Book

Corrosion Prevention by Protective Coatings (Munger) (1)

Topic
Corrosion-Resistant Zinc Coatings
From page 127 to 167
1. Which of the following is NOT a characteristic of metallic zinc coatings?
a. Highly reactive to atmospheric conditions
b. Forms a continuous and long-lasting barrier
c. Provides cathodic protection to steel
d. Relatively inert to atmospheric conditions

2. What is the primary advantage of using zinc coatings over other metals for protecting
steel surfaces?
a. Lower cost and high availability
b. Higher resistance to corrosion
c. Greater flexibility in application methods
d. Ability to form a thicker protective layer

3. Which method of applying zinc to steel involves dipping the steel into molten zinc?
a. Continuous line galvanizing
b. Electrogalvanizing
c. Hot dip galvanizing
d. Thermal spraying

4. What characteristic of zinc coatings allows for protection against rust for long periods
of time?
a. Rapid oxidation rate
b. High reactivity with atmospheric pollutants
c. Formation of a continuous and inert oxide film
d. Lower corrosion rate compared to steel

5. Which process involves adding a small amount of aluminum to the zinc bath to
produce a coating with good adhesion and ductility?
a. Hot dip galvanizing after fabrication
b. Continuous line galvanizing
c. Electrogalvanizing
d. Thermal spraying

6. Which of the following statements about electrogalvanized steel is true?

a. The coating weight ranges from 0.2 to 0.6 ounces per square foot.
b. It is generally applied as a thick film.
c. It is typically not painted due to its smooth surface.
d. Phosphatizing is used to prepare it for painting.
7. What is the purpose of phosphatizing in preparing electrogalvanized steel for
painting?
a. To increase the thickness of the zinc coating
b. To remove the zinc coating entirely
c. To smooth out spangled characteristics
d. To prepare the surface for better paint adhesion

8. Which method of applying zinc coatings is suitable for small parts such as nuts, bolts,
and small castings?
a. Sherardizing
b. Zinc plating
c. Zinc spraying
d. Electrode-position steel

9. What is a characteristic of zinc plating?

a. It is a continuous process.
b. The coating is typically alloyed.
c. It is applied as a batch process.
d. It is primarily used for large structures.

10. Which method of applying zinc coatings involves melting zinc in a spray gun and
projecting it onto a steel surface?
a. Sherardizing
b. Zinc plating
c. Zinc spray (thermal spray)
d. Zinc dust coatings

11. What is the purpose of heating the steel surface before applying thermal sprayed
zinc?
a. To increase the melting point of zinc
b. To accelerate the oxidation process
c. To improve the bond with the base metal
d. To decrease the viscosity of the zinc coating

12. Which method of flame spraying zinc involves an electrical current between two
wires causing the tips of the zinc wire to melt?
a. Plasma spraying
b. Arc spraying
c. Wire process spraying
 d. Gas-fed flame spraying

13. What is a significant advantage of zinc dust coatings?

a. They are only applicable to small structures.
b. They cannot be applied to existing structures.
c. They provide excellent corrosion protection for large or existing structures.
d. They are primarily used as a finish coat for galvanized steel.

14. In which decade was the concept of using zinc dust as an anticorrosive coating
conceived?
a. 1800s
b. 1900s
c. 1930s
d. 1950s

15. What was the primary material used with zinc dust coatings during the 1930s?
a. Phenoxies
b. Silicones
c. Drying oils
d. Chlorinated rubber

16. Which type of zinc-rich coating performed the best in seawater immersion tests?
a. Drying oil-type zinc-rich coating
b. Chlorinated rubber zinc-rich coating
c. Styrene-type zinc-rich coating
d. Epoxy zinc-rich coating

17. Which resin was primarily used in early commercial zinc-rich coatings?
a. Epoxy
b. Chlorinated rubber
c. Styrene
d. Polyurethane

18. What percentage of zinc by weight is generally required for particle-to-particle

contact in organic zinc-rich coatings?
a. 70-80%
b. 80-90%
c. 90-95%
 d. 95-100%

19. Which of the following is NOT a characteristic of organic zinc-rich coatings?

a. Compatibility with various surfaces
b. Limited cathodic protection
c. Inability to resist chemical reactions
d. Wide range of application conditions

