Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
UTM-MPRC, Institute for Oil and Gas, Universiti Teknologi Malaysia, 81310, Skudai, Johor, Malaysia
2
Department of Materials, University of Oxford, Parks Road, OX1 3PH, Oxford, United Kingdom
zalilah@petroleum.utm.my, john.sykes@materials.ox.ac.uk
Abstract
This research concentrates on the thermal ageing of a full 3-coat system with sacrificial pigment (zinc rich) primer on mild steel
where the temperature dependence test is conducted to explore the correlation between the coating resistances with the corrosion rate
underneath the coating. Electrochemical impedance spectroscopy (EIS) is introduced over a range of temperature to extract
activation energies for the rate of controlling processes in the corrosion reactions. It is expected that the zinc rich primer does not
form a barrier coating for the metal substrate rather it will be the most active component of the substrate in the electrochemistry. Full
3-coat system with zinc rich primer show the extracted activation energy from coating resistance is significantly lower than the
activation energy extracted from the charge transfer resistance. This suggested that the coating resistance from EIS cannot be
controlling the corrosion reaction. The activation energies generated for the corrosion process here (7897 kJmol-1) are very much
higher than those of ion transport through the coating (1937 kJmol-1) during early immersion. Further interesting findings come
from the activation energy trends over time particularly for the corrosion process which shown that the value is decreasing where at
the end of exposure, the activation energy values for coating and charge transfer resistance become quite similar. It is suggested that
at this stage ion transport in the coating might be controlling the corrosion process unlike at the beginning; the activation energy is
getting smaller due to coating degradation.
Index Terms: epoxy coating, electrochemical impedance spectroscopy, thermal effect, zinc rich primer
-----------------------------------------------------------------------***----------------------------------------------------------------------1. INTRODUCTION
Temperature changes impose a direct impact on the corrosive
protective performance of coatings; especially in an
environment where the value of temperature keeps changing.
For example, a natural gas pipeline network often has
continuous changes in temperature, with possible range as
high as 135oC in the vicinity of a natural gas well to an
ambient temperature at a pumping station.
Previous work [1, 2] has established that it could be possible
to separate resistances for the coating and the coating-metal
interface from EIS spectra. The plotted Arrhenius of logarithm
resistance against reciprocal of temperature yielded larger
activation energies for the corrosion process than for ion
conduction in the coating, showing that the coating resistance
could not be responsible for controlling the corrosion rate.
Here further coatings, including a full 3-coat system with
sacrificial pigment primer are studied. In this work, the
electrochemical activity of the zinc rich primer (coupled to the
steel substrate) plus barrier properties of those two topcoats
were in concern. Thus, steel with zinc rich primer (ZRP) alone
of
its
2. EXPERIMENTAL PROCEDURE
A commercial zinc rich primer with 50m thickness was
tested. Coatings were applied to grit-blasted mild steel panels
by air spraying. Further tests were conducted on a full 3-coat
system consisting of a zinc rich pigmented 2-component
epoxy primer (50m), a low volatile organic content (VOC),
high-solid, high-build epoxy barrier coat pigmented with
micaceous iron oxide (180m) and a 2-component acrylic
polyurethane topcoat (60m), prepare and applied similarly.
The edges of all panels were protected with a thick highperformance
epoxy
coating.
The
electrochemical
measurements were made using a three-electrode cell with
vertical working electrode of area 40 cm2.The reference
electrode was a saturated calomel electrode (SCE) and the
counter electrode a platinised titanium electrode of area of 9
cm2. The samples were exposed in hot 3% NaCl solution (800
cm3), made from analytical grade chemicals and deionised
water, held at constant temperature in a water bath (or slowly
__________________________________________________________________________________________
Volume: 02 Issue: 10 | Oct-2013, Available @ http://www.ijret.org
134
z'', ohm.cm2
40000
20000
0
0
(b)
40000
60000
80000
100000
120000
z', ohm.cm2
The EIS spectra from zinc rich primer were fitted with circle
fit from the ACM software whereas EIS spectra from zinc rich
full system coating were fitted to a non-linear least squares
fitting software (with ZSimWin) to a R[Q[R[QR]]] model
circuit as illustrated in Figure 1 [Q=constant phase element].
