1472282

Upload: freeuser3

Post on 02-Apr-2018

215 views

Category:

Documents


0 download

TRANSCRIPT

  • 7/27/2019 1472282

    1/10

    Progress in Organic Coatings 46 (2003) 148157

    EIS studies of coated metals in accelerated exposure

    Gordon Bierwagen a,, Dennis Tallman b, Junping Li a, Lingyun He a, Carol Jeffcoate c

    a Department of Polymers and Coatings, North Dakota State University, Fargo, ND 58105, USAb Department of Chemistry, North Dakota State University, Fargo, ND 58105, USA

    c Honeywell, 55 Federal Road, Danbury, CT 06810, USA

    Abstract

    One of the most popular uses of electrochemical impedance spectroscopy (EIS) is the characterization of the protective properties of

    coatings on corrodible metals. From early studies up to the present time, many EIS studies have been devoted to the study of the changes

    in the impedance of coated metals as they undergo either natural or artificial exposure to conditions that cause corrosive failure of such

    systems. With the current improvements in instrumentation and software for EIS studies of coated metals, one no longer needs to be an

    expert electrochemist to utilize EIS in ones studies of protection by coatings. In this paper, the use of EIS from the point of view of the

    coatings scientist will be presented, with an emphasis on its application simultaneous with accelerated exposure. EIS is used by coating

    scientists for several purposes, among them the detection of changes due to exposure, prediction of the lifetime of corrosion protection,

    identification of the corrosion processes that lead to failure, ranking of coatings systems, measurement of water uptake by coatings, and

    the development of models for coating/metal system performance. This paper will discuss several specific examples of the use of EIS in

    the study of coatings in accelerated exposure and the analysis of EIS data from such studies. The importance of cyclic vs. steady state

    exposure of samples will be shown by EIS results, and some of the problems in the use of standard continuous salt fog exposure as

    exemplified by ASTM B117 for a coating specification will be discussed. Considering Tg effects on EIS data will show the importance of

    considering thermal effects in the testing of coatings. The extremely important role of water uptake in coatings during exposure will also

    be discussed using EIS results to analyze changes in both the coating resistance (low frequency |Z| data) and capacitance (higher frequency

    Zdata). During exposure to cyclic changes in temperature and electrolyte solution concentration, a coating over a metal substrate appears

    to undergo both physical aging and chemical degradation. The coating appears to have a memory of past exposure events such thateach subsequent exposure to water and temperature creates and enlarges transport pathways within the coating for water and electrolyte.

    As cyclic exposure continues, damage to the bulk-coating layer above the coating/metal interface accumulates until there begins to be a

    permanent accumulation of electrolyte at this interface and local small-scale corrosion begins. This is the initiation of corrosion failure of

    the system, but it only occurs following the decrease of bulk-coating layer barrier properties caused by cyclic temperature and humidity

    processes characteristic of exterior exposure. This whole process can be accelerated by immersion in a flowing electrolyte, emphasizing

    the role of transport processes in coating degradation processes. If there is simultaneous UV exposure, as Skerry has so well described, one

    must also account for photodegradation of the outermost layer of the coating system. The role of the coating scientist is now to assimilate

    the data that EIS now provides us during the exposure process and develop meaningful models for the molecular level changes that occur

    in the coating film in order to enable use of the EIS results for true coating performance ranking and lifetime prediction.

    2003 Published by Elsevier Science B.V.

    Keywords: EIS; Photodegradation; Electrolyte; Accelerated testing; Lifetime prediction

    1. Introduction

    1.1. Brief history of EIS use in coatings

    Review of the use of electrochemical impedance spec-

    troscopy (EIS) in the study of corrosion protection by coat-

    ings has been considered by several authors [15]. Early

    measurements of EIS values on coated metals were very

    difficult due to the lack of computer controlled data acqui-

    Corresponding author. Tel.: +1-701-231-8294; fax: +1-701-231-8439.

    sition systems. Much of this has been reviewed before, and

    will not be repeated here. From the point of view of coating

    scientists, when relatively easy to use, control and standard-

    ized EIS equipment became available, the domination of

    this area of research by pure measurement electrochemists

    ceased. At this time, coating users began to see EIS as a

    valuable tool to characterize coating systems. The use of

    equivalent circuit methods to model the physical behavior

    of coatings as they aged and failed in immersion was intro-

    duced, with software that allowed the easy fitting of coating

    data [1].