20. Inorganic zinc coatings were first developed by whom?

a. Victor Nightingall
b. Mil-P-21035B
c. Mil-P-46105
d. Corps of Engineers

21. What was Victor Nightingall's primary goal in developing inorganic zinc coatings?
a. To create coatings resistant to mechanical shock
b. To simulate the chemical characteristics of zinc ores
c. To replace galvanizing
d. To increase the life expectancy of steel structures

22. Which type of zinc coating is credited with revolutionizing corrosion protection for
industrial and marine structures?
a. Epoxy zinc-rich coatings
b. Polyurethane zinc-rich coatings
c. Inorganic zinc coatings
d. Chlorinated rubber zinc-rich coatings

23. Which resin type provides chemical resistance in organic zinc-rich coatings?
a. Polyurethane
b. Epoxy
c. Chlorinated rubber
d. Silicones

24. Which zinc-rich coating type is mentioned as providing resistance in cold, humid
locations since the 1970s?
a. Epoxy esters
b. Polyurethanes
c. Chlorinated rubber
 d. Phenoxy resins

25. What aspect of surface preparation is often claimed to be less critical for organic
zinc-rich coatings compared to inorganic zinc coatings?
a. Removal of organic contaminants
b. Removal of rust
c. Elimination of surface imperfections
d. Application of primer coat

26. What was the key reason behind the effectiveness of the coating on the Morgan
Wyalla pipeline?
a. Direct immersion in water
b. Presence of carbon dioxide during the coating process
c. Use of red lead in the coating mixture
d. Application of zinc chloride solution

27. What was the main purpose of heating the completed iron goods in an oven after the
initial coating?
a. To dry the coating quickly
b. To dissolve excess zinc
c. To complete the chemical reaction and molecular combination
d. To remove any pickling deposits

28. What was the primary ingredient used in the coating mixture for the Morgan Wyalla
pipeline?
a. Sodium chloride
b. Zinc oxide
c. Sodium silicate
d. Carbon dioxide

29. How was the interior of the Morgan Wyalla pipeline coated?
a. By spraying a chemical mixture
b. By spinning a concrete lining
c. By applying a layer of red lead
d. By dipping the pipe in a zinc solution

30. What limitation did the stoving process have according to the text?
a. It was ineffective for large structures.
 b. It required excessive amounts of heat.
c. It couldn't be applied to offshore drilling platforms.
d. It didn't provide long-lasting protection against corrosion.

31. What was the objective of the early laboratory work in the United States regarding
zinc silicate coatings?
a. To study marine life's impact on coatings
b. To develop a cure for zinc silicate at ambient temperatures
c. To find alternatives to sodium silicate
d. To investigate the effects of different weather conditions on coatings

32. Which chemical was finally determined to be effective for post-curing the zinc silicate
coating?
a. Sodium bicarbonate
b. Zinc chloride
c. Phosphoric acid neutralized with an amine
d. Potassium silicate

33. What marked the beginning of the IOZ revolution according to the text?
a. Development of sodium silicate coatings
b. Use of red lead in coating mixtures
c. Discovery of dibutylamine phosphate as a post-cure material
d. Introduction of stoving as a curing method

34. What is one of the primary goals of research on IOZ coatings?

a. Increasing the complexity of product formulations
b. Developing coatings that require heat curing
c. Simplifying product application and development
d. Focusing solely on single-container products

35. Which of the following materials is NOT mentioned as a component of IOZ coatings?
a. Sodium silicate
b. Zinc oxide
c. Lithium silicate
d. Colloidal silica

36. What was a significant drawback of the zinc phosphate coating compared to other
developments?
 a. It lacked self-curing properties.
b. It required complex application procedures.
c. It was not effective in marine atmospheres.
d. It was overshadowed by other developments and had challenging application
processes.

