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The purpose of this study was to determine the atmospheric corrosion behavior of aluminium (Al) exposed to the industrial and coastal environments of northeastern Arabian Peninsula for a period of 15 months.

The samples were exposed under atmospheric, underground and splatter zone conditions at the coastal region. Soil, groundwater, seawater and air particulate samples obtained from the exposure site were analyzed. Secondary electron microscopy was used to identify and study the microstructural features of the corrosion products formed at the surface of the test coupons. The corrosion rates of the samples were determined by the weight loss method.

The results showed that Al exhibited a moderate corrosion rate despite high degree of variation in temperature and humidity and large concentrations of chloride and sulfate in this region. Splatter zone environment was the most corrosive because of high chloride concentrations in seawater and the alternating wetting–drying cycles.

In this paper, corrosion of Al was evaluated in atmospheric, soil and splatter zone conditions along the northeastern coast of Arabian Peninsula and was also compared with the results of the test reported for other international locations.

The purpose of this paper was to determine the mode and cause of failure of polyester-coated galvanized corrugated steel sheets that exhibited degradation of the coating after seven months into service.

Visual inspection and light microscopy revealed the extent of damage exhibited by the panels. Standard metallographic techniques were used to prepare samples obtained from both unused and failed sections. Light microscopy, scanning electron microscopy combined with energy dispersive x-ray spectroscopy and x-ray diffraction techniques were used to study the surface morphology, microstructural features, elemental composition and structure of the samples.

The failure occurred in the form of delamination and blistering of coated layer. Presence of solar radiation, humidity and water retention resulted in loss of adhesion, leading to coating delamination and flaking especially at the top surface. The coating at the bottom surface of the panels showed evidence of blistering caused by water vapor differential that existed between the environment and the coating because of prolonged (four months) wet conditions that existed at the manufacturer’s site during storage.

It is recommended that the coated panels are stored in covered area where direct exposure to atmospheric conditions can be prevented. If open storage is unavoidable, then the use of tarpaulin or plastic sheet as covering and vapor-phase inhibitors was recommended.

This paper provides an account of failure analysis of metal sheet panels. It identifies the mode and cause of failure and also provides recommendations to avoid such occurrences in the future. The information contained in this paper is useful for plant engineers and project managers working in the metal sheet industry.