Polarization-Accelerated Seawater Splash Simulation for Rapid Evaluation of Protection Performance of an Epoxy Coating on Carbon Steel

The application of organic coatings is the most cost-effective and common method for metallic equipment toward corrosion, whose anti-corrosion property needs to be improved and evaluated in a short time. To rapidly and rationally assess the anti-corrosion property of organic coatings in the ocean splash zone, a new accelerated test was proposed. In the study, the corrosion protection property of the coating samples was measured by an improved AC-DC-AC test in a simulated seawater of 3.5 wt.% NaCl solution, a simulated ocean splash zone test and a new accelerated test combining the above two tests. The results showed that the corrosion rate of the coating samples was high in the improved AC-DC-AC test, which lost its anti-corrosion property after 24 cycles equal to 96 h. The main rapid failure reason was that the time of the water and corrosive media arriving at the carbon steel substrate under the alternating cathodic and anodic polarization with symmetrical positive and negative electric charges was shortened. The entire impedance of the coating samples was improved by about 1.6 times more than that in the initial early time in the simulated ocean splash zone test, which was caused by the damage effect from the salt spraying, drying, humidifying, salt immersion, high temperature and UVA irradiation being weaker than the enhancement effect from the post-curing process by the UVA irradiation. In the new accelerated test, the samples lost their corrosion resistance after 12 cycles equal to 288 h with the fastest failure rate. On account of the coupling process of the salt spraying, drying, humidifying, salt immersion, high temperature combined with the cathodic and anodic polarization and the UVA irradiation, the penetration and transmission rate of water and corrosive media in the coating were further accelerated, the corrosion rate on the carbon steel substrate was reinforced even larger and the destruction of the top polymer molecules was more serious. The new accelerated test showed the strongest damage-acceleration effect than that in the other two tests.