NT POLY 185

Approved 2002-09

1(4)

DETERMINATION OF FLEXIBILITY AND FATIGUE RESISTANCE OF AGED BALLAST TANK COATINGS

Key words: Coatings, ballast tanks, cracking, fatique resistance, flexibility, test method

UDC 620.1

INTRODUCTION

SCOPE

The conditions in ballast tanks on ships are in many ways extreme. The temperature can reach more than 70C in the top of the tanks when the sun shines on the deck in tropical areas, and drop to 0C in cold waters and seas. The water in the tanks can vary from fresh to brackish and is not necessarily clean. Corrosion protection is achieved by applying coatings to the steel structure. Although the coating is normally very ductile when it is fresh [1], it loses ductility with age [2]. In ageing ships, cracking of the paint is often observed as the primary cause of subsequent, severe corrosion damage to the steel structure. The cracking is typically located in areas of stress concentrations, i.e. fillet welds, transition between structural details, weld toes, etc., where the local stresses are highest [3], [4]. Cracking of the paint due to increasing brittleness or loss of initial flexibility with ageing is often considered to be a primary cause of subsequent, severe corrosion damage to the steel structures in ships hulls, notably in seawater ballast tanks. There is a recurring state of cyclic loading in ships, due to both temperature variations and movement, which leads to repeated stresses and the presence of relatively large strain magnitudes [5]. According to this reference, very little seems to have been published on the subject of the influence of straining and mechanical fatigue of aged coatings on steel structures for ships. There is an ASTM-standard [6], which describes testing of flexibility properties of polymeric coatings on steel, a bending test done over mandrels of different radii. In the Thesis [5], results are reported from some fatigue tests on aged coatings on steel substrates. The tests were performed on specimens according to ASTM-standard E609-92 for uniaxial Low Cycle Fatigue tests [7]. The results from the investigations [5] showed a great spread in the number of cycles to failure of the coating at 0,4% strain, with a variation between 4 and 1 000 cycles. At some of the specimens the cracks appeared at the waist parts of the specimens. An alternative technique for fatigue loading is to use fourpoint bending [8]. The advantages with this method are that a large part of the specimen is exposed to a uniform stress and that specimen preparation is simple. One disadvantage, however, is that only the outer surface is exposed to the maximum stress. Published by Nordtest Tekniikantie 12 FIN02150 Espoo Finland

This Nordtest method describes procedures to evaluate the strain capacity of aged organic coatings on substrates of steel panels. The method covers determination of the resistance to cracking of attached coatings both by monotonically increasing loads (flexibility) and by cyclic loading (fatigue resistance).

FIELDS OF APPLICATION

The method is applicable to aged organic coatings on steel panels and especially to coatings intended for use as protective coatings for ballast tanks. The method concentrates on the mechanical testing procedures and the ageing procedure is based on standard methods (EN - ISO, ASTM and IEC).

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[1] [2]

REFERENCES
Askheim, E., Nokleby, J. O., Carlsson, L. & Palm, M. Why Paints Crack?PCE March 2001. P. 49. Maurer, F. Viscoelastic behaviour of polymers, Part 5. Department of Polymer Technology, Chalmers University of Technology, Gothenburg, Sweden, 1993. Det Norske Veritas. Guidelines No. 8 for Corrosion Protection of Ships, 1996. Tanker Structure Cooperative Forum. Guidelines for Ballast Tank Coating Systems and Surface Preparation, 3rd draft, 1999. Molin, M. Strain Capacity of Aged Polymeric Coating on Ship Structures. Thesis, Department of Naval Architecture and Ocean Engineering, Chalmers University of Technology, Gothenburg, Sweden, 1999. Standard test methods for mandrel bend test of attached organic coatings. American Society for Testing and Materials, ASTM Standard D522-93a, 1995. Standard practice for strain-controlled fatigue testing. American Society for Testing and Materials, ASTM Standard D2370-92, 1995. Nikkil, Antti-Pekka. Tampere University, Department of Materials Science, Finland, Private communication, 1998. ISSN: 14592843 Project: 1498-00

[3] [4]

[5]

[6]

[7]

[8]

Phone: + 358 9 455 4600 Fax: + 358 9 455 4272 E-mail: nordtest@nordtest.org Internet: www.nordtest.org

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[9]

Advanced technical ceramics Monolithic ceramics Mechanical properties at room temperature Part 1: Determination of flexural strength, EN 843-l: 1995.

