Using electrochemical impedance spectroscopy to predict the corrosion resistance of unexposed coated metal panels

The goal of the current work was to determine if electrochemical impedance spectroscopy (EIS) testing of a series of coated but unexposed metal panels could predict the corrosion results of other sections of the same coated panels that were subjected to both continuous and cyclic corrosion testing. Variables included metal, pretreatment, primer, and topcoat. EIS results were shown to be strongly dependent upon the time-of-residence in the electrochemical cell prior to commencement of testing, and to the choice of electrolyte used in the cell. Good correlations between EIS and corrosion testing were seen for topcoat effects, but not for pretreatment effects. EIS results appear to relate mostly to barrier properties rather than electrochemical properties of coatings. It is suggested that the variation seen in EIS solution resistance values (R_s) can be utilized to quantify total system error. Total error was estimated by three techniques: total R_s variation, panel replicate variation, and EIS reading replication. The three approaches yielded similar results: total error for equivalent circuit components expressed in log₁₀ form was on the order of 50%, expressed as percent standard deviation.