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Accelerated Testing and Durability
Qualifying your Industrial Anticorrosive Coatings
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OverviewStatic Test MethodsCyclic Test MethodsExterior ExposureComparison of Accelerated TestingEvaluating a Coating for Corrosion PerformanceSummary
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Weathering Factors which cause coatings to fail
Light – UV (short wavelength)TemperatureMoisture – dew, rain, and high humidityOther contributing factors include: pollution, marine environments (electrolytes),
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Common Accelerated Tests used for Qualification of Coatings – Static Tests
Salt Spray (ASTM B117)Humidity Testing (ASTM D2247)Immersion Test (ASTM D870)EIS
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Accelerated Tests used for Qualification of Coatings – Cyclic Tests
Filiform Corrosion Test (ASTM D2803)QUV Condensation, QUV/Prohesion (ASTM D5894)Xenon Arc (ASTM D2568, G26)
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Static Accelerated Tests
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Salt Spray (ASTM B-117)Samples are placed in racks at an acute tilt angle.A 5% NaCl solution (6.50-7.20 pH) is mixed with humidified air at a spray nozzle in center of cabinetThe temperature of the cabinet is maintained at 95oFPanels are subjected to static fog until failure or desired number of hours is obtained
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Salt Spray test – The GoodWidely used and requested in numerous industries Can be used as a quality control methodProcess of Elimination – can eliminate coatings which have poor anticorrosive properties sooner.
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Salt Spray test – The Bad & The Ugly
High concentration of salt (5%)Corrosion rates differ among substrates (galvanized steel in sulfide environment)No exposure to UV lightVariance between replicatesCabinet to cabinet reproducibilityStatic fog and temperature
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Example of Salt Spray Failure
100 hours salt spray – Water based Acrylic – Substrate: CRS – 2.0 mils D.F.T
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Humidity Test (ASTM D2247)Also referred to as Water Resistance TestSamples are exposed to 100% relative humidityWater vapor condenses on surfaceFailure can occur in many forms
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Humidity Testing – Cleveland Condensation Tester
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Humidity Testing Example
336 Hours Humidity
Long Oil Alkyd – CRS - 2.0 mils D.F.T
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Humidity Testing Example500 Hours Humidity – 2K High Solids Epoxy – Blasted Hot Rolled Steel –
3.0 mils D.F.T
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Immersion Test (ASTM D870)Samples are immersed in 100oF de-ionized water bath Failure can be blistering, loss of adhesion, coating breakdownOther methods include using salt water,acids, bases,etc. Also at varying temperatures
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Electrochemical Impedance Spectroscopy (EIS) – A brief summary
Can detect changes in a coating before damage is observedMeasures the breakdown of a coating due to electrolyte attackMeasures the resistance (charge transfer) and capacitance (how the coating behaves when exposed to the electrolyte)
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EIS- How does it work? Equivalent Circuit for an intact coated metal
Electric Double Layer
Capacitance of the coating
Solution electrolyte solution
Resistance of the Coating
Higher Coating Resistance or lower capacitance is desired
Reference: J.M. Fildes, P. Chen, and X. Zhan, North Western University, IL.S. Koka, A. Shi and J.S. Ullett, S & K Technologies, Dayton, OH
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EIS Equipment
Reference Electrode - Ag / AgCl
Working Electrode - Coating Sample
Counter Electrode - Platinum Mesh
Pictures courtesy of S. Koka, A. Shi and J.S. Ullett, S & K Technologies, Dayton, OH
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Data Collection
Nyquist Plot Bode Phase & Magnitude Plots
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Cyclic Accelerated Tests
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Filiform CorrosionFiliform Corrosion is a unique differential oxygen cell occurring on coated substrates. FFC leads to development of thin thread-like filaments full of corrosion products beneath the coating.It occurs on Aluminum, Steel, Magnesium and other metals. Filaments grow by anodic propagation or undermining.De-lamination: corrosion products push up coating causing it to delaminate. The head is anodic and tail end tail cathodic.What conditions cause it to occur?
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Filiform Corrosion Test (ASTM D2803)Scribed panels placed in corrosive atmosphere (salt spray ASTM B-117 for 4 to 24 hours) or immersed in a NaCl solution Panels exposed to humidity (77oF & 85% RH)
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QUV (ASTM G154)QUV cycle – UV light –4 hr followed by condensation cycle – 4 hr Fluorescent UV lamps• UVA-340• UVB
Condensation Cycle – chamber maintains 100% RH, 50oC
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Prohesion Cycle (ASTM G85 A5)Prohesion Cycle –Samples exposed to an electrolyte solution (0.05% NaCl + 0.35% ammonium sulfate) at 35oC for one hour then dried at 40oC for one hour, the cycle repeats
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Example of Prohesion Failure
1080 Hours of Prohesion
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QUV/Prohesion Test (ASTM D5894-5)Cyclic corrosion test consisting of one week in QUV and one week in ProhesionCyclic, panels exposure to wet/dry periodsUV exposure Correlates more to real world exposure
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Example of QUV/Prohesion Failure
Initial 5 Cycles – 1680 Hours
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Xenon Arc (ASTM D2568, G26) Light Simulation
Simulates full spectrum solar radiation-UV, visible, and infared Xenon arc spectrum must be filtered• Daylight• Window Glass• Extended UV
Photo courtesy of Q-Lab Corporation
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Xenon ArcMoisture cycle
Water spray Humidity controlled