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Introduction
Polymeric coating adhesion to metal substrate is critically
important for various industrial applications.18 It is
particularly true when the coating systems are subjected
to environmental degradation, thermal degradation, and
mechanical impact, which can further weaken the coating
adhesive strength.1,2 One such example is the utilization
of fusion-bonded epoxy (FBE) coating to protect steel
pipes against corrosion for oil and gas pipeline applications. The integrity of FBE coating adhesion on steel
substrate is critically important for preventing corrosion
and for extending service life of steel pipes.
Numerous research efforts have been carried out
and many methodologies, such as impact tests, bend
tests, pull-off tests, blister test, acoustic emission, etc.,
have been employed to evaluate coating adhesive
strengths.38 Assessment of the wet-adhesive strength,
i.e., the adhesion performance under wet condition of
FBE coatings on steel substrate is crucial for the
pipeline coating industry. While quantitative assessment of adhesive strength under dry condition can be
easily made by most of the above test methods, their
usage for coating adhesive strength measurement
under wet environment is not considered reliable due
to their difficulties in sample preparation and in data
analysis. Thus, these methods are only suitable for pass
or fail evaluation of the coating wet adhesion performance. A reliable test method that can provide
quantitative assessment of the coating-metal adhesive
strength under a wet environment is still lacking.
Although significant research efforts have been
performed on scratch of metallic/ceramic coatings,912
few have been focused on the study of scratch behavior
of polymeric coatings. A recent development of the
polymer scratch test method (ASTM D7027-05 and
ISO 19252:2008),1315 which has been demonstrated to
be effective for quantitative scratch performance
evaluation of bulk polymers,1518 can also be adopted
255
Experimental
Fig. 1: Typical scratch-induced damage patterns of an acrylic coating system. (a) Three damage zones are observed:
zone 1coating debonding, zone 2in-layer cracking, and zone 3buckling damage, (b) onset of in-layer cracking,
and (c) onset of buckling damage18
256
Fig. 2: Direct visual detection of onset coating debonding (normal load 180 N) after 1 day water immersion: (a) System I
(smooth substrate surface) and (b) System II (smooth substrate surface)
257
Fig. 3: Detection of onset coating debonding (normal load 180 N) by oxidative liquid exposure
Debonding
Bonded interface
Polymer
coating
Steel
substrate
Polymer
coating
Steel
substrate
Coating layer
Substrate
258
31
+1.4e+07
+1.2e+07
+9.1e+06
+6.5e+06
+3.9e+06
+1.3e+06
1.3e+06
3.9e+06
6.5e+06
9.1e+06
1.2e+07
1.4e+07
1.7e+07
3
1
S, S23
(Avg: 75%)
S, S13
(Avg: 75%)
33
+2.3e+07
+2.0e+07
+1.6e+07
+1.3e+07
+9.4e+06
+6.0e+06
+2.6e+06
8.0e+06
4.2e+06
7.6e+06
1.1e+07
1.4e+07
1.8e+07
3
2
32
Fig. 6: Stress components corresponding to possible debonding modes (I, II, and III)
80
In-layer tensile stress
70
Interfacial stress
Stress (MPa)
60
50
Tip diameter = 2 mm
Coating thickness = 100 microns
40
30
20
10
0
0
10
20
30
40
50
60
70
80
259
Fig. 9: Surface roughness effect on coating adhesive strength (System I with smooth substrate surface)
1 day
2 day
3 day
4 day
1 week
Fig. 10: Scratch of System II after up to 2 weeks of hot water exposure (DFT = 100 lm)
260
2 day
3 day
4 day
1 week
2 week
Fig. 11: Scratch of System II after up to 2 weeks of hot water exposure (DFT = 200 lm)
2 day
3 day
4 day
1 week
2 week
Fig. 12: Scratch of System II after up to 2 weeks of hot water exposure (DFT = 300 lm)
Table 1: Onset location and critical normal load for debonding of FBE coating
Immersion
time (days)
0
1
2
3
4
7
14
DFT = 100 lm
DFT = 200 lm
Location (mm)
Load (N)
X
77.8
49.6
44.7
33.7
25.1
O
81.7
51.7
46.5
34.7
25.6
0.6
3.1
1.4
2.1
2.3
Location (mm)
X
X
79.0
69.5
63.5
61.5
56.5
1.4
0.7
2.1
2.1
0.7
DFT = 300 lm
Load (N)
X
X
75.3
66.3
60.7
58.8
54.1
Location (mm)
X
X
82.5
80.8
79.0
77.5
69.5
0.7
1.8
2.8
3.6
0.7
Load (N)
X
X
78.6
76.9
75.3
73.9
66.3
261
of
Adhesive
Adhesive
Immersion
Adhesive
time (days) strength (MPa) strength (MPa) strength (MPa)
DFT = 100 lm DFT = 200 lm DFT = 300 lm
0
1
2
3
4
7
14
X
58
41
30
18
8
O
X
X
47
35
21
13
10
X
X
50
38
23
14
11
262
Conclusion
Based on the standardized scratch test method and FEM
modeling, a new approach has been established to
quantitatively determine the wet-adhesive strength of
FBE coating on steel substrate. With the experimentally
determined critical scratching load of coating debonding, the wet-adhesive strength can be calculated and
determined via FEM. The influences of coating thickness and steel surface roughness on the degradation of
coating adhesive strength have also been investigated.
A rougher substrate surface leads to greatly enhanced
wet-adhesive strength. A thicker coating provides a
better resistance against interfacial adhesion degradation and lowers the debonding stress at the interface.
This study has demonstrated that the proposed testing
protocol is effective for evaluation of epoxy coating wetadhesive strength and for development of optimized
coating systems for industrial applications.
Acknowledgments The authors would like to acknowledge the financial support from the Department of
Transportation (DTPH56-06-T-000022). Significant
inputs, discussion, and experimental assistance from
NOV Tuboscope, 3M, Dow Chemical, and ShawCor in
this research endeavor are also greatly appreciated.
References
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Adelaide, Australia, 2002
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