(a)
20000
(c)
__________________________________________________________________________________________
Volume: 02 Issue: 10 | Oct-2013, Available @ http://www.ijret.org
135
-0.40
2.0E+03
ZR-primer 1
25
25oC
ZR-primer 2
o
30
30 C
-0.60
z'', ohm.cm2
Potential, V/SCE
-0.50
-0.70
-0.80
-0.90
EPP
1.0E+03
50oC
50
0.0E+00
10
12
14
16
18
20
22
o
40
40 C
o
45
45 C
2.0E+03
0.0E+00
-1.00
0
o
35
35 C
0.0E+00
0.0E+00
1.0E+03
24
2.0E+03
2
z', ohm.cm
Time, days
6.E+03
25oC
25
z'', ohm.cm2
30
30oC
0.E+00
0.E+00
35
35oC
6.E+03
o
40
40 C
o
45
45 C
3.E+03
o
50
50 C
0.E+00
3.E+03
6.E+03
2
z', ohm.cm
3.0
slope = 1674
R2 = 0.9764
2.5
2.0
0.00305
0.00315
EA = 34 + 2.3 kJ/mol
EA = 32 + 9.9 kJ/mol
3.5
Log Resistance (ohm.cm )
0.E+00
0.00325
0.00335
3.5
slope = 1785
R2 = 0.9907
3.0
2.5
0.00305
0.00315
0.00325
1/T (1/K)
1/T (1/K)
(a)
(b)
0.00335
Fig- 7: Arrhenius plot for ZRP coating after (a) 7 days and (b)
14 days of exposure at 50oC
__________________________________________________________________________________________
Volume: 02 Issue: 10 | Oct-2013, Available @ http://www.ijret.org
136
over the zinc rich epoxy primer and the second semicircle
corresponded to the electrochemical activity of the zinc rich
primer coupled to the steel substrate. To be certain a test is
conducted to investigate the effect of changing the signal
amplitude on the semicircles as a way of identifying the
different features displayed in Nyquist plots. EIS spectra were
taken at amplitudes ranging from 20 mV to 120 mV. It is clear
from Figure 9 that changing the applied potential only changes
the shape of the second semicircle.
Panel 1
Panel 2
Panel 3
Panel 4
21oC
-0.4
2.0E+07
50oC
-0.5
3.E+06
50oC
-0.6
2.E+06
-0.7
20mV
21 C
z'', ohm.cm2
-0.3
Epp
-0.8
-0.9
0
10
20
30
40
50
60
70
80
1.0E+07
0.E+00
0.E+00
50mV
4.E+06
100mV
90
120mV
0.0E+00
0.0E+00
1.3E+07
2.5E+07
z', ohm.cm2
3.2.3
Temperature
Dependence
of
Coating
Parameters
Figures 10 to 11 show the effect of changing temperature on
the EIS response of full system coating after 21 and 35 days
exposure at 50oC. Similar to epoxy-phenolic paint and full
system with an inhibitive primer as studied previously [1, 2]
the size of the semicircles decreases as temperature rises.
These semicircles were fitted to the equivalent circuit in
Figure 1 and this procedure give the most accurate
determination of coating resistance (Rp) at high frequency and
charge transfer resistance (Rct) at low frequency. Then the
logarithm of Rp and logarithm of Rct were plotted against
reciprocal of temperature to determine activation energies for
conduction in the coating and the corrosion reaction. A
straight line was fitted to the data points in Figure 12 to
calculate the activation energies by multiplying the slope with
the gas constant, R.
Circuit Model
ZRP (primer only) gave two semicircles (Figure 3) and here
again two semicircles were observed (Figure 9) for the full
system. The first semicircle was expected to be the top coating
__________________________________________________________________________________________
Volume: 02 Issue: 10 | Oct-2013, Available @ http://www.ijret.org
137
8.0E+06
o
25oC
25
C
35oC
35 C
40oC
40
C
7.5
o
z'', ohm.cm2
50oC
50 C
4.0E+06
7.0
Rct
EA = 20 + 0.5 kJ/mol
Rp
EA = 28 + 1.9 kJ/mol
0.0032
0.00325 0.0033
1/T (1/K)
6.5
6.0
5.5
5.0
0.00315
0.0E+00
0.0E+00
4.0E+06
8.0E+06
z', ohm.cm2
3.0E+06
z'', ohm.cm2
25oC
25oC
30oC
30oC
35oC
35oC
o
40oC
40
C
0.0034
(b)
1.2E+07
0.00335
Fig- 12: Arrhenius plots of Rp and Rct for zinc rich full system
coating after (a) 21 days and (b) 35 days of exposure at 50oC
It is evident from Figure 13 that the activation energy for the
corrosion process decreasing overtime, and at the end of the
exposure, they are quite similar. It is suggested that at this
stage ion transport in the coating might be controlling the
corrosion process. In the beginning the activation energy
values get smaller over time because of coating degradation.
