The use of electrochemical noise methods (ENM) to study thick, high impedance coatings

Thick, high impedance organic coatings are those class of coatings used to provide corrosion protection to naval vessels, pipelines, gasoline storage tanks, and other large structures such as bridges and plant structures. These coatings, especially the newest generations now being used in practice, can provide exceptional protection and lifetime of performance such that properly and accurately assessing and differentiating among competing coatings is a very difficult task. The standard protocol of salt fog testing (ASTM B117), immersion testing, and outdoor exposure in a corrosive environment with subjective evaluation of a coating's performance durings and after testing, does not adequatcly rank and predict coating lifetimes for new coating systems, especially for the environmentally compliant coating systems such as powder coatings (especially the thick, fusion bonded epoxy (FBE) coatings used for pipelines), two component epoxy and urethane coatings and waterborne coatings. New, objective test methods are desperately needed by users and manufacturers of coatings. A relatively new electrochemical test procedure, electrochemical noise methods (ENM), as developed by Skerry and Eden, has been shown in our laboratory to be very successful in the ranking and prediction of relative coating performance. We have used the method successfully on naval ship coatings, several pipeline coatings and other related systems, and Skerry has used them successfully on industrial maintenance coatings. We have used these methods in conjunction with electrochemical impedance spectroscopy, d.c. resistance measurements and cyclic salt fog testing of the Prohesion^TM type. In our studies of pipeline coatings, we needed to investigate thermal effects because of their extended range of use temperature. In these studies, we have discovered that electrochemical methods can be used for an in situ measurement of the T_g of coatings in electrolyte immersion. Further, the ‘plasticizing’ effect of aqueous electrolyte absorption as well as its relative irreversibility has been shown. For all coatings studied, ENM provided useful, objective, numerical data which rapidly ranks coatings and provides useful information on the relative lifetime prediction of coatings which may provide up to 30 years of service.