    0300-9440/03/$ see front matter 2003 Published by Elsevier Science B.V.

    doi:10.1016/S0300-9440(02)00222-9

  • 7/27/2019 1472282

    2/10

    G. Bierwagen et al. / Progress in Organic Coatings 46 (2003) 148157 149

    1.2. EIS usage by electrochemists and

    metallurgists in coatings

    The use of EIS by electrochemists to study the corrosion

    protective properties of organic coatings over metals has

    been dominated by an emphasis on the methodologies and

    instrumentation of EIS. The primary consideration is the cor-rosion occurring on the metal itself, and on the metal/coating

    interface and what happened when this occurred [6]. Very

    often the period of time during which a coating completely

    protected a metal was given minimal consideration, for the

    interest was in what happened to a metal surface as it cor-

    roded, and how the coating changed the mechanisms of cor-

    rosion [3]. Attention was not directly paid to the coating and

    the measurement of the properties of the system before fail-

    ure by corrosion began at the metal/coating interface. Much

    attention was paid to the metal substrate and its composi-

    tion. Classes of coatings were compared by EIS, and the EIS

    modeling of failing systems was very popular. Equivalent

    circuits with many elements were used to provide physical

    models for failed systems, but not much modeling of the

    changes occurring in coatings systems leading to failure was

    performed.

    1.3. EIS measurements by coatings scientists

    The coatings scientist views EIS as a tool to exam-

    ine coatings and the way they protect metals. The metal

    substrate was viewed by the coatings scientist as a fea-

    ture of the system controlled by the user of the coating,

    and as something beyond their control [7]. They view the

    pre-treatment of the substrate as very important to the pro-tective performance of the coating, much like it is for all

    other coating/substrate systems. They tend to be very con-

    cerned with the variability seen in EIS characterization of

    coated metals [4,8]. Wet adhesion, the ability to maintain

    adhesion to a metal substrate in the presence of water or

    electrolyte, was identified as being a very important coating

    parameter in the performance of coated metals [9].

    2. Accelerated life testing in coatings

    2.1. Goals of accelerated life testing

    Accelerated life testing is used in many areas of science

    and technology to determine the effective performance life-

    time of various types of systems. In general, one seeks a

    physical or chemical acceleration of the failure of a specific

    system by placing the system under stress larger than it

    would receive in its normal lifetime, and monitor its per-

    formance to failure from that stress. Ideally the stress only

    causes the system to fail faster than it normally would, hence

    the term accelerated, but the mechanism of failure remains

    the same as in the non-accelerated conditions. A good intro-

    duction to accelerated testing along with some introductory

    references to this area of science is given in the recent book

    chapter by Meeker et al. [10]. The goal of accelerated life

    testing of corrosion protection of coatings is to impose a

    repeatable, measurable stress, in excess of that it normally

    undergoes, to a coating/metal system. One then determines

    the time to failure under this stress as well as the changes in

    system variables under the stress conditions chosen. Ideally,as mentioned above, these imposed stress conditions will

    not cause the mechanism of corrosion protection failure to

    change from that seen in normal use of the coating. The goal

    of accelerated testing is most often to predict the lifetime

    of the system in question under normal use conditions.

    Accelerated testing when properly performed enables the

    user of a system to obtain good estimates of when to replace

    that system as well as allowing the developer of such sys-

    tems to study, rank and predict performance lifetimes of

    new systems with no prior field use history without com-

    plete field use testing. The latter use is especially important

    for good systems because the increasing lifetimes of per-

    formance make the acquiring of true field performance life-time data so time-consuming that it is too impractical and

    expensive to acquire. A proper accelerated test also requires

    a very clear definition of what constitutes failure so that

    proper measurement methods can be chosen and utilized to

    characterize the properties involved in failure [11].

    2.2. Accelerated testing of the lifetimes of coatings

    corrosion protection

    The goal of accelerated testing for coatings corrosion

    protective lifetimes is twofold: first, to screen and test

    newly developed coatings systems and second, to qualifynew coatings for field use. This type of testing usually

