Protective properties of epoxy-based organic coatings on mild steel

The protective properties of epoxy-based organic coatings on mild steel substrates have been studied using the electrochemical impedance spectroscopy (EIS) technique. The effects of coating composition, film thickness and curing temperature on the lifetime of the epoxy coating were investigated. The results obtained indicate that the film composition dramatically affects the rate of corrosion of the metallic substrate. Coatings with low and high content of curing agent exhibit early failure when exposed to an air-saturated 0.5 M aqueous solution of NaCl. Extended lifetimes were observed for samples with a content of the curing agent equal to 8.5% by weight. An increase in lifetime was also observed on increasing the film thickness and the curing temperature. The failure mechanism seems to occur in two steps: the first step is related to water uptake in the film while the second step is related to Cl⁻ ion diffusion through the coating. The results have been interpreted in terms of a model in which the dielectric properties (capacitance and resistance) of the coating depend strongly on the coating composition and are affected by both the water and salt uptake into the film.