HzO,
expected that the corrosion product would be very similar. CU4(OH)6Ch.3HzO, and CU7CI4(OH)z.2HzO.These are all
Thus, the corrosion product of alloy 102 was combined very similar, differing only in their basicity and the amount
with that of alloy 101, and that of 926 with that of 905. of water of hydration which they contain. Consequently,
Alloys 101 and 102 are very similar high purity coppers, .all the basic copper chlorides have been grouped together
and alloys 905 and 926 are both nickel silvers, 905 having a as one constituent in the corrosion products and included
somewhat higher nickel content. under the heading of the major constituent. With some
The alloys in Table 6 have been listed in order of exceptions, within this group there is a correlation
decreasing copper content. Alloys 101, 144,203,523,548, between decreasing copper content in the alloy and
and 801 can be grouped together as having corrosion increasing amounts of basic copper chlorides and a
decreasing amount of cuprous oxide in the corrosion
Table 5 Maximum depth of pitting corrosion observed products.
following exposure to acidified salt spray and to Alloy 912 (75-25 cupronickel) produced a corrosion
neutral salt spray at 80°C, ,..m product containing 94°10 cuprous oxide and 6°1o basic
copper chlorides. This composition of corrosion product
Alloy Acidified salt spray Neutral salt spray could fit in the above sequence if nickel were considered to
act as a substitute for copper in these alloys corroding in
523 <3 0 acidified salt spray. This suggestion is supported by the
548 6 5 fact that in some applications a copper equivalent for
912 8 5 nickel with 1·2%Ni being equivalent to 1·0%Cu has been
926 11 0 proposed.2
905 15 0 Alloy 207 (70-30 brass) gave only 5°/0 cuprous oxide in
102 15 11
the corrosion product, the remainder being basic zinc
101 15 17
144 18 14 chloride formed as a result of dezincification.
203 33 21 The nickel silver (alloy 905) had a corrosion product
801 62 38 containing no cuprous oxide, 61°/0 basic copper chlorides,
207 64 60 and 39°/0 nickel chlorides. This make up of the corrosion
products is different from that observed on the related

Dr. Corros. J., 1990, Vol. 25, No.4

 Sterling et al. Accelerated atmospheric corrosion of copper 275

Table 6 Corrosion products produced during exposure to acidified salt spray

and their concentrations

Alloy compo-
sition, wt-% Corrosion product composition, wt-%

Alloy Cu Ni Zn CU20 CuC12.3(Cu(OHh) ZnC12·4(Zn(OH)2 NiC12

101 99·9 70 30
144 99·8 81 19
548 97 2·5 81 19
801 96 61 39
523 95 78 22
203 90 10 40 60
912 74·7 25 94 6
207 70 30 5 95
905 55 18 25 61 39

alloys 75-25 cupronickel (912) and 70-30 brass (207).
Thus the presence of both nickel and zinc in the alloy has
changed the corrosion process to produce nickel chloride
and basic copper chloride.
Neutral salt spray
There are some interesting trends in the X-ray data from
the corrosion products (Table 7). The compounds and
their relative. concentrations were very similar on the three
high purity alloys: tough pitch copper (101), phosphorus
deoxidised copper (102), and Cu-Sn finstock alloy (144).
The addition of extra tin up to 5% in phosphor bronze
(523) does not change the pattern. In all these alloys (101,
102, 144, and 523) the corrosion product was predomin-
antly (83%) cuprous oxide, with small amounts of cupric
oxide (60/0) and basic copper chloride (9%) and traces of
NaCI and CuClz.
In alloys 548, 203, and 207, containing 2·5, 10, and
300/oZn respectively, increasing zinc content correlates
with corrosion products containing decreasing concentra-
tions of cuprous oxide, increasing concentrations of cupric
oxide, and a greater amount of chloride compounds.
Coinage bronze (548) had in its corrosion products 14% of
the basic copper chloride, and amounts of NaCI and CuClz
similar to those for alloy 101. The 90-10 brass (203)
showed slightly more basic copper chloride (16 %
and
),
substantially more NaCI (9%) and CuClz than alloy 101.
Th~ corrosion product on 70-30 brass (207) contained no
cuprous oxide, but an increased amount of cupric oxide
(16%
) and chlorides as basic zinc chloride; there was also a
large amount of ZnO.
The alloying sequence 801, 905, and 912 can be com-
pareo with 101 in terms of decreasing total copper content
in the alloy, the alloying elements being respectively
silicon and manganese, nickel and zinc, and nickel. This
sequence produced corrosion products containing decreas-
ing concentrations of cuprous oxide, no cupric oxide, and
increasing concentrations of basic copper chloride.
GM test
The GM test samples evinced very little corrosion. After
35 cycles (each of 24 h duration) there was no sign of any
black oxide or patina; the only change was the loss of
metallic lustre as the samples acquired a very thin cover-
age of corrosion product. There was insufficient corrosion
product to carry out an X-ray identification of the
compounds present.
Second series of tests
The weight loss results for specimens after 10 exposure
cycles (each of 24 h duration) to neutral salt spray at 80°C
are given in Table 8. For each alloy, the weight loss due to
cleaning in acid for 5 min ~ wand the weight loss ~ W due
to exposure to the salt spray are listed for both the acid
cleaned and as received conditions. ~ W has also been
converted to an equivalent penetration based on the
assumption of uniform corrosion.
With the sole exception of alloy 905, ~ w is small
compared with d W, implying a small relative error in ~ W
(see equation (1». For alloy 905 the weight loss due to
exposure of the acid cleaned samples to the neutral salt
spray d Wacid is very low (0·021 g) and as a consequence
only slightly larger than ~w; in this case the fractional
errors inherent in the measurement are likely to be large
because the corrosion rate is low.
The results for alloys 101, 102, 144, 523, 548, and 801
showed a greater weight loss for the as received condition
than for the acid cleaned condition. There are two experi-
mental considerations which, taken together, establish
that this difference in weight loss for the two conditions is
in fact statistically significant. First, ~w for the specimens