    involves two components: the imposed stress environment

    that drives the system to failure and the measurement of

    system quality during stress imposition. Examples of the

    stress environments used for accelerating coatings system

    failure are immersion in electrolyte, continuous salt fog at

    35 C, SO2 salt fog, and cyclic salt fog [12]. These methods

    were developed around the idea that electrolyte and oxygen

    are needed for corrosion at a metal surface while increasing

    temperature increases the transport of oxygen and elec-

    trolyte through paint films, and also increases corrosion

    reaction rates. Skerry and co-workers [1315] provided evi-

    dence that true emulation of the effects of exterior exposure

    on corrosion protective coatings systems requires inclusion

    of UV effects. The proper measurement of coating quality

    during the imposed stress environment is not totally re-

    solved. The ASTM B117 continuous salt fog test in its most

    used form involves only qualitative examination of panels

    after exposure by a trained observer, with some guidance

    given on blister density, appearance judgments, etc. This

    makes this protocol very weak and almost unusable due to

    the almost entirely objective nature of the characterization

    performed, irregardless of the fact that the stress used in the

    test is unrealistic and takes many coatings above their Tgs,

  • 7/27/2019 1472282

    3/10

    150 G. Bierwagen et al. / Progress in Organic Coatings 46 (2003) 148157

    rendering them non-protective and poor in film properties.

    A discussion of quantitative coatings measurements which

    may be used in a corrosion protection lifetime test protocol

    is given in a recent paper from this laboratory [16].

    2.3. Requirements and recommendations for accelerated

    test protocol for corrosion protection by coatings

    A proper test protocol has a stress environment specified,

    that accelerates the failure of a system by the same mech-

    anism that is observed in field use of the system without

    altering the failure mechanism. It also provides quantitative

    measurement(s) which can be performed on the system

    which will allow clear identification of the failure time

    as well as the changes in the system with time under the

    imposed stress. For coatings systems that must provide cor-

    rosion protection under exterior exposure conditions, the

    test protocol must provide the primary stresses that coat-

    ings systems endure in exterior exposure. Most generally,these are UV exposure as from the sun along with (cyclic

    temperature + dilute electrolyte) exposure. This has been

    most carefully examined, prior to our studies on aircraft

    coatings, in industrial maintenance coatings and automotive

    coatings. A more complete discussion of these issues is

    given in Refs. [1215]. Based on these references, for our

    work on exterior coatings, the ASTM D 5894-96 exposure

    protocol supplemented by various physical measurements

    was chosen. The details of this are given in Fig. 1.

    This protocol has been successfully used in our laborato-

    ries for many coatings systems, especially aircraft coatings,

    and it has proven quite useful in examining and ranking

    coatings [17]. Other test cycles including thermal cyclinghave also been examined in our laboratory [18], but the

    one that is generally most useful for ranking and compar-

    ing systems in exterior exposure is the protocol shown in

    Fig. 1.

    Fig. 1. Test protocol used with exterior coatings.

    2.4. Problems in present use of accelerated

    testing of coatings

    Many problems exist in the present use of accelerated

    testing of the corrosion protective properties and lifetimes of

    coatings. One problem that has arisen constantly is that users

    are unwilling to stop use of a specification test protocol thathas been in place for any extended amount of time. Such a

    specification test protocol is the ASTM B117 test protocol

    and the accompanying qualitative observations are used for

    the measurements for this protocol. The measurements are

    all qualitative and subjective, and the test method does not

    emulate the conditions of use and failure in use conditions.

    The continuous high temperature (35 C) and continuous

    high salt concentration (5% NaCl fog) do not fit any common

    use condition. One must make sure that the temperature does

    not exceed the Tg of the coating under test otherwise false

    failures will result [18,19].

    3. Lifetime prediction from EIS data

    3.1. Previous use of |Z(t)| data

    Impedance data on coatings have been in use extensively

    in a semi-quantitative way to measure and predict the corro-

    sion protective lifetimes of organic coatings on metals. As

    Mansfeld et al. [20] have observed, the most efficient way to

    analyze EIS data when examining coatings is in Bode plot

    format. The EIS data from newly applied coatings on metals

    is often purely capacitive in nature with only one time con-

    stant, and only levels off to a low frequency limit at quite ahigh values of |Z|. As the coating performance decays, the

    signal begins to show non-linear behavior at intermediate

    frequencies and displays more than one time constant. Many

    former workers have examined time changes in EIS data

  • 7/27/2019 1472282

    4/10

    G. Bierwagen et al. / Progress in Organic Coatings 46 (2003) 148157 151

    from coated metals in exposure [6,7,21,22]. However, very

    few authors have considered examining the low frequency

    |Z| values as a function of exposure time for extended ex-

    posure times. This type of data analysis has been done in

    our laboratories for several types of coatings, and the initial

    results have already been published [17].