37. Which type of silicate is primarily used in single-package IOZ systems?

a. Sodium silicate
b. Ethyl silicate
c. Potassium silicate
d. Lithium silicate

38. What is the primary role of silica in the formation of IOZ coatings?
a. Providing color to the coatings
b. Acting as a binder for zinc powder
c. Increasing the rate of corrosion on steel surfaces
d. Preventing the formation of zinc salts on the coating surface

39. What is the chemical reaction representing the normal corrosion of zinc, as stated in
the passage?
a. Zn + H2O + CO2 → ZnCO3 + H2
b. Zn + 2H2O → Zn(OH)2 + H2
c. Zn + 2NaCl + 3H2O → ZnOZnCl2 + 2NaOH + H2
d. Zn + H2O → Z++ + 2e—

40. What is the primary reason for the adhesion of IOZ coatings to steel surfaces?
a. Formation of zinc salts on the coating surface
b. Zinc reacting with silicic acid
c. Inclusion of potassium silicate in the coating
d. Absence of iron ions in the coating matrix

41. Which statement accurately reflects the process of IOZ coating reactions?
a. The coatings remain unchanged once applied to steel surfaces.
b. Different silicate types result in vastly different end products.
c. Silicate chemistry plays a minimal role in IOZ coating reactions.
d. All silicate types ultimately lead to the formation of a similar polymer of silicic
acid.
42. What is the significance of the "post-cured coating"?
a. It represents a breakthrough in self-curing properties.
b. It is the least effective type of IOZ coating.
c. It requires complex application procedures.
d. It is not affected by atmospheric conditions.

43. What is the ultimate effect of IOZ coatings on steel surfaces?

a. Formation of a weakly acidic film
b. Decrease in corrosion resistance
c. Formation of an inert film
d. Increase in corrosion protection

44. What is the primary purpose of the initial reaction in the formation of coatings based
on sodium or potassium silicate or ethyl silicate?
a. To neutralize acidic compounds on the metal surface
b. To create a metallic coating layer
c. To provide adherence between the coating and the metal surface
d. To initiate the formation of zinc carbonate

45. What occurs during the second stage of the reaction in the formation of zinc
coatings?
a. Formation of a solid, insoluble coating on the metal surface
b. Neutralization of sodium in the silicate solution
c. Deposition of zinc particles within the coating matrix
d. Continuing activity of carbonic acid on the coating

46. Which process is responsible for completing the formation of the zinc silicate matrix
within the coating?
a. Ionization of zinc within the coating
b. Reaction between zinc ions and silicic acid
c. Formation of zinc carbonate and zinc hydroxide
d. Neutralization of sodium by acid amine phosphate

47. What is the function of acid amine phosphate salt in the reaction process of post-
cured IOZ coatings?
a. Neutralizing sodium in the silicate solution
b. Enhancing the curing process of the coating
c. Providing adherence between zinc particles
d. Forming zinc and lead phosphates within the coating
48. Which factor significantly affects the drying phase of water-based inorganic zinc
coatings?
a. Temperature, relative humidity, and air movement
b. The concentration of sodium silicate solution
c. Presence of zinc ions on the metal surface
d. Ratio of silicate to alkaline metal in the coating

49. What is the primary purpose of dehumidification in tank lining work?

a. To accelerate the curing process of coatings
b. To control temperature during coating application
c. To reduce the humidity for effective water evaporation
d. To neutralize acidic compounds on metal surfaces

50. What reaction leads to the formation of a silica-oxygen-zinc polymer, which forms
the matrix of water-based inorganic zinc coatings?
a. Reaction between zinc ions and silicic acid
b. Neutralization of sodium in the silicate solution
c. Ionization of zinc and lead by acid phosphate
d. Insolubilization of the silicate matrix by zinc ions

51. Which factor contributes to the long-term saturation of the silicate polymer with zinc
in the coating?
a. Reaction with carbonic acid and moisture in the air
b. Presence of organic contaminants on the metal surface
c. Application of acid amine phosphate salt
d. Neutralization of sodium by acid amine phosphate

52. What is the primary difference between organic silicate coatings and water-based
self-cure products?
a. Application method
b. Composition of the coating
c. Reaction mechanism
d. Resistance to water

53. Which reaction leads to the initial insolubility of organic silicate coatings?
a. Evaporation of solvent
b. Hydrolysis of ethyl silicate
c. Polymerization of polysilicic acid
d. Formation of lithium carbonate
54. What is the purpose of incorporating metal ions in organic silicate coatings?
a. To improve initial cure
b. To enhance flexibility
c. To increase resistance to high temperatures
d. To prevent mud cracking

55. What role does lithium hydroxide play in lithium silicate-based coatings?
a. It reacts with carbon dioxide to form lithium carbonate.
b. It stabilizes the polymerization process.
c. It enhances resistance to water.
d. It prevents porosity in the coating.