Table 7 Corrosion products produced during exposure to neutral salt spray at 80°C and their
concentrations

Corrosion product composition, wt-O/o

Alloying
Alloy addition, wt-% CU20 CuO CuCI2.3(Cu( 0 H)2) NaCI CuCI2 ZnO ZnCI2.4(Zn(OH)2)

101 0·030 83 6 9 1 1
102 0·03P 83 6 8 2 1
144 0·2Sn 82 7 9 1 1
523 5Sn 82 6 9 2 1
548 2·5Zn 78 7 14 1 1
203 10Zn 65 6 16 9 5
207 30Zn 16 73 11
801 3Si-1Mn 67 33
905 18Ni-25Zn 5 95
912 25Ni 100

Br. Corros. J., 1990, Vol. 25, NO.4

276 Sterling et at. Accelerated atmospheric corrosion of copper

Table 8 Weight loss* and penetration for as received and acid cleaned specimens exposed to
neutral salt spray at 80°C

Acid cleaned As received

Alloy ~w, g 6.W,g Penetrationt, Ilm 6.W,g Penetrationt, Ilm ~ Was received - 6. Wacid, g

101 0·016 0·611 4·6 0·690 5·2 0·079

102 0·012 0·436 3·3 0·597 4·5 0·161
144 0·015 0·625 4·7 0·780 5·8 0·155
523 0·010 0·631 4·7 0·779 5·8 0·148
548 0·011 0·778 5·8 0·865 6·4 0·087
801 0·012 0·546 4·1 0·563 4·2 0·017
203 0·014 0·657 4·9 0·646 4·8
207 0·037 0·940 7·0 0·876 6·6
912 0·002 0·272 2·0 0·147 1·1
905 0·010 0·021 0·16 0·043 0·32
926 0·004 0·025 0·19 0·029 0·22

* 6. w = weight loss during acid cleaning; ~ W = weight loss during test.

t Calculated assuming uniform corrosion.

