Unit 6 Coating Failure Case Histories
Download
Report
Transcript Unit 6 Coating Failure Case Histories
Coating Failure
Analysis
An overview
© KTA-Tator, Inc.
Coating Failure Consequences
Damage to substrate
Costly rework
Downtime
Product contamination
Coating Failure Consequences :
Damage to Substrate
Substrate repair
Substrate replacement
Pedestrian
Bridge
Coating Failure Consequences:
Costly Rework
Condition of the existing system?
Field repairing a shop applied system
Coating Failure
Consequences: Downtime
Can cost more than the coating failure
Examples areas where corrosion has developed
and may be difficult to address.
5a– The surfaces above grating slots are below motor and lock pin assemblies.
5b– Grating strips and angle iron beneath sidewalk grating and curb.
5c– Corrosion above lift span girder below the steel curb over deck/sidewalk grating.
5d- Back to back angles of a counterweight.
5e– Rusted fasteners behind electric (latch pin) motor.
5f– Steel above a lift span girder -the underside of various steel elements deck surface.
SCRUB COLUMNS
Coating Failure Consequences:
Product Contamination
Tanks, vessels, pipelines
Product contact with disbonded coating
Product contact with exposed substrate
Coating Failure Analysis
Receiving the “telephone call”
(Background)
Field Investigation
Laboratory analysis
Report and Recommendations
Background
Location
Substrate
Age of Site and of Coating
Location,storage, or exposure of coating
Coating Specification
Coating Product Data Sheets
Coating Inspection
Background
Substrate preparation
Environmental conditions during coating
application
Time reference between failure and
application of coatings
Description of failure including any
noticeable patterns
Field Investigation
View condition of the applied coatings
Investigate the nature of the failure
Dry film thickness of the coating
Field testing of coating; physical parameters
Condition of the substrate
Obtain samples from “failing” areas that are
representative of the failure
Field Investigation
Obtain samples from “non-failing” areas that
are representative
Note any patterns
Laboratory Techniques
for Coatings Failure
Analysis
Laboratory Testing
Optical / Digital Microscopy
Infrared Spectroscopy
Gas Chromatography / Mass
Spectroscopy / Pyrolysis
High Performance Liquid Chromatography
SEM / EDS
Atomic Absorption Spectroscopy
Differential Scanning Calorimetry
Electrochemical Impedance Spectroscopy
Optical / Digital Microscopy
Visual examination of coating samples
20X to 1000X magnification
Inexpensive, rapid gathering of information
May change the course of a failure analysis
Cross-section Diamond Blade
50X
© KTA-Tator, Inc.
Cross-section at Edge/Corner
Tank lining –cross-section
Coating Thickness
Fourier Transform Infrared
Spectroscopy (the IR)
Produces a fingerprint of an individual paint
Can determine if the paint specified was the
one actually applied
How an IR Works
A spectrometer passes infrared light through
a coating sample
Molecules absorb light at different rates
An IR produces a spectrum
Each coating type has its own spectrum
Amine Cured Epoxy Coating
Gas Chromatography
Detects the presence of solvents trapped in a
coating
Gas Chromatography works on the principle
of attraction
Each solvent eludes (comes out) at a
different rate
Solvent Entrapment
Entrapped solvents can cause serious
problems
Solvent entrapment can be detected years
after application
Pyrolysis / Gas Chromatography /
Mass Spectroscopy
Pyrolysis- allows for vaporization of a solid
sample
Mass Spectroscopy- allows universal
identification of separated components
Review-Gas Chromatography- allows for
separation of components within a mixture
High Performance Liquid
Chromatography (HPLC)
Wide range of testing
Employs a liquid, rather than a gas, to carry
a sample through the testing columns
HPLC includes:
Ion chromatography
Gel permeation chromatography
Ion Chromatography
Six salts can be identified through a single test
1. Chloride
4. Nitrite
2. Phosphate
5. Nitrate
3. Sulfate
6. Bromide
Gel Permeation
Chromatography
Looking for problems within a resin system
Allows separation of coating components by
molecular weight
SEM/EDS
Uses magnification up to 5000X and beyond,
if necessary
Examines defects in the coating surface
Compares failing and non-failing areas
Provides Elemental Information
SEM – EDS of Zinc Layer - Elemental Analysis of Filler
filler
consisted
elementally
of calcium
and
silicon……
most likely
calcium
silicate
Differential Scanning
Calorimetry
Used to determine if a product has
properly cured
Useful for product with high mix ratios
© KTA-Tator, Inc.
Electrochemical Impedance
Spectroscopy
AC (alternating current) electricity to measure
electrical resistance (impedance)
Impedance used to assess coating integrity
and to follow deterioration
-
Excellent
Results of Laboratory
Techniques
Optical Microscopy
Starting point /Observation/ Determine
path of investigation
Infrared spectroscopy Resin types/mix ratios
Gas chromatography Solvent identification
Ion chromatography
Salt identification
GPC
Separation / formulation discrepancy
SEM/EDS
High magnification / elemental analysis
AA spectroscopy
Toxic Metals/ Environmental issues
DSC
Degree of cure
EIS
Barrier properties / track degradation