56. Which of the following is NOT a vehicle additive used to improve inorganic zinc
coatings?
a. Trimethyl borate
b. Polyvinyl butyral
c. Ethylhexoic acid
d. Sodium hydroxide

57. What is the purpose of ethyl dimethylsiloxane in zinc-rich primer formulations?

a. To enhance flexibility
b. To prevent mud cracking
c. To improve adhesion
d. To increase corrosion resistance

58. Which patent describes the first zinc-rich paint modified with borosilicate?
a. U.S. Patent 3,392,130
b. U.S. Patent 2,649,307
c. U.S. Patent 3,730,746
d. U.S. Patent 3,412,063

59. What is the source of zinc dust used in the formation of inorganic zinc coatings?
a. Zinc ingots
b. Scrap die castings
c. Zinc dross
d. All of the above
60. What compound is formed during the distillation of zinc dust that can hydrolyze into
zinc hydroxide and ammonia?
a. Zinc oxide
b. Zinc chloride
c. Zinc nitride
d. Zinc sulfate

61. What effect does the hydrolysis of zinc nitride have on inorganic zinc coatings?
a. It enhances adhesion.
b. It improves flexibility.
c. It increases resistance to high temperatures.
d. It aids in insolubilization and curing.

62. What is the primary reason for the use of desiccating packages of silica gel in zinc
containers?
a. To absorb ammonia gas
b. To prevent the reaction of zinc nitride with moisture
c. To increase the graininess of the zinc-silicate solution
d. To facilitate the mixing process of zinc with the silicate liquid

63. Which grade of zinc dust is primarily used in single-packaged systems for improved
suspension?
a. Regular coating grade
b. Intermediate grade
c. Superfine grade
d. Course grade

64. How is zinc dust manufactured?

a. By chemical precipitation
b. By reduction of zinc oxide
c. By distillation process
d. By electrolysis

65. What is the purpose of incorporating lead oxide (red lead) into inorganic zinc
coatings?
a. To improve corrosion resistance
b. To regulate the speed of the reaction
c. To reduce the porosity of the film
d. To change the color of the coating
66. Why have chromates generally been removed from water-based IOZ products?
a. Due to their high cost
b. Due to their toxicity and environmental concerns
c. Due to their ineffectiveness in preventing corrosion
d. Due to their adverse effect on coating hardness

67. Which pigment is added to IOZ coatings to attempt to add decorative character to
the coating?
a. Iron oxide
b. Lead oxide
c. Chrome oxide
d. Black pigment

68. What is the purpose of adding inert pigments to zinc dust in coatings?
a. To increase coating toughness
b. To improve adhesion to the substrate
c. To enhance color vibrancy
d. To reduce the viscosity of the coating

69. Which inert pigment is widely acclaimed for use with IOZ coatings and can substitute
for zinc?
a. Asbestos fiber
b. Mica
c. Di-iron phosphide
d. White Portland cement

70. Why is di-iron phosphide pigment commonly used in zinc coatings for the automotive
industry?
a. To improve color vibrancy
b. To reduce porosity
c. To enhance weldability
d. To increase corrosion resistance

71. What is the primary characteristic of di-iron phosphide pigment that makes it
suitable for use in zinc coatings?
a. High conductivity
b. High tensile strength
c. Low density
d. High reflectivity
72. What is one of the main advantages of including di-iron phosphide in primer
formulations for spot welding in the automotive industry?
a. Improved adhesion
b. Reduced electrode wear
c. Faster drying time
d. Increased corrosion resistance

