Accelerated Performance Evaluation of Railcar Coatings: A State of the Art Update
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1 Accelerated Performance Evaluation of Railcar Coatings: A State of the Art Update Brian Skerry The Sherwin-Williams Company October 4 th, 2016 Omaha, Nebraska RSI/CMA
2 Testing Paints Fitness for Use Standardized Testing Methods Physical/Performance Properties ASTM D5894 Standard Practice for Cyclic Salt-Fog/UV Exposure of Painted Metal (Alternating Exposures in a Fog/Dry Cabinet and a UV/Condensation Cabinet ASTM B117 Standard Practice for Operating Salt Spray (Fog) Apparatus ASTM D4587 Standard Practice for Fluorescent UV-Condensation Exposures of Paint and Related Coatings ASTM D4585 Standard Practice for Testing Water Resistance of Coatings Using Controlled Condensation ASTM D1735 Standard Practice for Testing Water Resistance of Coatings Using Water Fog Apparatus ASTM D4541 Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion Testers ASTM D522 Standard Test Methods for Mandrel Bend Test of Attached Organic Coatings ASTM D2794 Standard Test Method for Resistance of Organic Coatings to the Effects of Rapid Deformation ASTM D4060 Standard Test method for Abrasion Resistance of Organic Coatings with Taber Abraser ASTM D870 Standard Practice for Testing Water Resistance of Coatings Using Water Immersion ASTM G8 Standard Test Methods for Cathodic Disbonding of Pipeline Coatings ASTM G95 Standard Test Method for Cathodic Disbondment Test of Pipeline Coatings (Attached Cell Method) NACE TM0174 Method A & B Standard Test Method Laboratory Methods for the Evaluation of Protective Coatings and Lining Materials on Metallic Substrates in Immersion Service ISO (NORSOK) Paints and varnishes Performance requirements for protective paint systems for offshore and related structures ISO Paints and varnishes Corrosion protection of steel structures by protective paint systems RSI/CMA
3 Accelerated Coatings Testing Lab RSI/CMA
4 Physical Testing - Lab Adhesion Flexibility Impact Abrasion RSI/CMA
5 Performance Testing Weathering/Durability Color Gloss Corrosion Resistance Rusting Blistering Delamination Undercutting RSI/CMA
6 Weathering Tests Lab Q-UV Xenon Arc Weatherometer RSI/CMA
7 Weathering Testing - Exterior Solar concentrator:low- Temperature EMMA /EMMAQUA Natural Exposures RSI/CMA
8 Corrosion Testing Lab Salt-Fog ASTM B-117 Wet/Dry Cyclic Testing ASTM G-95 Cyclic Corrosion/Weathering Testing ASTM D-5894 RSI/CMA
9 Test Methods Product Development Mimic the Service Environment Required Correlation: (Lab vs. in service ) * Rank order performance * Degradation (rusting/blistering/delamination) * Intact paint (polymer/resin chemistry changes) * Damaged sites (structure/morphology/chemistry of corrosion products) Accelerate the correct rate determining step Results obtained depend on the test method not on the coating! RSI/CMA
10 Corrosion Electrochemistry * Electrochemical Impedance Spectroscopy (EIS) - Coatings performance ranking. - Performance changes before visual detection. * Electrochemical Noise Method (ENM) - Coatings performance ranking - Mechanistic information - Performance predictions (?) RSI/CMA
11 LABORATORY TESTING REPRESENTATIVE PROTOCOLS - ISO, NACE, ASTM, MATERIALS SYSTEM SPECIFICATIONS Atmospheric Immersion Chemical resistance Autoclave Adhesion Abrasion resistance Flexibility Temperature resistance Cathodic disbondment Hardness Atlas Cell Application properties Cure time Solvent content DFT VOC RSI/CMA
12 What s New in Protective Coatings/Testing/Technology? Roadmap to the Future! RSI/CMA
13 Industry Trends 2016 Drives Need for Improved Testing Procedures Regulations force change (lower or 0 VOC s/solvent free/0 HAPs) Fewer coats (2-coats 1-coat) Less surface preparation/more surface tolerant Faster return to service Longer working time/pot life Less maintenance Single component Improved performance/service life RSI/CMA
14 Advancements in Coatings Technology High Performance Acrylics - cross-linking, 0 VOC WB High Build Acrylic Epoxies high performance 100% DTM/WB Urethanes high performance > S/B ($$) Polysiloxanes appearance, durability ($$) Polyaspartics durability, working times, 1-coat ($$$) Fluoropolymers appearance, life cycle costs ($$$$) Styrene-free Vinyl Esters - safety, HAPS free, green RSI/CMA
15 Lab vs. Field - Correlation Replicate rate determining steps in degradation Measure/monitor electrochemistry, analytical RSI/CMA
16 % Gloss Retention and Color Lab vs. Field - Correlation Accelerated Weathering Testing Accelerated Weathering (QUV) WB Urethane Fluoropolymer Assess value of this additional time period of higher performance? Solvent Based Polyurethanes 0 Time RSI/CMA
17 Lab vs. Field Correlation RSI/CMA
18 Where will the future take us? Improved Test Methods Are Available! Water - 1K waterborne = 2K solventborne for steel/atmospheric Waterborne tank linings New polymer designs Nanotechnology Engineered surfaces Self-healing and smart coatings Renewable resources/biobased RSI/CMA
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Approved 388;26160 1,2 388 unsaturated polyester ^(ValidationDate) 1 Product description This is a glass flake reinforced unsaturated polyester coating. It is an ultra high build, extremely abrasion resistant
Property Test/Standard Description. semi gloss (35-70) Flash point ISO 3679 Method 1 32 C
Approved 18420;18360 1,2 18420 epoxy ^(ValidationDate) 1 Product description This is a two component amine cured, glass flake reinforced, abrasion resistant epoxy coating. It is a surface tolerant, high
Salt Spray Resistance
Salt Spray Resistance Test No. TP02 This test procedure is used to determine the resistance of the paint/polymer system used for the Texture Plus system in resisting degradation when subject to salt spray.
Property Test/Standard Description. matt (0-35) Flash point ISO 3679 Method 1 30 C calculated VOC-USA / VOC Hong Kong EPA Method 24
Other Technical Data Sheet 27800;27801 1 27800 VValidationDate). 1 Product description This is a two component amine cured pure epoxy coating. It is a fast drying, high solids, high build product. It provides