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Effects of De-Icing Agents (Magnesium Chloride and Sodium Chloride) on Corrosion of Truck Components

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Effects of De-Icing Agents (Magnesium Chloride and Sodium Chloride) on Corrosion of Truck Components Report No. CDOT-DTD-R-1000-lO Final Report Effects of De-Icing Agents (Magnesium Chloride and Sodium Chloride) on Corrosion of Truck Components Prof. Yunping Xi Patricia J. Olsgard November 2000 COLORADO DEPARTMENT OF TRANSPORTATION RESEARCH BRANCH Effects of De-Icing Agents (Magnesium Chloride and Sodium Chloride) on Corrosion of Truck Components by Principal Investigators Prof. Yunping Xi University of Colorado at Boulder and Patricia J. Olsgard Western Highway Institute Report No. CDOT-DTD-R-OO-IO Final Report Prepared by Colorado Department of Transportation Research Branch November 2000 Colorado Department of Transportation Research Branch 420 1 E. Arkansas Ave. Denver, CO 80222 (303) 757-9506 Technical Report Documentation Page 1. Report No. 2. Government Accession No. 3. Recipient's Catalog No. CDOT -DTD-R-2000-10 4. Title and Suotitle S. Report Date Effects of De-Icing Agents (Magnesium Chloride and Sodium Chloride) on November 2000 Corrosion of Truck Components 6. Performing Organization Code 7. Author(s) 8. Performing Organization Report No. Prof. Yunping Xi, University of Colorado at Boulder Patricia 1. Oisgard, Western Highway Institute 9. Perfonning Organization Name and Address 10. Work Unit No. (TRAIS) University or Colorado at Boulder Western Highway Institute 11. Contract or Grant No. 12. Sponsoring Agency Name and Address 13. Type of Report and Period Covered Colorado Department of Transportation 4201 East Arkansas Avenue Final Report Denver, Colorado 80222 14. Sponsoring Agency Code 15. Supplementary Notes Prepared in cooperation with the U.S. Department of Transportation, Federal Highway Administration 16. Abstract Colorado DOT has been using MgCl2 for anti-icing and deicing for several years. Some concerns have surfaced that the chemicals may affect various components of cars and trucks. In this experimental study carried out at the Materials Laboratory at CU-Boulder, representative metals were selected from the automobile industry to compare their corrosion behaviors under exposures to deicing salts NaCI and MgCh. Both reagent grade MgCh and the MgCh used by CDOT (which contains a corrosion inhibitor) were used in the testing process. Two testing methods were applied to the selected metals: SAE 12334 (an accelerated cyclic test); and, ASTM B 117 (a continuous spraying test). The testing environment of SAE 12334 provided cyclic exposure, which is a better simulation of actual service conditions. While CDOT specifications state that magnesium chloride must be 70% less corrosive than sodium chloride, experimental results obtained by SAE J2334 indicated that MgCl2 is more c011"osive than NaCl to the bare metals tested. Corrosion varied from only slight differences for some metals to 13 time more corrosion for SS41O. The experimental results from ASTM B 117 showed inconsistencies when compared with thc results of SAE 12334, especially for the stainless steel SS41O, for which NaCI is more corrosive than MgCI2• The experiment also indicated that the mixture of MgCl2 and NaCl caused slightly more corrosion to the metals than either single salt (either MgCh or NaCl) on three of the four metals tested does. This implies that there are coupling effects between the two chlorides to the corrosion of the metals. Implementation Deicers provided by vendors should be monitored independently by CDOT for chemical characteristics. Any significant changes in processing or source material should be disclosed by the vendor. Colorado-based specifications, specifically with respect to corrosion inhibitors must be strictly adhered to. Because mild steel was not included in this research study, further implementation of findings from this report will be delayed until an additional study on the con'osive effects of magnesium chloride on mild steel is completed. 17. Key Word!; 18. Distribution Statement Environment, Winter Maintenance, Deicing, Magnesium No restriction. This document is available to the public through: Chloride, Sodium Chloride, Corrosion National Technical Information Service 5825 Port Royal Road Springfield, Virginia 19. Security Classlf. (of this report) 20. Security Classif. (of this page) 21. No. of Pages 22. Price None None 78 Table of Contents Section I: Introductioll Page 1.1 Background I 1.2 Overview of Study 2 1.3 Theory of Metal Corrosion 2 1.4 Mechanisms of the Corrosion of Metallic 3 Materials Caused by Deicing Salts Section ll: Research Procedures, Methods and Results 2.1 Corrosion Testing Methods Used in Project 5 2.2 Experiment Materials 8 2.3 Equipment 10 2.4 Field Testing Procedures 10 Section m: Experimental Results and Discussion 3.1 Cyclic Exposure Test by the SAB J2334 Method 14 3.2 Continuous Spray Test by the ASTM BI17 Method 18 3.3 Comparison of the Cyclic Exposure Test 19 and the Continuous Spray Test 3.4 Corrosion of Copper Tubes 19 3.5 In-service Tests 22 3.6 Chemical and Microscopic Analyses 24 3.7 Corrosion induced by MgCI2 27 3.8 Conclusions from Experimental Testing 28 