    3.2. Observed trends in EIS vs. exposure time

    As mentioned above, there have been an extensive num-

    ber of EIS measurements of coating performance in actual

    or accelerated exposure. However, much of the focus of

    these studies has been on the period of time after the metal

    surface begins corroding, and not on the time over which

    the coating performance is degrading but the metal surface

    is essentially intact. However, work in our laboratory indi-

    cates that for accurate evaluation of the protective lifetimes

    of organic coatings over metals, the period of time one

    should consider in detail is that, before the onset of sig-nificant corrosion of the metal substrate during which the

    coating somehow degrades and loses its corrosion protec-

    tive properties. When the coating is still largely intact (no

    physical damage like scratches or stone dings) the metal is

    not undergoing significant local corrosion. The most impor-

    tant property of the coating is its ability to impede the flow

    of current between anodic and cathodic areas of the metal

    substrate. This property is the resistance of the coating and

    is best characterized from EIS measurements by examining

    the low frequency limit of |Z()|. In a practical measure-

    ment sense, this is the value of |Z()| at the lowest value of

    for which there is still no significant noise as 0, and

    which does not require an unreasonable measurement time.If one considers the EIS literature on coatings, this value of

    is somewhere between 103 and 5102 Hz.

    In data from our laboratory for |Z| at the lowest frequency

    that can be accurately measured as a function of exposure

    time for coatings that are physically intact and provides cor-

    Fig. 2. |Z|0.012Hz vs. exposure time for various aircraft coatingsSet A.

    rosion protection, and only for systems which are in steady

    state over the measurement time necessary to acquire the

    data, an exponential decay of the low frequency modulus

    with exposure time has been observed. This has been more

    completely described in Ref. [17]. Other authors have seen

    this type of data also and commented likewise on this trend

    in data of |Z|lowfreq when plotted vs. exposure time [23].Examples of these types of data are shown in Figs.2 and3.

    These data are from aircraft coatings as identified in the

    figure over Al alloy 2024 T-3 panels exposed in the exposure

    cycle described in Fig. 1. The topcoats are DoD Specification

    MIL-C -85285, the extended lifetime topcoat (ELT), and

    primer MIL P23377 materials from Deft Coatings Inc. In

    Fig. 4 are shown photographs of the panels from which the

    data in Fig. 3 was measured after the indicated exposure

    time.

    The data of Figs. 2 and 3 can be analyzed from the fol-

    lowing equations:

    |Z|(t) = |Z|m + (|Z|0 |Z|m) expt

    (1)

    ln

    |Z|(t) |Z|m

    |Z|0 |Z|m

    =

    t

    (2)

    where |Z|m is the limiting bare metal value |Z|, |Z|0 is the

    film resistance values at t= 0, and the constants, , has the

    dimension of time and can be considered the characteristic

    decay times for the coating under consideration. The decay

    constant (the inverse of the slope of the exponential fit

    line in the graph of ln(|Z|(t) |Z|m) vs. exposure time) is

    presented for different samples.

    If one takes Eq. (2), and solves for the time it takes todecay to a specific failure value, |Z|fail, one has an expression

    for the failure time of the coating as a function of the chosen

    failure modulus:

    tfail =

    ln

    |Z|0 |Z|m

    |Z|fail |Z|m

    (3)

  • 7/27/2019 1472282

    5/10

    152 G. Bierwagen et al. / Progress in Organic Coatings 46 (2003) 148157

    Fig. 3. |Z|0.012Hz vs. exposure time for various aircraft coatingsSet B.

    This analysis holds true for other types of coatings as well,

    such as alkyd marine coatings and epoxy marine coatings

    [17], and should be considered for other types of coatings

    as well. Eq. (3) implies that the failure time is a function

    of the chosen failure modulus value. This is illustrated

    in Fig. 5, and the corresponding values of the failure rate

    constant are given in Fig. 6. The failure rate constant is

    most useful for comparative ranking of substrate lifetimes

    when a complete prediction of failure time is not necessary,

    such as in rapid screening testing.All coating systems examined under the exposure protocol

    ofFig. 1 have shown the first-order decay behavior described

    above that allow the use of this lifetime prediction protocol.

    This is not always true for other exposure protocols, or for

    shorter time periods of exposure, and this will be discussed

    in a later publication.

    Fig. 4. Photographs of panels used in testing of Fig. 3.

