Interim Report on the Examination of Corrosion Damage in Homes Constructed with Imported Wallboard: Examination of Samples Received September 28, 2009

Since many household systems are fabricated out of metallic materials, changes to the household environment that accelerate corrosion rates will increase the frequency of failures in these systems. Recently, it has been reported that homes constructed with imported wallboard have increased failure rates in appliances, air conditioner heat exchanger coils, and visible corrosion on electrical wiring and other metal components. At the request of the Consumer Product Safety Commission (CPSC), the National Institute of Standards and Technology (NIST) became involved through the Interagency Agreement CPSC-1-09-0023 to perform metallurgical analyses on samples and corrosion products removed from homes constructed using imported wallboard. This document reports on the analysis of the first group of samples received by NIST from CPSC. The samples received by NIST on September 28, 2009 consisted of copper tubing for supplying natural gas and two air conditioner heat exchanger coils. The examinations performed by NIST consisted of photography, metallurgical cross-sectioning, optical microscopy, scanning electron microscopy (SEM), and x-ray diffraction (XRD). Leak tests were also performed on the air conditioner heat exchanger coils. The objective of these examinations was to determine extent and nature of the corrosive attack, the chemical composition of the corrosion product, and the potential chemical reactions or environmental species responsible for accelerated corrosion. A thin black corrosion product was found on samples of the copper tubing. The XRD analysis of this layer indicated that this corrosion product was a copper sulfide phase and the diffraction peaks corresponded with those for the mineral digenite (Cu9S5). Corrosion products were also observed on other types of metals in the air conditioner coils where condensation would frequently wet the metals. The thickness of the corrosion product layer on a copper natural gas supply pipe with a wall thickness of 1.2 mm ± 0.2 mm was between 5 μm and 10 μm. These results indicate that a chemical compound that contains reduced sulfur, such as hydrogen sulfide (H2S), is present in the environment to which these samples were exposed. The literature indicates that these species strongly influence corrosion rates of most metals and alloys even at low concentrations. None of the samples examined were failed components, and no evidence of imminent failure was found on any of the samples examined. All of the corrosion damage observed to date is consistent with a general attack form of corrosion that will progress in a uniform and relatively predictable manner. No evidence of localized attack was found, but these forms of attack typically require an incubation period before they initiate. Therefore, the number of samples examined to date is too small to draw a conclusion on the relative probability of these forms of corrosion being able to cause or not cause failure. Samples from failed systems or from laboratory tests conducted over a wide range of metallurgical and environmental conditions will be required to assess the probability of these other forms of corrosion causing failure.