依照ASTM G161 《腐蝕失效分析標準指南》，編輯整理了腐蝕失效分析檢查單，如下。

1、關鍵因素的識別Identification of key factors

(1)設備名稱Name of equipment

(2)失效部位的名稱和描述（含尺寸）Name and description(including dimensions) of failed part

(3)失效的日期和時間Date and time of failure

(4)失效位置Location of failure

(5)失效位置的可獲取性Accessibility of failure location

(6)關鍵人員姓名Name of key personnel

2、失效條件概覽（使用日記、示意圖、照片、視頻資料）Overview of failure conditions(Use notes, sketches, photographs, and video tapes)

(1)失效位置Physical arrangement

(2)現場氣味Smells or odors

(3)顏色Colors

(4)沉積物或殘留物Deposits or residues

(5)周圍的環境條件Surrounding conditions

(6)現場位置調整的證據Evidence of rearrangement or movement

3、失效分析計劃總覽（人員、工作內容、工作時間、工作地點）Overall plan of attack(include who, what, when, where for each action)

(1)信息類型Types of information

(2)文件類型Types of documentation

(3)取樣Sampling

(4)測試Testing

(5)評估Evaluations

(6)報告Reporting

4、信息類型Types of information

(1)失效時的服役條件Conditions at time of failure

①工藝參量Process variables

②天氣Weather

③人員活動Observations by personnel

④穩定狀態Stability

⑤正常或異常現象Normal or unusual

⑥開啟/停車/維修/停用/建設；Startup/shutdown/maintenance/layup/construction

(2)歷史信息History

①設計資料Design

②建設和組裝資料Construction/fabrication

③建筑材料Materials of construction

④改造Modifications

⑤運行Operation

⑥工藝變更Process changes

⑦以往失效記錄Previous failures

⑧維護記錄Maintenance practices

⑨清理記錄Cleaning practices

⑩維修記錄Repairs

5、文件類型Types of documentation

(1)運行日記Operating charts and logs

(2)天氣狀況Weather station observations

(3)工藝材料規范（含MSDS手冊）Process materials specification(including materials safety data sheets(MSDS))

(4)建設用材料規范和證明材料Materials of construction specification and certifications

(5)安裝規范Fabrication specifications

(6)竣工圖As-built drawings

(7)取樣計劃（拍照、位置識別）Sampling plan(including identification system photographs, and locations)

(8)測試報告Test reports

(9)現場檢查記錄、示意圖、影像資料Site inspection notes, sketches, photographs, and video tapes

(10)調研記錄Interview notes and tapes

6、取樣Sampling

(1)金屬（失效和未失效）Metal(failed and unfailed)

(2)工藝材料Process materials

(3)腐蝕產物Corrosion products

(4)其他沉積物、殘留物Other deposits and residues

(5)環境（氣體、水、土壤、其他）Environmental (air, water, soil, and other)

7、測試Testing

(1)金屬成分Metal composition

(2)金屬機械性能Metal mechanical properties

(3)金屬物理性能Metal physical properties

(4)電化學測試結果Electrochemical test results

(5)腐蝕產物組成Corrosion product composition

(6)沉積物、殘留物組分（如，微生物等）Deposit and residue composition (including microbiological, if conducted)

(7)環境構成（介質濃度、污染物等）Environment composition (including concentrations and contaminants)

(8)pH值、溫度、導電率Environment pH, temperature, and conductivity

(9)工藝介質材料和組分Process material composition

(10)腐蝕類型、微觀組織、端口形貌Corrosion type and morphology (micro-structures, fractography)

(11)工藝參數模擬Process simulation exposures

(12)EDS或其他表面分析技術Surface analysis by EDS or other suitable technique

8、評估Evaluations

(1)實驗結果和規范Test results versus specifications

(2)腐蝕機理Corrosion mechanism

(3)腐蝕成因Cause of corrosion

(4)腐蝕測量和計算Measurement and calculations of extent of corrosion

(5)實際腐蝕速率和預測腐蝕速率的差異（如有）Discrepancies (if any) between predicted and actual corrosion rates

9、報告Reports

(1)過程報告或中期報告Progress or interim

(2)最終報告Final

附：最常見的腐蝕失效類型The most common corrosion related failure modes

(1)全面腐蝕General corrosion

(2)電偶腐蝕Galvanic corrosion

(3)應力腐蝕Stress corrosion

(4)點腐蝕Pitting

(5)沖蝕磨蝕Erosion and wear

(6)氫脆Hydrogen embrittlement

(7)微生物腐蝕Micro biologically induced corrosion（MIC）

(8)高溫腐蝕（氧化，碳化，硫化）Surface reactions（Oxidation, Carburization, Sulfidation)

(9)焊縫腐蝕Weld corrosion

(10)晶間腐蝕Intergranular corrosion

(11)腐蝕疲勞Corrosion fatigue

注1：參考ASTM G161 Standard Gudie for Corrosion Related Failure Analysis整理；

注2：圖片來源SwRI。