    4. Thermal effects in coatings examined

    electrochemically

    4.1. General comments

    The general effects of temperature are often used to

    accelerate exposure tests for coating lifetime such as the

    high temperature periods of the Prohesion test cycle. The

    reasoning behind the use of increased temperature to

    accelerate failure is that there is an increase in rates ofchemical reactions, transport properties, molecular mobil-

    ity, etc. with increasing temperature. An Arrhenius-type of

    effect is often invoked in the use of increasing temperature

    to accelerate the failure of materials [10]. As discussed in

    Ref. [10], caution must be exercised in extrapolation of

    results from thermally accelerating failure. The ideal acce-

  • 7/27/2019 1472282

    6/10

    G. Bierwagen et al. / Progress in Organic Coatings 46 (2003) 148157 153

    Fig. 5. Failure time dependence on failure modulus.

    lerated test increases the rate of failure without changing the

    mechanism of failure. We have examined the effects of tem-

    perature on coatings performance by EIS as an attempt to

    identify the validity of thermal acceleration of coatings fail-

    ure and to provide numerical evaluation of coatings proper-

    ties vs. exposure at elevated temperatures [19].

    4.2. Early studies: examination of pipe-line coatings

    Our earliest studies of thermal effects were performed

    in conjunction with our examination of pipe-line coatings

    [24]. We showed that thermal acceleration study had to

    Fig. 6. |Z|(t) decay constant () for different aircraft coating systems.

    consider the effects of the glass transition temperature, Tg,

    in the coatings under study as well as the effects of the wa-

    ter plasticization of the coating during the measurements.

    This was more fully documented in Ref. [19], it gives a full

    discussion of how examination of EIS data as a function of

    temperature can be used to characterize the Tg in coatings

    in immersion, as well as the plasticization effect of water on

    many coating polymers. The barrier and electrical resistance

    properties of coatings are significantly lowered above theirTgs, and care must be taken not to exceed the Tg of the

    coating under study during accelerated testing if one wants

    an accurate evaluation of the coating in question. Similarly,

  • 7/27/2019 1472282

    7/10

    154 G. Bierwagen et al. / Progress in Organic Coatings 46 (2003) 148157

    use of coatings above their Tg will drastically shorten their

    lifetime of protection.

    4.3. Thermal cycling effects

    What all of these studies have shown is that EIS mea-

    surements track very effectively the effects of temperature,water ingress and coating plasticization, and Tg in coatings.

    Ref. [18] discusses the effect of reversible and irreversible

    changes due temperature cycling on Tg and other coating

    properties, and suggests that irreversibility in coatings prop-

    erties is due to permanent degradation of the coatings prop-

    erties. Observation of irreversible degradation of coating

    properties in thermal cycling is an early indicator of coating

    failures.

    4.4. Tg effects in dry and wet systems

    Below the Tg, the activation energies for diffusion andconductivity are both quite high and the magnitudes of the

    diffusion coefficient and the conductivity are quite small (re-

    sistance is large). Above the Tg, or any other orderdisorder

    transition, the energies of activation for transport processes

    undergo threshold behavior, and diffusion sharply increases

    while electrical resistance drops drastically. Plotting the

    properties of polymer coating films above and below the

    Tg has shown a distinct change in slope around the Tg. The

    extent of irreversibility in cycling above and below the Tgis dependent on the coating composition. For coatings in

    immersion, the plasticization effect of water must be con-

    sidered, and the reversibility of this plasticization is very

    important [18,19]. For ionomer types of coating polymers,

    above the Tg, there is considerable water ingress due to

    solubility and plasticization effects [25,26].

    4.5. Thermal effects on water ingress and uptake as

    assessed by EIS

    We have earlier examined water ingress and uptake by EIS

    for an epoxy powder coating over steel and a ionomer coat-

    ing over steel [25,27]. It was noted that the ionomer coat-

    ing, once taken over its Tg in immersion, had irreversible

    changes in its low frequency |Z| values and its capacitance

    as estimated from EIS. Measurement of the electrochemical

    properties of the film by impedance spectroscopy enables us

    to calculate the capacitance which incorporates the dielectric

    constant of the film. Both these properties change with in-

    creased water content and plasticization of the polymer film.

    Caution is required over the choice of frequency since

    one needs to choose a frequency at which the dielectric

    properties rather than the electrochemical are measured.

    Too low a frequency, (below the break point frequency) and

    the electrochemical properties of the film and any corrosion

    processes occurring will be measured. The dielectric con-

    stants for most polymers are in the range of = 34 [28].