in the as received condition was observed to be the same as
that for the specimens already acid cleaned. This indicates
that no significant corrosion product was present on the
surface of the as received specimens. Second, the differ-
ences between the weight losses in the two conditions are,
in almost all cases1 much larger than those due to acid
cleaning.
These observations that the corrosion rate of some as
received samples was greater than that of the correspond-
ing acid cleaned samples support the suggestion of
Moreton! that the corrosion rate can be increased by
residual contaminants from rolling, and indicate that this is
an area where more systematic work is required.
Alloys 101, 102, 144, 203, 523, 548, and 801 showed
essentially the same corrosion rate; the average weight loss
for these alloys was 0·61 ± 0·10 g, which corresponds to a
penetration of 4·6 (.tm, in the acid cleaned condition and
o·70 ± 0·11 g, which corresponds to a penetration of
5·2 (.tm,for the as received condition.
The 70-30 brass (207) showed a somewhat higher corro-
sion rate due to dezincification. The corrosion rate of 75-
25 cupronickel was less than half that shown by the alloy
group listed above, whereas the nickel silvers (905 and
926) have corrosion rates whi.ch are slower by a factor of
30 and also lower by at least a factor of 13 than those of the
high purity coppers.
As noted above, alloys 101, 102, 144, 203, 523, 548, and
801 have similar corrosion rates, which correlate, for all
except 801, with similar corrosion products (Table 7),
composed of mainly cuprous oxide, some cupric oxide,
and some basic copper chloride. However, the corrosion
product on alloy 801 is made up of cuprous oxide and basic
copper chloride only.
Dezincification occurs" with 70-30 brass, producing
different corrosion products and a higher corrosion rate.
The alloys with lower corrosion rates, 912, 905, and 926,
have corrosion products containing very high concentra-
tions of basic copper chlorides, indicating that these may
provide better protection, at least in the present short term
tests. The lowest corrosion rates were observed for the
nickel silvers, which had corrosion products containing
95% basic copper chloride and 50/0 cuprous oxide - a
mixture that proved to be particularly protective in these
tests.
RELATION TO ATMOSPHERIC CORROSION
The corrosion rate data, specifically Tables 5 and 8, reveal
a picture of copper corrosion consistent with the
literature2-6 related to atmospheric corrosion; in general,
alloying does not decrease the corrosion rate of copper
alloys; there are alloys with corrosion rates higher than
those of pure copper (in particular 70-30 brass, which
exhibited dezincification) and there do exist alloys with
corrosion rates lower than those of pure copper. One
interesting development from the present work is the very
good performance of nickel silvers (alloys 905 and· 926),
the corrosion rates for which were smaller by a very
significant factor than those of high purity coppers.
Nickel silvers have also been observed by Herman and
Castillo,7 in a study lasting 4 years, to corrode in marine
atmospheres at a rate substantially (by a factor of 7) lower
than that of coppers, but to undergo dezincification, with
an accompanying corrosion rate higher. than that of
coppers, during exposure to industrial atmospheres. Holm
and Mattsson3 also observed that nickel silvers showed
corrosion rates somewhat lower than those of pure
coppers during 16 years' exposure to .marine atmospheres
and somewhat higher corrosion ~rates\vhenexpose9, ~o..an
industrial atmosphere; in this study no dezincification was
observed in either atmosphere. By contrast, in their 20
year exposure tests, Scholes and Jacob8 found that nickel
silvers showed higher corrosion rates than coppers in both
marine and industrial atmospheres and also observed:
dezincification in both environments. .
The conclusions of this comparison between the present
study and the literature3,7,8 suggests that nickel silvers
have corrosion rates lower than those of high purity
coppers for 'short term' exposure (less than 16 years) to
marine environments and that dezincification leads to
higher corrosion rates for nickel silvers exposed to indus-
trial environments, indicating scope for the development
of an inhibited form of nickel silver. It should also be
noted that the work of Castillo and Popplewe1l9 has indi-
cated that nickel silvers are susceptible to transgranular
stress corrosion cracking during exposure to marine
atmospheres.
The observations that 70-30 brass exhibited a corrosion
rate higher than that of pure coppers is in disagreement
with the observations of Herman and Castillo.? In their
tests the corrosion rafeof 7(f-30 brass was lower than
those of pure coppers during exposure to marine atmos-
pheres for 4 years, although dezincification was observed,
in agreement with the present study. In contrast, Holm
and Mattsson3 observed that 70-30 brass showed a corro-
sion rate higher than those of pure coppers during 16 year
exposure tests in a marine atmosphere; dezincification was
also reported. Scholes and Jacob8 have observed dezincifi-
cation in 70-30 brass and corrosion rates comparable to
those of high purity. coppers during 20 year exposure tests
in marine and industrial environments.
Thus, on balance, the present observations of dezincifi-
cation in 70-30 brass, together with corrosion rates higher