[10] Paint and varnishes. Determination of resistance to liquids, Part 2: Water immersion method. EN IS0 2812-2. [11] Practice for Preparation of Substitute Ocean Water. ASTM D 1141 l-90. [12] Basic environmental testing procedure, Part 2: Test Db and guidance: Damp heat, cyclic IEC 68230.

a) For relatively low strains up to about 4% the specimens are loaded in a four-point test jig, which gives a constant stress on the outer surface of the coating between the two inner rolls. For higher strains, bending over cylindrical mandrels with different radii should be used. b) The cyclic loading of the test panels is performed in a four-point test jig equipped with eight rolls, which permits the specimens to be loaded to both positive and negative strains. In both method a) and b), the loading is performed in a suitable mechanical testing machine at ambient temperature.

DEFINITIONS

For the purpose of this NORDTEST method, the following definitions apply; Mandrel bend test, as defined in Ref. [6]. A means of bending a coated panel over cylindrical mandrels of various diameters where the resistance to cracking of the coating is determined. Four-point bending test, as defined in Ref. [9]. A means of bending a coated test panel whereby the test piece is supported on bearings near its ends, and is loaded equally at two positions symmetrically disposed about the centre of the supported span. Coating resistance to cracking (flexibility), the highest strain the coating can stand without cracking in the mandrel or the four-point bending tests. Cyclic fatigue test, a means of cyclically loading a test piece a number of cycles in a four-point eight roll test jig at a certain positive and negative stress amplitude. Coating fatigue resistance, the number of cycles a specimen can be cycled at a certain strain level without coating surface cracking.

7.1

Test samples

The substrates should be made of steel, with a thickness of 3 mm and 30 mm in width and 150 mm in length. Before the coatings are applied, the panels should be blasted. The applied organic coatings should be about 300 m in thickness on both sides. The edges of the panels should be coated with at least the same thickness.

7.2

Ageing of test samples

The ageing should consist of immersion conditioning. One cycle consists of one week. in artificial seawater, humidity exposure a) 72 hours immersion according to EN-IS0 2812-2 at 40C Ref. [l0]. The water shall be artificial seawater according to ASTM D 1141-90, Ref. [11]. b) 24 hours conditioning at 23C and RH = 50%. c) 72 hours damp heat test including condensation according to IEC 68230, Ref. [12], temperature interval 2090C. Maximum exposure time shall be 12 weeks, i. e. 12 cycles, with inspection and mechanical testing after every three weeks.

SAMPLING

This Nordtest method is intended to be applied to aged coated test panels, but can also be used for other coated panels. Due to variations in coating properties between different units, the number in a lot should be at least fifty test pieces. Each test object shall be numbered and records shall be kept including the following information. a) Specification of coating material and base metal of panel to be tested. b) Specification of ageing procedure.
NOTE. For screening purposes, fewer specimens can be used.

7.3

Equipment

The cyclic fatigue tests are performed in an eight roll fourpoint bend test jig, schematically shown in Figure 1. The flexibility tests in which the test panels are monotonically loaded to a certain strain, for strains up to about 4%, are performed in a four-point test jig schematically shown in Figure 2. The cylindrical mandrel test for flexibility determinations at strains higher than about 4% is schematically shown in Figure 3. All mechanical loading shall be performed in a calibrated mechanical testing machine, with a load cell capacity of 2 5 kN. The loading rate in the flexibility test shall be such that the maximum strain is obtained in less than 10 seconds. The frequency which can be used in the cyclic fatigue tests depends on the properties of the testing machine used. For

TEST METHOD

These methods cover the determination of a) the resistance to cracking (flexibility) of attached organic coatings on steel panels when the strain in the surface of the coating is monotonically increased and b) the resistance to cracking when the strain in the surface of the coating is cyclically changed between positive and negative values.