    Table 1

    DSC data on powder coating and ionomer coating

    Estimated Tg (C) Wf (%)

    Epoxy powder coating detached film sample

    Dry 100 Nor detected

    In 3% NaCl 8 months at

    25

    C+ 1h at 90

    C

    82 1.4

    Ionomer powder coating detached film sample

    Dry 81 Not detected

    In 3% NaCl 24h at25 C 75 0.3

    In 3% NaCl 1 h at100 C 74 1.6

    Table 2

    Weight measurements on coating films

    Estimated Tg (C) Weight (%)

    Epoxy powder coating detached film sample

    In 3% NaCl for 8 months

    at 25 C+ 1h at 90 C

    73 1.35

    Ionomer powder coating detached film sampleIn 3% NaCl for 1 h at100 C 74 1.6

    Entry of water which has a much higher dielectric constant

    (w = 80 is the dielectric constant of water at room temper-

    ature) into the coating will increase the coating capacitance

    (Cc). From the Brasher and Kingsbury (BK) [29] empirical

    formula, measuring Cc should be a measurement of water

    permeation into the coating as given by

    =log(Cc/C0)

    log w(4)

    where is the volume fraction, Cc the coating capacitance,

    C0 the coating capacitance at the beginning of exposure,

    and w is the dielectric constant of water.

    There is good agreement between the thermal and weight

    measurements for water uptake. A slight modification of the

    BK empirical equation to

    =(Cc/C0)

    w

    1

    w(5)

    gives better agreement of these impedance calculations to

    the thermal and weight measurements for these samples.

    This was not true for all of our impedance data.

    As expected, good agreement is possible from weight andthermal measurements of the water uptake by a film. DSC,

    weight measurement, TGA data are shown in Tables 13.

    The water uptake data for our samples as measured by

    TGA was the most reliable and the most reproducible results

    of the methods applied. This method provided us with a very

    Table 3

    TGA measurements of relative water uptake

    Wet film boiled

    in 3% NaCl

    FBE Sample 1 FBE Sample 2 Ionomer

    Water uptake (%) 1.15 1.14 3.27

  • 7/27/2019 1472282

    8/10

    G. Bierwagen et al. / Progress in Organic Coatings 46 (2003) 148157 155

    Fig. 7. Water uptake estimated by EIS using the BK equation: ionomer powder coating.

    accurate, almost absolute method for determining water con-

    tent when the EIS data based on the BK estimating proce-

    dure for water content gives very misleadingly high results.

    The data calculated by the BK and modified BK equations

    are given in Figs. 7 and 8 for the ionomer and the epoxy

    coatings, respectively. As can be seen from these figures, the

    estimates of water content when using the BK equation are

    quite large as compared to the weight measurements. The

    estimate for water content calculated with the modified BK

    are much closer to the experimentally determined values.The disparities between the TGA and DSC results and the

    Fig. 8. Water uptake estimated by EIS using the modified BK equation: epoxy powder coating.

    BK estimates seem to be significant when some of the as-

    sumptions in the BK estimate, especially the assumption that

    there is a separate water phase with no solvency interactions

    between water and coating, are no longer true. The ionomer

    coating, as one might expect, shows the greatest disparities

    between the electrochemical and weight-based estimates of

    water content. In our measurements, the failures of the as-

    sumptions seem to occur especially when water enters the

    coating above the Tg and/or the water is a strong plasticizer

    for the coating, or enters it as a neutralizing electrolyte as itdoes with the ionomer.

  • 7/27/2019 1472282

    9/10

    156 G. Bierwagen et al. / Progress in Organic Coatings 46 (2003) 148157

    This is documented in a recent study in our laboratory.

    The techniques that we developed in our thermal cycling

    studies [18] have shown that when panels are exposed above

    their Tg to aqueous electrolyte and then cooled, the apparent

    water content as measured by EIS via a BK type of rela-

    tionship does not equal the amount of water as determined

    gravimetrically or by TGA. This implies that the water im-bibed above the Tg is not phase-separated, as required by

    the BK relationship, but probably acts as a partial solvent

    for the polymer phase which apparently alters the dielec-

    tric constant significantly yielding a higher apparent water

    content than predicted by BK. Others have seen related

    results [30].

    5. Summary and conclusions

    In summary, EIS techniques provide an excellent method

    to examine the corrosion protective properties of organic

    coatings as well as other properties of the coatings suchas thermal properties, water solubility, and perhaps even

    physical aging processes. In conjunction with accelerated

    weathering protocols developed by corrosion scientists to

    qualitatively estimate the corrosion protective lifetimes of

    coatings, the numerical evaluation of metal substrate/organic

    coatings systems by EIS measurements provides an objective

    assessment of system performance that tracks performance

    changes in such systems quite well. For relatively undam-

    aged systems, a simple parallel Randles circuit (RC) is suffi-

    cient to model systems performance, but as systems become

    significantly damaged due to exposure and corrosion at the

    metal/coating interface, more complex circuits are required.These may offer insight into final failure mechanisms.