Br. Corros. J., 1990, Vol. 25, No.4


than those of high purity coppers, would be expected
during long term atmospheric exposure on the basis of the
literature evidence. For such applications therefore an
inhibited alloy is to be preferred.
Similarities also exist between the products of atmos-
pheric corrosion and the sequence in which corrosion
products formed and covered the surfaces of the speci-
mens in the present accelerated atmospheric corrosion
tests. For alloys 101, 102, 144, 203, 523, 548, and 801 the
following sequence was observed in the neutral salt spray
tests:
(i) the specimen loses its metallic lustre as the first
corrosion products cover the surface
(ii) an increasing fraction of the surface becomes
reddish brown
(iii) areas of the surface become black
(iv) areas become covered with a green corrosion
product patina.
The observations in the acidified salt spray tests are consis-
tent with a similar sequence. Although the above sequence
was followed, differences in detail were found between
individual alloys; for example, the time of observation of
the first black colour or patina. In particular, for alloys
101, 102, 144, and 523 the relative area covered with
reddish brown or black corrosion product was significantly
different at the end of 10 cycles of the neutral salt spray
test. Since the analysis of the corrosion products for these
alloys under this condition showed a constant compo-
sition, it must be concluded that both the reddish brown
and the black areas correspond to cuprous oxide. This is
substantiated by the fact that no reddish brown or black
areas were observed on alloy 207 and no cuprous oxide
was detected by the X-ray analysis. The different appear-
ances and colours of the same compound may have various
causes: differences in optical properties due to differences
in oxide thickness is the most obvious.
The sequence of corrosion products observed in the
present tests corresponds to the sequence on coppers
exposed to the atmosphere. 3--5,7.8.10 In atmospheric corro-
sion of essentially pure copper, cuprous oxide first forms.
This is subsequently converted to a green patina, the
composition of which depends on the composition of the
atmosphere; in marine environments the patina consists of
basic copper chlorides.3--5,10The process. of atmospheric
patina formation on copper takes a considerable time, up
to 70 years, and during this time the corrosion rate
decreases as the patina becomes more protective. The
present observations reveal that the same pattern of corro-
sion product formation occurs on alloys 101, 102, 144,203,
523, 548, and 801, except that patina formation begins in
the present tests much earlier than during atmospheric
corrosion. Two deductions can be made: first, the neutral
salt spray test is useful in giving accelerated indications
concerning atmospheric corrosion; second, since alloys
101, 102, 144, 203, 523, 548, and 801 had essentially the
same corrosion rate in the neutral salt spray, it is likely
that these alloys will also have similar atmospheric corro-
sion rates in humid marine environments. This indicates
that there is no significant beneficial effect with respect to
atmospheric corrosion in alloying copper with phosphorus,
tin, zinc, or silicon.
It is interesting to note that the alloys with the lowest
corrosion rates, 905, 912, and 926, have corrosion prod-
ucts containing very high concentrations of basic copper
chlorides, similar to the naturally occurring patina on
coppers. The corrosion products on these would thus be
expected to offer reasonable protection against further
corrosion, as was in fact observed to be the case. This
implies that patina formation on these alloys can be rapid
compared with the times required for higher purity
coppers.
The question of the relationship between atmospheric
Sterling et al. Accelerated atmospheric corrosion of copper 277
corrosion and accelerated tests is an important practical
one. The tests in the present study use a variety of means
to provide an acceleration of the corrosion mechanism
compared with atmospheric corrosion. All three tests
included NaCI as the atmospheric contaminant, as would
be expected for atmospheric corrosion in humid marine
regions. Both the acidified salt spray test and the neutral
salt spray test contained NaCI concentrations much higher
than would be expected in atmospheric corrosion. The
D
neutral salt spray test had a temperature of 80 C, which is
also greater than that during ambient atmospheric expo-
sure. However, when operating radiators are considered,
80 C is not a particularly elevated temperature, and the
D
radiator operating temperature cycle is the chief feature of
the GM test. The results of the present study imply a
relationship between atmospheric corrosion and the
neutral salt spray test. This relationship is not so clear for
the acidified salt spray test. Moreover, the low pH values
used in this test probably occur seldom in atmospheric
corrosion, leading to greater doubts about the validity of
this test with respect to atmospheric corrosion. The GM
test proved to be very mild, so that no comment can be
made concerning its relationship with atmospheric
corrosion.
The literature reveals that the corrosion rate of coppers
exposed to humid marine environments is both time and
locality dependent. Typical reported values from long
term tests are 0·6-1·2 (Ref. 8),1·1-2·1 (Ref. 10), 2·2-3'2
(Ref. 9), 2·1-2·6 (Ref. 7), and 0·5-0·9 (Ref. 2) I-tm/year.
These values give an average corrosion rate of 1·7 Ilm/
year, which is to be compared with an average penetration
rate of 0·44 I-tm/(24 h cycle) measured for exposure of
alloys 101 and 102 to the neutral salt spray at 80 C. ThisD
provides a calibration relating four 24 h salt spray cycles to
1 year's atmospheric corrosion. This calibration must be
used with caution, as it is only expected to provide an
indication of the relative severity of the neutral salt spray
test and should not be used as a numerical predictor of
lifetime for specific components. Moreover, the corrosion
rates taken from the literature exhibit a range of values
differing by over a factor of five, and consequently a
similar factor must be inherent in the relationship between
the accelerated test results and atmospheric corrosion.
On the basis of this comparison, the maximum pit
depths recorded are not unreasonable compared with the
values observed by Scholes and Jacob8 during 20 year
exposure tests in a marine environment, when it is taken
into account that pit growth rate decreases with time.
CONCLUSIONS
1. Of the three atmospheric corrosion tests applied to
copper and some copper alloys, the GM test involving
neutral salt spray with thermal cycling was less aggressive
than the acetic acid salt spray (ASTM B289-1980) or
neutral salt spray at 80 C (ASTM Bl17"'::1979)tests.
D
2. The sequence of corrosion product formation on
specimen surfaces during exposure to the neutral salt spray
test was very similar to that on specimens exposed to
natural atmospheres, thus indicating that this test can be
used to give accelerated indications of corrosion to be
expected in humid marine regions. It is suggested that four
24 h salt spray cycles are approximately equivalent to 1
year's exposure to such an atmosphere.
3. The corrosion products formed under all three test
conditions were only partially protective~ but basic copper
chlorides were more protective than copper oxides.
4. Tough pitch copper, phosphorus deoxidised copper,
Cu-Sn alloy (as used in radiator fins), phosphor bronze,
coinage brass, 90-10 brass, and silicon bronze all showed
essentially the same corrosion rates in the neutral salt
spray test, indicating that these alloys will have similar
atmospheric corrosion rates and that no improvement in
Br. Corros. J., 1990, Vol. 25, NO.4
278 Sterling et al. Accelerated atmospheric corrosion of copper

