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H. RadovEiC
Brodarski Institti, Marine Research and Naval Technologies, Zagreb [Croatia)
Abstract
Steel panels coated wlth a coal tar epoxy composition were studied by impedance
spectroscopy in the dry condition as well as during exposure to synthetic seawater and
to 10% NaOH solution. In the temperature range from 0 to 20 “C the dry coating behaves
as an almost ideal capacitor with a dielectric constant ranging from 3.0 to 3.2. The coal
tar epoxy coating immersed in synthetic seawater showed capacitative behaviour over
a long period of exposure, in the frequency range 100 Hz to 100 kHz. However, the
thinner coatings ( - 50 pm) were subject to a permanent slow degradation and their
resistance decreased to approximately 107Rcm2 after 7 months of continuous immersion,
whereas the degradation process for thicker coatings (- 125 pm) was slower and the
resistance was still above lo8 Rem’ after 9 months of continuous immersion. The water
uptake showed an initial rapid rise to between 9 and 13%. The coating degradation in
a 10% NaOH solution is rather more rapid and after only one day of immersion a coating
resistance of lo6 Szcm’ and a water uptake of 30% was found.
Key wards: Impedance spectroscopy; Nondestructive testing; Paint film resistance; Coal
tar epoxy coating; Synthetic seawater
1. Introduction
Steel products are used in almost all industrial sectors of the economy.
Virtually all such products are coated with organic paints for aesthetic reasons
and corrosion protection. Since metallic corrosion is an electrochemical
phenomenon, the application of electrochemical methods is clearly appropriate
in developing procedures for assessing paints for their corrosion protection
characteristics. During the last decade or so, considerable success has been
achieved by the use of electrochemical impedance spectroscopy [ l-8 1, which
has the virtue of being a small signal perturbation technique.
Marine corrosion is an area of particular importance and in the last few
years a large number of papers have appeared dealing with the performance
of polymer-coated steel in chloride media [ 9-19 1. The paints studied have
included coal tar epoxy compositions [20-261 which provide excellent coat-
ings, the quality of which is attributed to the fact that they combine the
best qualities of coal tar (water resistance, brine resistance, chemical resistance
etc.) with the adhesion properties of epoxy resins [ 201. The protective
properties have been studied as a coating on a metal surface [20-241, or
as a detached paint film [25]. The physicochemical characteristics of the
coal tar epoxy film, especially permeability to water, oxygen, chloride and
hydroxyl ions, have also been investigated [20, 261.
It is generally agreed that the coated metal system may be described
in terms of the equivalent circuits presented in Fig. 1 [ 2 7-291, where C,
and R, represent the capacitance and the resistance of the coating respectively,
and R,,the electrolyte resistance. The term 2, describes the general impedance
of the metal/electrolyte interface, the magnitude of which depends on the
rate controlling step of any electrochemical reaction, that is, diffusion and/
or charge transfer.
A perfect protective coating has no free ions, oxygen or water present
in it, and shows zero mobility of ions and zero diffusion coefficients of
oxygen and water. Such a protective coating would prevent both atmospheric
or electrochemical corrosion of the underlying metal. The impedance of such
a coated metal when in contact with a corrosive solution would be entirely
capacitive, and would vary inversely to the frequency, with the capacity, C,,
given by
C, = e. EA/d (1)
where A is the surface area of the coated metal, d is the coating thickness,
co is the absolute permittivity (8.85 X lo-14),and E is the dielectric constant
of the film.
Real protective coatings generally have a finite ionic conductivity which
is due either to defects in the coating which contain an aqueous solution,
or to true ionic conductivity within the bulk of the coating.
When the coating is immersed in a chloride solution, the latent dis-
continuities or defects eventually give rise to an ionically conducting low
resistivity path perpendicular to the coated surface which may eventually
penetrate to the metallic substrate. Assuming a direct concentration depen-
dence of the degradation mechanism [30], the resistivity of these paths will
decrease as a function of the exposure time as water, oxygen, and anionic
and cationic species are transported through the coating. Figure 1(b) suggests
that the initial impedance properties of the coating and any changes during
exposure to electrolyte can be determined at relatively high frequencies,
RC RC
(4 @>
Fig. 1. Equivalent circuits for the impedance of coated metal electrodes. (a): Dry organic
coating as an ideal dielectric layer; (b): Electrode with defective organic layer.
277
while the corrosion reaction on the metal surface can be evaluated at relatively
low frequencies [lo, 311.
The principal objective of the present work was the study of the protective
properties of coal tar epoxy coating on steel in seawater. As painted structures
in seawater are very often cathodically protected, the influence of increased
alkalinity, caused by the electroreduction of oxygen on coating the properties
is of great importance. The study of the coal tar epoxy coatings was therefore
extended to include immersion in an alkaline solution. For a better under-
standing of the initial coating properties, a dry coating was also investigated.
2. Experimental
thickness from 36 to 44 pm. Typical experimental data for IZI and 0 for
a 44 pm coating in a temperature range from 0 to 20 “C are represented
in Bode plots in Fig. 2. It can be seen that the coal epoxy coating behaves
in a purely capacitive manner with the log 121 versus log f slope ranging
from - 1 at 0 “C to -0.97 at 20 “C, and 0 between - 83 and - 89 degrees.
Thus, a coal tar epoxy coating can be considered as an almost ideal capacitor
and can be represented by the equivalent circuit shown in Fig. l(a). The
dielectric constant was calculated from the capacitance values at 35000 Hz:
at 20 “C its value is 3.2 and with decreasing temperature it decreases slightly
to 3.0 at 0 “C.