73. What is the nugget size range achieved after 2,000 consecutive spot welds with a
primer containing 40% di-iron phosphide and 60% zinc?
a. 0.46 to 0.56 cm
b. 0.61 to 0.69 cm
c. 0.18 to 0.22 in
d. 0.02 to 0.06 in

74. What is the purpose of using IOZ preconstruction primers in steel fabrication?
a. To increase steel hardness
b. To reduce steel conductivity
c. To provide a corrosion-free surface
d. To enhance steel flexibility

75. Which type of zinc-based preconstruction primer is suitable for warm steel
application but not recommended for cold steel under highly humid conditions?
a. Water-based inorganic
b. Solvent-based inorganic
c. Organic-based zinc-rich
d. Water-based epoxy/acrylic

76. What is a characteristic of water-based high-ratio potassium silicate (WB HRZS) IOZ
preconstruction primers?
a. They require airless spray guns for application.
b. They have a longer duration of full protection compared to other types.
c. They react with metallic gun parts, causing gun plugging.
d. They contain a high amount of VOC emissions.

77. What is the primary difference between full thickness IOZ coatings and IOZ
preconstruction primers?
a. Application method
b. Zinc concentration
c. Film thickness
 d. Corrosion resistance

78. Which statement about electrode wear reduction is supported by the text?
a. Electrode wear decreases electrical current density.
b. Electrode wear increases weld strength.
c. Electrode wear is primarily caused by copper vapor.
d. Including di-iron phosphide in primer formulations can reduce electrode
wear.

79. What is a benefit of using IOZ preconstruction primers with a light color?
a. They provide better corrosion resistance.
b. They improve welding speed.
c. They enhance visibility during fabrication work.
d. They increase surface hardness.

80. Which factor does not influence the choice between types of zinc-based
preconstruction primers?
a. Surface preparation method
b. Application equipment
c. Steel temperature during application
d. Welding technique

81. What is the purpose of the IOZ preconstruction primer's low DFT (dry film thickness)?
a. To increase coating durability
b. To minimize coating's influence on welding and cutting speeds
c. To enhance adhesion to steel
d. To improve corrosion resistance

82. What is a key advantage of single-package inorganic zinc coatings over two-package
inorganic zinc products?
a. Lower cost
b. Higher durability
c. Faster drying time
d. Greater ease of handling

83. In single-package inorganic zinc coatings, what initiates the reaction with
atmospheric moisture after application?
a. Zinc particles
 b. Solvent base
c. Amine
d. Organic polysilicate vehicle

84. Which of the following is NOT mentioned as a benefit of using 1-nitropropane in the
formulation of single-package inorganic zinc coatings?
a. Control of gas evolution
b. Enhanced hydrogen scavenging
c. Prevention of settling characteristics
d. Improved paint stability

85. In the context of inorganic zinc coatings, what is the role of metallic aluminum and
metallic magnesium?
a. Provide color pigmentation
b. Form a cathodic surface over steel
c. React with silicic acid to form a protective film
d. Act as a substitute for zinc in corrosion resistance

86. What distinguishes inorganic zinc coatings from galvanizing?

a. Chemical compound bonding
b. Use of metallic zinc
c. Resistance to acid atmospheres
d. Formation of continuous zinc layer

87. Which statement regarding the comparison of IOZ coatings and galvanizing is true?
a. Galvanizing provides longer life span under most conditions.
b. IOZ coatings react more rapidly to acid atmospheres than galvanizing.
c. Galvanizing involves a chemical compound of iron and silica.
d. IOZ coatings offer controlled reactivity and conductivity.

88. How does the reactivity of metallic zinc in inorganic zinc coatings compare to that in
galvanizing?
a. Metallic zinc in galvanizing is less reactive.
b. Metallic zinc in galvanizing is completely inert.
c. Metallic zinc in inorganic zinc coatings is more reactive.
d. Metallic zinc in inorganic zinc coatings is chemically identical to that in
galvanizing.
89. Which property of inorganic zinc coatings contributes to their abrasion resistance?
a. Malleability of zinc particles
b. Rock-like character of zinc silicate matrix
c. Reactivity with atmospheric moisture
d. Formation of continuous zinc layer

90. What is one of the most significant properties of inorganic zinc (IOZ) coatings?
a. High gloss finish
b. Low chemical resistance
c. Poor adhesion to steel
d. Cathodic protection

91. Which of the following statements about the weather resistance of IOZ coatings is
true?
a. They are highly affected by ultraviolet radiation.
b. They tend to chalk and degrade over time.
c. They remain intact and unchanged even after many years of exposure.
d. They are susceptible to fungal growth.