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a mechanical screw machine a frequency of 0,2 Hz is convenient. If a servo-hydraulic machine is used, a higher frequency can be chosen.

7.4

Strain determinations

The strain in the four-point loading test can be determined from the deflection relative to the unloaded position of the test panel at a position midway between the two inner rolls. The following equations apply: l/R = (1 + e)/(R + h/2) R2 = (R A)2 + L2 where R= e= h= D= L= radius of neutral axis of specimen strain thickness of specimen deflection of midpoint of specimen half the distance between the inner rolls of test jig. The distance between the outer rolls is 4L. (1) (2)

Which gives: e = h D/L2 (3)

Figure 1. Schemantic presentation of eight roll 4-point bend jig.

The strain obtained in the mandrel bend test can be calculated from Equation (3) and approximately from the radius of the cylinder used. The maximum strain in the cyclic fatigue tests is obtained from Equation (3).

7.5

Crack density determination

Figure 2. 4-point bend test jig.

After the flexibility tests or after cyclic loading through a number of cycles, the crack density in the surface of the specimens is determined. The determination is performed in an optical microscope at a magnification of at least 40 times. In order to facilitate the determination, the surface under examination is covered with ink, which is wiped off with a wad of cotton soaked in alcohol. Some of the ink is left in the cracks, which facilitates the determination. The number of cracks per unit area is then plotted against strain in the flexibility tests and against the number of cycles in the fatigue tests.

7.6

Test procedure

With 48 specimens in the lot, 12 shall be taken out after each three, six, nine and 12 weeks. Measure the thickness, using a calibrated micrometer, of each test piece at a minimum of three positions, approximately equidistant between the two inner rolls in the four-point test jig, for specimens to be loaded in the four-point test jig, and in three positions near the middle of the panel, for specimens to be used in the mandrel tests. a) Flexibility tests

Figure 3. Cylindrical mandrel test.

In the flexibility tests, select a machine displacement rate such that the selected strain is obtained in less than 10

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seconds. For strains lower than about 4%, the four-point test jig is used. The strain is calculated from Equation (3) from the displacement of the midpoint of the test panel. The displacement can be measured with strain gauges or with a calibrated sliding calliper. The displacement should be measured when the specimen is under load. Unload the specimen and take it out from the test jig. Determine the crack density according to the procedure in 7.5. If no cracks are observable, repeat the loading at 0,5% higher strain on the same specimen until cracks can be observed in the surface. If no cracks are observed at about 4%, use cylindrical mandrels to increase the strain. The panels should be bent approximately 135 over the cylinders in less than 10 seconds. Repeat the bending until cracks are observed in the surface of the specimen. The resistance to cracking (flexibility) is taken as the highest strain at which cracking is not observed. Determine the resistance to cracking for specimens from each of the four ageing groups. b) Cyclic fatigue tests For these tests, use at least 9 specimens from each ageing group. It is suggested that 3 specimens should be cycled at a maximum strain of 1,0 with R = 1, where R = emax/emin, 3 specimens at maximum strain 0,7% and 3 specimens 0,4%. For each chosen maximum strain level, cycle one specimen 100 cycles, one specimen 200 cycles and one

specimen 300 cycles. After each completed test, determine the number of cracks per unit area according to Clause 7.5 and plot the crack density against the number of cycles for each maximum strain level. Repeat this procedure for specimens aged three, six, nine and twelve weeks.

TEST REPORT

The report shall be in accordance with EN ISO/IEC 17025 and shall contain the following information: a) the name of the testing establishment; b) the date of the examination, a unique identification of the report and of each page, the name and address of the customer, and the signatory of the report; c) a reference to this procedure, i. e. determined in accordance with this Nordtest method; d) a description of the specimens evaluated, and any ancillary information available; e) a description of the ageing procedure of the specimens; f) a description of the testing equipment and testing environment; g) the deductions made from the test results, using photographic evidence where appropriate.

Nordic
COUNCIL OF MINISTERS