1.5E+06
0.0E+00
0.0E+00
3.0E+06
6.0E+06
z', ohm.cm2
120
97
100
80
60
37
40
20
20
19
20
25
24
11
24
10
0
3
14
Time, days
21
30
120
7.0
6.5
Rct EA = 25 + 2.5 kJ/mol
6.0
5.5
Rp
EA = 45 + 3.2 kJ/mol
100
84
80
0.0031
0.0032
1/T (1/K)
(a)
0.0033
60
40
45
37
30
28
20
20
25
28
20
0
1
5.0
0.0030
78
14
Time, days
21
35
0.0034
__________________________________________________________________________________________
Volume: 02 Issue: 10 | Oct-2013, Available @ http://www.ijret.org
138
CONCLUSIONS
In contrast with the zinc phosphate full system coating [1],
zinc rich full system gave the same conclusion as the thinner
coatings [2] where the coating resistance from EIS cannot be
controlling the corrosion reaction. The activation energies
generated for the corrosion process here (7897 kJmol-1) are
very much higher than those of ion transport through the
coating (1937 kJmol-1) during early immersion (Figure 13).
Further interesting findings come from the activation energy
trends over time particularly for the corrosion process where
the value is decreasing, so that at the end of exposure the
values for Rp and Rct become quite similar. It is suggested
that at this stage ion transport in the coating might be
controlling the corrosion process unlike at the beginning; the
activation energy is getting smaller due to coating degradation.
ACKNOWLEDGEMENTS
We are grateful to Ministry of Higher Education of Malaysia
for awarding the scholarship that supported this research and
Shell Global Solution International BV for providing samples
and financial support.
REFERENCES
[1] Z. Sharer Sahir, J.M. Sykes, Effect of Temperature on the
Impedance Response of Coated Metals, Application of
Electrochemical to Organic Coating, Conference Paper,
Switzerland (2013)
[2] Z. Sharer, J. Sykes, Insights into Protection Mechanisms
of Organic Coatings from Thermal Testing with EIS,
Progress in Organic Coatings, 74, 2 (2012), p. 405-409
[3] A. Meroufel, S.Touzain, EIS Characterization of New
Zinc-Rich Powder Coatings Journal of Progress in Organic
Coatings, 59, 3 (2007), p. 197-205
[4] S. Feliu, Jr., R. Barajas, J. M. Bastidas, M. Morcillo, S.
Felliu, Study of Protection Mechanism of Zinc Rich Paints
by
Electrochemical
Impedance
Spectroscopy,
Electrochemical Impedance: Analysis and Interpretation,
ASTM STP 1188, J.R. Scully, D.C. Silverman and M.W.
Kending (eds) American Society for Testing and Materials,
Philadelphia (1993) p. 438-449
[5] D. Pereira, J. D. Scantlebury, M. G. S. Ferreira, M. E.
Almeida, The Application of Electrochemical Measurements
to the Study and Behaviour of Zinc-Rich Coatings Journal of
Corrosion Science, 30, 11 (1990), p. 1135-1147
[6] S. E. Faidi, J. D. Scantlebury, P. Bullivant, N. T. Whittle,
R. Savin, An Electrochemical Study of Zinc-Containing
Epoxy Coatings on Mild Steel, Journal of Corrosion Science,
35,5-8 (1993), p. 1319-1328
[7] X.R. Novoa, M. IZquierdo, P. Merino, L. Espada,
Electrical Impedance Spectroscopy and Zero Resistance
Ammeter (ZRA) as Tools for Studying the Behaviour of ZincRich Inorganic Coatings, Materials Science Forum, 44&45
(1989) p. 223 234
__________________________________________________________________________________________
Volume: 02 Issue: 10 | Oct-2013, Available @ http://www.ijret.org
139