92. What is a significant advantage of IOZ coatings over organic coatings in terms of
shrinkage?
a. They shrink parallel to the surface.
b. They bridge pits and cavities effectively.
c. They crack easily when applied too thick.
d. They do not shrink upon drying or curing.

93. IOZ coatings are generally recommended for temperatures up to:

a. 500°F
b. 750°F
c. 1000°F
d. 1500°F

94. Which of the following chemicals can IOZ coatings withstand continuous exposure
to?
a. Ketones and chlorinated hydrocarbons
b. Water-based solvents
c. Aromatic hydrocarbons
d. Gasoline and jet fuel
95. What is a notable characteristic of IOZ coatings regarding radiation resistance?
a. They degrade significantly under gamma ray bombardment.
b. They are sensitive to neutron bombardment.
c. They have shown failure in radiation tests.
d. They remain unaffected even under high levels of atomic radiation.

96. IOZ coatings have excellent friction characteristics, making them suitable for:
a. Lubricating joints in steel structures
b. Providing smooth surfaces in industrial environments
c. Coating faying surfaces in structural steel
d. Enhancing corrosion in marine atmospheres

97. Which property of IOZ coatings is particularly beneficial in areas of severe abrasion,
such as ship hulls?
a. Low friction coefficient
b. High gloss finish
c. Abrasion resistance
d. High chemical reactivity

98. IOZ coatings are resistant to burning and fire due to their:
a. Organic nature
b. Susceptibility to combustion
c. Inorganic nature
d. Low melting point

99. Where are IOZ coatings commonly used to provide fire resistance?
a. Rocket launching structures
b. Petroleum storage tanks
c. Industrial chimneys
d. Electrical appliances

100.What is one of the primary concerns when welding galvanized steel?

a. Reduction of weld strength due to zinc inclusions
b. Health problems for welders due to fumes
c. Difficulty in achieving high-speed production welding
d. All of the above
101.According to the tests conducted by Battelle Memorial Institute, what were the
conclusions regarding welding IOZ coated steel?
a. Reduction of weld strength compared to bare plate
b. Health hazards for welders due to increased zinc oxide in the air
c. Welds with equivalent strength to uncoated steel are achievable
d. Welding speed is significantly affected by IOZ coatings

102.What was the concentration of zinc, iron, and lead in the air during welding,
according to the recommended threshold limits?
a. Zinc: 0.5 mg/m3, Iron: 0.2 mg/m3, Lead: 1.5 mg/m3
b. Zinc: 5 mg/m3, Iron: 0.2 mg/m3, Lead: 15 mg/m3
c. Zinc: 0.05 mg/m3, Iron: 0.7 mg/m3, Lead: 0.1 mg/m3
d. Zinc: 0.005 mg/m3, Iron: 3.7 mg/m3, Lead: 0.09 mg/m3

103.Which specification covers weld-through IOZ primers?

a. SSPC-Paint 20
b. AASHTO M300
c. Canadian Specification 1-GP-171
d. SSPC-Paint 30

104.What is the primary advantage of using IOZ coatings as base coats according to the
text?
a. They provide longer and better protection compared to other coatings.
b. They are cheaper than other types of coatings.
c. They are easier to apply than other coatings.
d. They do not require any additional topcoat application.