Fig. 2. Bode plots for a 44 pm coal tar epoxy coating in steel/coating/brass system as a
function of temperature between 0 a.nd 20 “C.
279
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log f slope ranges from - 0.90 after 2 hours to -0.86 after 3 months of
continuous immersion, while the slope for thicker coatings ranges from - 0.96
after 2 hours to -0.90 after 9 months continuous immersion. However,
after a few months’ continuous immersion the thinner coatings show a
response departing from the log 121 versus log f linear dependence and
below lo3 Hz the phase angle, 0, drops below - 70”.
Since the system under investigation can be described in terms of the
equivalent circuit presented in Fig. 1, it is supposed that the values of C,
and R,, at any immersion time, represent the protective ability of the coating
at that time. The value of C, can be determined by extrapolating the impedance
data to infinite frequency:
c, = l/d” (2)
for o+ a,, and also from the value of the frequency corresponding to the
top of the high frequency semicircle in the Nyquist plot, (when this is well
defined).
The change in capacitance of a coating on exposures to a corrosive
environment is a widely used parameter for evaluating its protective properties
because of the good reproducibility of the measurements and that it depends
exclusively on deterioration on a microscopic scale. It does not, however,
give a direct indication of the corrosion rate of the underlying metal since
280
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Fig. 4. Bode plots for a 125 pm coal tar epoxy coating on a steel substrateas a functionof
exposure time to synthetic seawater.
Fig. 5. Percentage water uptake for coal tar epoxy coating on a steel substrate: (a) in synthetic
seawater (Cl, n thin coatings, 0, 0 thick coatings); (b) in 10% NaOH solution.
282
However, the results presented in Pigs. 3 and 4 show that the coating
thickness is an important parameter as far as protective ability is concerned.
Very thin coal tar epoxy coatings (below 40 pm) in seawater, according to
Rowlands and Schuter [ 23 1 showed high capacitance and low resistance after
only a few days immersion, whilst coating layers 200-300 pm thick kept a
high resistance even after one year’s exposure. This can be explained by
the inhomogeneous nature of polymer films and its effect on ionic resistance.
A number of polymer films have been shown to be heterogenous in structure,
containing small areas, termed direct or D-type areas, which have a lower
ionic resistance than the rest of the film called inverse or I-type areas [37].
Differences between D- and I-type areas have been connected with differences
in crosslink density within the polymer film. Breakdown of painted metal
has been shown to occur at D-type areas of low resistance, where polymer
crosslinking density is presumably lower, leading to corrosion of the substrate.
The effect of high film thickness is to reduce dramatically the number of
D-type areas. D-areas are small and the chance of one D-area overlapping
another D-area is low; for two coat films it is almost nil [ 401. Thus, multicoat
films are more effective in providing good corrosion resistance than a single
film of the same equivalent thickness.
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in pore density, and (2) the partial sealing of the pores by corrosion products
or paint aggregates. The first phenomenon prevails for short immersion time,
whereas blockage of the pores, that is the second phenomenon, becomes
more prominent over a long immersion time, as can be seen in Fig. 7.
A value of pore resistance of between 1O6and 1O7ficm2 is often supposed
to represent the boundary between good and poor coating protective properties,
although there is evidence that corrosion beneath an organic coating can
occur at an appreciable rate at R, equal to lo6 Rcm2 [ 381.
The change in water absorption during immersion in NaOH solution,
calculated in the same way as for synthetic seawater is represented in Rig.
5. The Brasher and Kingsbury equation for calculating water uptake may
not be appropriate at these high levels of absorption because it assumes
random uptake uniformly over the whole surface which is more likely at the
lower levels. A rapid initial water uptake can again be observed followed by
a stationary state, which is in agreement with the change in pore resistance.
285
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Fig. 7. Variation of the coating resistance with immersion time in 10% NaOH solution for a
64 @rn coal tar epoxy coating on a steel substrate. Nyquist plot for the same coating after
immersion time of 24 hours.
4. Conclusions
Steel samples coated with coal tar epoxy compositions were studied by
impedance spectroscopy (100 Hz to 100 kHz) in a dry condition as well as
during exposure to synthetic seawater and to 10% NaOH solution. From
these investigations the following conclusions can be drawn:
(1) the dry coating behaves as an almost ideal capacitor in the temperature
range from 0 to 20 “C. In this temperature range its dielectric constant varies
from 3.0 to 3.2;
(2) the coal tar epoxy coating immersed in synthetic seawater shows
a purely capacitative response over a long initial period of exposure. However,
after a few months immersion thinner coatings ( - 50 pm) depart from purely
capacitative behaviour below 1 kHz;
(3) the calculated percent water uptake after an initial rapid rise is
between 9 and 13%, with minor dependence upon the coating thickness.
The thiier coatings showed a slow permanent degradation, but their electrical
resistance after 7 months of continuous immersion was still above 1O7acrn’.
The thicker coatings ( - 125 pm) showed coating resistance above lo8 Rem’
after 9 months of continuous immersion;
(4) in 10% NaOH solution the degradation of the coal tar epoxy coating
is a more rapid process. The calculated water uptake after the initial rapid
rise on the first day stayed at around 30% during the 10 days of exposure.
The coating resistance versus immersion time showed a minimum (1 O6ncm2)
after approximately one day’s immersion followed by a slight increase up
to 1.3 X lo6 &m2 and no further change;
(5) the impedance spectroscopy parameters were shown to be useful
in the study of the coating degradation process.
286
References