    From the work we have presented and the work of others

    cited in this work, it can be definitely concluded that EIS

    and other electrochemical measurements of metal/organic

    coating systems offer significant advantages to those eval-

    uating such systems, especially when used with accelerated

    exposure protocols. The numerical, objective nature of the

    results from EIS enable quantitative assessment of changes

    in metal/coating systems as they are artificially or naturally

    weathered, and allow objective evaluation of these sys-

    tems. EIS is an important measurement tool that should be

    used routinely by all those examining corrosion control by

    organic coatings.

    Acknowledgements

    This work was performed with the support of the

    following: (a) Office of Naval Research under grant no.

    N00014-95-10507, Dr. A.J. Sedriks, program manager;

    (b) Air Force Office of Scientific Research under grant

    F49620-96-1-0284, Lt. Col. P. Trulove and Maj. H. De-

    Long, program managers; (c) a sub-contract from Boeing,

    Dr. J. Osborne, PI, the prime contractor for DARPA under

    contract no. F33615-96-C-5078; (d) a subcontract with U.

    Missouri-Columbia, Prof. H. Yasuda, PI, the prime con-

    tractor for DARPA under contract no. F33615-96-C-5055.

    All of the military coatings samples studied here were gra-

    ciously provided by Deft Coatings Inc., 17451 Von Karman

    Ave, Irvine, CA 92614.

    References

    [1] J.H.W. de Wit, Inorganic and organic coatings, in: P. Marcus, J.

    Odar (Eds.), Corrosion Mechanisms in Theory and Practice, Marcel

    Dekker, New York, 1995, Chapter 16, pp. 581627.

    [2] W. Funke, Corrosion tests for organic coatingsa review of their

    usefulness and limitations, J. Oil Chem. Assoc. 62 (1979) 6367.

    [3] H. Leidheiser Jr., Electrical and electrochemical measurements as

    predictors of corrosion at the metalorganic coating interface, Prog.

    Org. Coat. 7 (1979) 79104.

    [4] W.S. Tait, A discussion of the reliability of electrochemical

    impedance spectroscopy data from coated metals, Division of

    Polymeric Materials: Science and Engineering, Am. Chem. Soc. Nat.

    Meet., Denver, 68 (1993) 101, Preprints.[5] J.R. Macdonald, D.D. Macdonald, M.C.H. McKubrie (Eds.), Impe-

    dance Spectroscopy, Wiley, New York, 1987, Chapter 4.3, p. 301.

    [6] J.R. Scully, Electrochemical impedance of organic-coated steel:

    correlation of impedance parameters with long-term coating

    deterioration, J. Electrochem. Soc. 136 (4) (1989) 979990.

    [7] B.S. Skerry, D.A. Eden, Electrochemical testing to assess corrosion

    protective coatings, Prog. Org. Coat. 15 (1987) 269285.

    [8] R.G. Groseclose, C.M. Frey, F.L. Floyd, Characterization of the

    variability in corrosion resistance of steel using electrochemical

    techniques, J. Coat. Technol. 56 (714) (1984) 3141.

    [9] W. Funke, Toward a unified view of the mechanism responsible for

    paint defects by metallic corrosion, Ind. Eng. Chem. Prod. Res. Dev.

    24 (1985) 343347.

    [10] W.Q. Meeker, L.A. Excobar, V. Chan, Using accelerated test

    to predict service life in highly variable environments, in: J.W.Martin, D.R. Bauer (Eds.), Service Life Prediction: Methodology

    and Metrologies, ACS Symposium Series 805, Oxford, New York,

    2001, Chapter 19, p. 396.

    [11] G.P. Bierwagen, The science of durability of organic coatingsa

    foreword, Prog. Org. Coat. 15 (1987) 179185.

    [12] B.R. Appleman, Survey of accelerated test methods for anti-corrosive

    coating performance, J. Coat. Tech. 62 (787) (1990) 5767.

    [13] C.H. Simpson, C.J. Ray, B.S. Skerry, Accelerated corrosion testing

    of industrial maintenance paints using a cyclic corrosion weathering

    method, J. Prot. Coat. Linings 8 (5) (1991) 2836.

    [14] B.S. Skerry, A. Alavi, K.L. Lindgren, Environmental and

    electrochemical test methods for the evaluation of protective organic

    coatings, J. Coat. Technol. 60 (765) (1988) 97106.