105.What is the coefficient of friction for galvanized surfaces?

a. 0.52
b. 0.47
c. 0.25
d. 0.06

106.Which type of zinc-rich coating is suitable for application in areas with high humidity
and relatively cooler temperatures?
a. Type 1-A
b. Type 1-B
c. Type 1-C
d. Type 2
107.Which type of zinc-rich coating is most effective for interior applications in tanks and
tankers under warm or hot climatic conditions?
a. Type 1-A
b. Type 1-B
c. Type 1-C
d. Type 2

108.Which zinc-rich coating type is primarily solvent-based and effective under cold,
highly humid conditions?
a. Type 1-A
b. Type 1-B
c. Type 1-C
d. Type 2

109.What is the primary advantage of using a modified IOZ primer (Type 1-C) over other
coatings?
a. Improved application properties
b. Smooth film formation
c. Easy and rapid overcoating
d. All of the above

110.In the "V" type test described in the text, what does the area of the "V" indicate?
a. Degree of corrosion protection provided by the coating
b. Thickness of the applied coating
c. Adhesion strength of the coating
d. Rate of coating degradation over time

111.Which type of zinc-rich coating is classified under SSPC Type 2?

a. Type 1-A
b. Type 1-B
c. Type 1-C
d. Type 2

112.What is the primary difference between inorganic topcoats and IOZ primers?
a. IOZ topcoats contain metallic zinc, while IOZ primers do not.
b. IOZ primers are water-based, while inorganic topcoats are organic-based.
c. IOZ topcoats provide better corrosion resistance than IOZ primers.
d. There is no significant difference between IOZ primers and inorganic topcoats.
113.What phenomenon occurs in IOZ coatings as they age and undergo exposure to the
atmosphere?
a. Increase in porosity
b. Decrease in density
c. Formation of a denser film
d. Loss of adhesion to the substrate

114.Which type of zinc-rich coating is most suitable for repair priming of damaged IOZ
primers and galvanized surfaces?
a. Type 1-A
b. Type 1-B
c. Type 1-C
d. Type 2

115.What is the main purpose of using the "V" type test for comparing zinc-rich coatings?
a. To determine the rate of coating degradation
b. To measure the thickness of the applied coating
c. To assess the degree of corrosion protection provided by different coatings
d. To evaluate the adhesion strength of the coatings

116.What is the primary reason why inorganic zinc (IOZ) coatings are not typically used
alone in direct contact with seawater?
a. They lack antifouling properties
b. They provide poor corrosion protection
c. They become inert after a certain period
d. They react negatively with seawater salts

117.What happens to the zinc coating after a period of approximately 18 months to two
years in seawater immersion?
a. It becomes anodic
b. It ceases to provide corrosion protection
c. It becomes cathodic
d. It becomes galvanically active

118.What is responsible for the formation of zinc hydroxide on zinc coatings immersed in
seawater?
a. Carbon dioxide
b. Sodium chloride
c. Sulfates
 d. Bicarbonate

119.Which of the following coating systems is recommended for effective immersion

service, particularly in water and saltwater?
a. Solvent-based IOZ alone
b. IOZ with an organic topcoat
c. Epoxy polyamide primer alone
d. Vinyl coating alone

120.What is the key to the success of IOZ coatings for immersion service?
a. The presence of zinc hydroxide
b. Proper topcoating with organic primers
c. High chloride content in seawater
d. Rapid depletion of zinc coating

121.What is the recommended total thickness for an effective immersion coating system?
a. 200 µm (8 mils)
b. 300 µm (12 mils)
c. 400 µm (16 mils)
d. 500 µm (20 mils)

122.What reaction takes place when zinc coatings react with sodium chloride under thin,
porous organic coatings?
a. Formation of zinc hydroxide
b. Formation of zinc carbonate
c. Formation of zinc oxychloride compound
d. Formation of zincates

123.Why may it be preferable to leave zinc coatings bare rather than applying a coating of
improper thickness or porosity over them?
a. To prevent corrosion
b. To enhance galvanic protection
c. To avoid severe damage caused by environmental reactions
d. To improve antifouling properties

124.Which of the following is NOT a recommended approach to overcoming blistering

when topcoating over an inorganic zinc-based coat?
a. Using a non-solvent topcoat
 b. Applying a coating with high boiling or slow evaporating solvents
c. Rapidly topcoating warm surfaces
d. Using water-based topcoats