atmospheric corrosion resistance is achieved by alloying testing were supplied by Austral Bronze Crane Copper
with phosphorus, tin, zinc, or silicon. Ltd.
~5. The 70-30 brass exhibited dezincification in both the
acidified salt spray and neutral salt spray tests, giving REFERENCES
corrosion products that were quite different from those on 1. B. MORETON: International Copper Research Association
the other alloys. Inc., Potters Bar, personal communication, 1987.
6. The nickel silvers (12 and 18%Ni) exhibited very low 2. E. G. WEST: 'Copper and its alloys'; 1982, Chichester, Ellis
corrosion rates - compared with the other alloys - and this Horwood.
behaviour is proposed to be associated with the rapid 3. R. HOLM and E. MATTSSON: in 'Atmospheric corrosion in

formation of a patina containing a high proportion of basic
copper chloride.
7. Six of the 11 coppers and copper alloys had a slightly,
but statistically significantly, higher corrosion rate for
specimens tested in the as received condition, this effect
being attributed to residual contaminants from rolling
treatments.
ACKNOWLEDGMENTS
This work was supported by the International Copper
Research Association Inc., as part of project 391, 'Exter-
nal corrosion of copper/brass radiators'. Materials for
metals', STP767, 83; 1982, Philadelphia, PA, ASTM.
4. w. H. J. VERNON: J. Inst. Met., 1932,49, 153.
5. w. H. J. VERNON and L. WHITBY: J. Inst. Met., 1929,42, 181;
1930,44, 389.
6. L. L. SHREIR (ed.): 'Corrosion', 2nd edn, Vol. 1,1:150-1:167;
1976, London, Butterworth.
7. R. S. HERMAN and A. P. CASTILLO: in 'Corrosion in natural
environments', STP558, 82; 1974, Philadelphia, PA, ASTM.
8. I. R. SCHOLES and w. R. JACOB: Proc. Conf. on 'Copper and its
alloys', 330; 1970, London, The Institute of Metals.
9. A. P. CASTILLO and J. M. POPPLEWELL: in 'Atmospheric corro-
sion in metals', STP767, 60; 1982, Philadelphia, PA, ASTM.
10. L. P. COSTAS: in 'Atmospheric corrosion in metals', STP767,
106; 1982, Philadelphia, PA, ASTM.

Advances in Physical Metallurgy

A collection of invited papers to mark the 70th birthday year of Professor
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• Radiation Damage and Point Defects • Strengths of Grain Boundaries in Pure Metals
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