Section IV: Survey of Colorado Tnll:king Companies 4.1 Overview of Survey 30 4 .2 Survey Results 30 "Section V: Literature Review and Secondary Information 5.1 Information from Other States 33 5.2 Literature Review/ Research on Automotive Corrosion 39 5.3 Research Summary of Deicer Studies 42 5.4 ASTM Standards on Corrosion Testing 45 5.5 Accelerated Corrosion Test Methods in the Automobile Industry 46 Section VI: Conclusions & Recommendations for Future Study 6.1 Conclusions 52 6.2 Recommendations for Future Study 54 Appendices: Appendix I: Tabulated Data 56 Appendix 2: Additional Corrosion Photos 62 Appendix 3: Trucking Company Survey 73 Appendix 4: References 75 Appendix 5: Trucking/State Contacts 77 Appendix 6: Research Team 78 Abstract Colorado DOT has been using MgCh for anti-icing and deicing fur several years. Some concerns have surfaced that the chemicals may affect various components of cars and trucks. In this experimental study carried out at the Materials Laboratory at CU-Boulder, representative metals were selected from the automobile industry to compare their corrosion behaviors under exposures to deieing salts NaCI and MgCh. Both reagent grade MgCh and the MgCh used by CDOT (which contains a corrosion inhibitor) were used in the testing process. Two testing methods were applied to the selected metals: SAE J2334 (an accelerated cyclic test); and, ASTM B117 (a continuous spraying test). The testing environment of SAE J2334 provided cyclic exposure, whieh is a better simulation of actual service conditions. Experimental results obtained by SAE 12334 indicated that MgCh is more corrosive than NaCI to the bare metals tested. The experimental results from ASTM B117 showed inconsistencies when compared with the results ofSAE J2334, especially for the stainless steel SS410, for which NaCI is more corrosive than MgCh. The experiment also indicated that the mixture ofMgCh and NaCI caused more severe corrosion to the metals than any single salt (either MgCh or NaCl) does. This implies that there are coupling effects between the two chlorides to the corrosion of the metals. Executive Summary The Colorado Department of Transportation (CDOT) uses liquid magnesIUm chloride (MgCI2) in several areas of Colorado as both an anti-icing and a deicing agent. Magnesium chloride is used in the Denver metro area, 1-70 west through Glenwood Springs and a few other spots where meeting air-born particulate standards is a problem. In conjunction with, and instead of magnesium chloride, CDOT also uses a dry mixture of sodium chloride (NaCl) &"1d sand (5-10%). The sand salt mixture is used when it is too cold for magnesium chloride to effectively melt snow and ice. Trucking companies expressed concern that the use of magnesium chloride has caused increased vehicle maintenance costs. Because of the nature of the industry, trucks often travel the same route on a daily basis, and subsequently encounter a high level of chemical deicers. To investigate whether the perception that magnesium chloride damages trucks is widespread, a survey was sent to over 150 Colorado trucking companies. Seventy-two percent of the respondents reported noticing increased wear on their equipment since Colorado began using rr~gnesium chloride. Companies reported the most damage to chrome, tractor or trailer bodies, aluminum parts, wheels, hoses and connectors, and electrical parts. The specific type of damage mentioned most often included corrosion, pitting, staining/tarnishing, discoloration, drying/cracking (hoses), and accelerated rust. The project started with an extensive literature review on the relevant information Based on the collected information, two experimental methods and several types of metal specimens were selected for the experimental program. Then, an experimental study was performed in the Materials Laboratory at CU-Boulder. Some of the specimens were also placed on trucks traveling in the state of Colorado. In this experimental study, representative metals were selected from the automobile industry to compare their corrosion behaviors under exposures to deicing salts NaCI and MgCh. Both reagent grade MgCh and the MgCh used by CDOT which contains a corrosion inhibitor w= used to test the metals. The metals tested included stainless steel 41 0 and 4L, aluminum 2024 and 5086. In addition to the metal coupons, coated coupons from automobile body sheets were also tested. Two testing methods were applied to the selected metals. One is SAE J2334, which is an accelerated cyclic corrosion test representing the in-service environments; and the other is ASlM B 117, which is a continuous spraying test representing a different corrosive environment and mechanism. For each of the two selected testing methods, two ~s (i.e., sodium chloride and magnesium chloride) were used as the corrosive medium, r~pectively. In order to examine the corrosiveness of the deicing salts to electrical components, an electrochemical test unit was devised, in which the difference in the corrosion potential of the copper specimens in the two chloride solutions were measured. The in-service exposure test was carried out on Colorado highways during the winter of 1999 to verify the results from the laboratory experiments.
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