    [15] B.S. Skerry, C.H. Simpson, Accelerated test method for assessing

    corrosion and weathering of paints for atmospheric corrosion control,Corrosion 49 (1993) 663674.

    [16] G.P. Bierwagen, D.E. Tallman, Choice and measurement of crucial

    aerospace coating system properties, Prog. Org. Coat. 41 (2001)

    201217.

    [17] G.P. Bierwagen, J. Li, L. He, D.E. Tallman, Fundamentals of the

    measurement of corrosion protection and the prediction of its lifetime

    in coatings, in: J.W. Martin, D.R. Bauer (Eds.), Proceedings of

    the Second International Symposium on Service Life Prediction

    Methodology and Metrologies, Monterey, CA, November 1417,

    1999, ACS Books, Washington, DC, 2001, Chapter 14, pp. 316350.

    [18] G.P. Bierwagen, J. Li, L. He, L. Ellingson, D.E. Tallman,

    Consideration of a new accelerated evaluation method for coating

    corrosion resistancethermal cycling testing, Prog. Org. Coat. 39

    (2000) 6778.

  • 7/27/2019 1472282

    10/10

    G. Bierwagen et al. / Progress in Organic Coatings 46 (2003) 148157 157

    [19] J. Li, C.S. Jeffcoate, G.P. Bierwagen, D.J. Mills, D.E. Tallman,

    Thermal transition effects and electrochemical properties in organic

    coatings. I. Initial studies on corrosion protective organic coatings,

    Corrosion 54 (1998) 763771.

    [20] F. Mansfeld, H. Shih, H. Greene, C.H. Tsai, Analysis of EIS data

    for common corrosion processes, in: J. Scully, D.C. Silverman,

    M. Kendig (Eds.), Electrochemical Impedance: Analysis and

    Interpretation, ASTM STP 1181, ASTM, Philadelphia, PA, 1993,

    p. 37.

    [21] J.R. Scully, S.T. Hensley, Lifetime predictions to organic coatings

    on steel and a magnesium alloy using electrochemical impedance

    methods, Corrosion 50 (9) (1994) 705716.

    [22] M.P.W. Vreijling, et al., Application of electrochemical impedance

    measurements in the determination of the service life of organic

    coatings, in: D. Scantlebury, M. Kendig (Eds.), Proceedings of

    the Symposium on Advances in Corrosion Protection by Organic

    Coatings II, vol. 95-13, Special Publication of the Electrochemical

    Society, 1995, pp. 132150.

    [23] E. Kuwano, T. Fujitani, T. Satoh, A new approach to the

    anti-corrosion function of coatings, in: Extended Abstracts of the

    International Symposium on Advances in Corrosion Protection by

    Organic Coatings, October 2931, Noda, Japan (abstract 111).

    [24] G.P. Bierwagen, C.S. Jeffcoate, D.J. Mills, J. Li, S. Balbyshev, D.E.

    Tallman, The use of electrochemical noise methods to study thick,

    high impedance coatings, Prog. Org. Coat. 29 (1996) 2130.

    [25] C.S. Jeffcoate, T.L. Wocken, G.P. Bierwagen, Electrochemical

    assessment of spray-applied thermoplastic coating barrier properties,

    J. Mater. Eng. Perform. 6 (1997) 417420.

    [26] C.S. Jeffcoate, J. Li, G.P. Bierwagen, in: S.R. Taylor, H. Isaacs,

    E. Brooman (Eds.), Electrochemical Testing of Thick Thermoplastic

    Powder Coatings, Proceedings of the Electrochemical Society

    Symposium, vol. 95-16, 1995, p. 60.

    [27] C.S. Jeffcoate, J. Li, G.P. Bierwagen, Measurement of water ingress

    into corrosion protective coating films, in: Proceedings of the

    Symposium on Research in Progress, Corrosion96, NACE Annual

    Meeting, Denver, CO, March 1996.

    [28] C.C. Ku, R.L. Liepens, Electrical Properties of Polymers, Hanser

    (New York) 1987.

    [29] D.M. Brasher, A.H. Kingsbury, J. Appl. Chem. 4 (1954) 62.

    [30] A.M. Simoes, Instituto Superior Tcnico, Lisbon, Portugal, Private

    communication;

    A.S. Castella, A.M. Simoes, Assessment of water uptake in coil

    coatings by capacitance measurements, Prog. Org. Coat. 46 (2003)

    5561.