125.What is the primary cause of blistering when an organic topcoat is applied over an
inorganic zinc-based coat prior to its advanced stage of cure?
a. Insufficient thickness of the topcoat
b. Rapid evaporation of solvents into the porous zinc coating
c. Excessive humidity during application
d. Lack of adhesion between the two coating layers

126.According to the text, which type of topcoat is most effective in preventing blistering
when applied over an inorganic zinc-based coat?
a. Solvent-based topcoat with high volatility solvents
b. Water-based topcoat with rapid drying properties
c. Non-solvent or low solvent topcoat
d. Organic topcoat with high moisture content

127.Which of the following statements regarding the rapid topcoating of inorganic zinc
coatings is TRUE?
a. Rapid topcoating is not recommended due to potential mechanical damage
to the coating system.
b. Special formulations of solvent-based inorganics have been created to extend
the curing time before topcoating.
c. Rapid topcoating is necessary to achieve optimum corrosion resistance.
d. The addition of moisture during topcoating process enhances the curing of
inorganic zinc coatings.

128.What is the primary advantage of using water-based topcoats over solvent-based

topcoats when topcoating over inorganic zinc coatings?
a. Water-based topcoats have higher vapor pressure, reducing the risk of
blistering.
b. Water-based topcoats evaporate more slowly, allowing for better penetration
into the zinc coating.
c. Water-based topcoats form a film through emulsion, reducing the risk of
voluminous salt buildup.
d. Water-based topcoats have faster drying times, minimizing the risk of solvent
penetration.
129.What is indicated about the effectiveness of zinc-rich coatings in Table 6.18?
a. Zinc-rich coatings provide poor corrosion protection
b. IOZ coatings outperform organic zinc-rich products
c. Organic zinc-rich products provide longer continuous service
d. Zinc-rich coatings have no significant impact on corrosion protection

130.According to the passage, what is a distinguishing feature of IOZ coatings?

a. They are less effective in severe corrosion areas
b. They require frequent maintenance
c. They reduce initial capital cost and maintenance cost
d. They are primarily used in decorative applications

131.What is suggested about the development of IOZ coatings in the passage?

a. They have reached their maximum potential
b. They are still in the early stages of development
c. They are primarily used for decorative purposes
d. Their outstanding qualities have not been proven

132.What does the passage suggest about the future potential of IOZ coatings?
a. They will likely become obsolete due to newer technologies
b. They may one day be used for both protection and decoration of metal
surfaces
c. They are only suitable for small-scale structures
d. They are ineffective in areas of severe corrosion

133.What advantage do IOZ coatings offer in terms of cost?

a. They increase both initial capital cost and maintenance cost
b. They require frequent reapplication, increasing maintenance costs
c. They reduce both initial capital cost and maintenance cost
d. They have no significant impact on cost.

ANSWERS
1. d 2. a 3. c
4. d 31. b 58. a
5. b 32. c 59. d
6. d 33. c 60. c
7. d 34. c 61. d
8. a 35. b 62. b
9. c 36. d 63. c
10. c 37. b 64. c
11. c 38. b 65. b
12. b 39. d 66. b
13. c 40. b 67. d
14. c 41. d 68. a
15. c 42. a 69. c
16. b 43. c 70. c
17. b 44. c 71. a
18. c 45. b 72. b
19. c 46. a 73. b
20. a 47. b 74. c
21. b 48. a 75. a
22. c 49. c 76. b
23. c 50. d 77. c
24. b 51. a 78. d
25. a 52. c 79. c
26. b 53. b 80. d
27. c 54. a 81. b
28. c 55. a 82. b
29. b 56. d 83. c
30. a 57. b 84. c
85. b 87. d
86. a 88. c
 89. b 112. a
90. d 113. c
91. c 114. d
92. d 115. c
93. b 116. c
94. a 117. c
95. d 118. a
96. c 119. b
97. c 120. b
98. c 121. d
99. a 122. c
100. a 123. c
101. c 124. c
102. d 125. b
103. d 126. c
104. a 127. b
105. c 128. c
106. b 129. b
107. b 130. c
108. c 131. b
109. d 132. b
110. a 133. c
111. d