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Corrosion Test Methods

The Moly-White Pigments Group maintains a state of the art accelerated testing laboratory for research and development projects.  Salt-spray, humidity, QUV and cyclic salt-spray testing is provided as a service to formulators evaluating Moly-WhiteŽ corrosion inhibitors.

Although conventional salt-spray tests (e.g., ASTM B117) are very widely used in the coatings industry, it has long been noted that correlation of salt-spray data with outdoor exposure results can be quite poor.  The Moly-White Pigments Group has taken a pioneering role in the development and promotion of more reliable test methods for corrosion resistant coatings.

Improved Test Methods
Test Methods based on altering exposure to cyclic salt-spray (e.g. `Prohesion´) and UV-condensation (e.g., QUV) have been shown to offer the best available correlation with outdoor exposure testing due to increasing industry interest, these cyclic methods were recently adopted as an ASTM standard under the designation ASTM D5894, "Cyclic Salt-Fog/UV Exposure of Painted Metal".  Typical test conditions are outlined in
Table 1.

Cyclic salt-fog/UV exposure tests are believed to offer better correlation with outdoor results due to the incorporation of:

  • a more appropriate choice of electrolyte (composition and concentration)
  • UV and condensation induced degradation
  • periodic cycling of test conditions, including temperature and wet/dry cycles

The superior `real-world´ correlation of cyclic salt-fog/UV exposure tests versus conventional salt-spray tests was very dramatically demonstrated
 in two recent industry studies on accelerated test methods.  As outlined in
Table 2. cyclic salt-fog/UV exposure tests were found to offer tremendously improved correlation with field data versus the use of conventional salt-spray and other new methods that have been suggested to the coatings industry.

 

 

Table 1
ASTM D5994 Cyclic Salt-Fog/UV-Exposure Test Procedure

Typical Test Cycle [1 cycle = 336 hrs (2 weeks)]

  • 168 hrs Cyclic UV/Condensation (e.g. 'QUV')
    (1 week)
    4 hrs UV Exposure, 60 degrees C (UVA-340)
    4 hrs Condensation, 50 degrees C

 

  • 168 hr Cyclic Salt-Spray Exposure (e.g. 'Prohesion')
    (1 week)
    1 hr Salt-Spray, 25 degrees C (using 0.35% NH4(SO4)2, 0.05% NaCl electrolyte)
    1 hr Dry-Off, 35 degrees C

The above cycle is then typically repeated for a total of 3 - 6 cycles (i.e., 1008 - 2016 hrs of exposure)

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Table 2
Correlation of Outdoor and Accelerated Testing

                  Correlation Coefficients

Test Method

SSPC data (1)

CSCT data(2)

     

ASTM B117 Salt Spray

-0.110

-0.107

Cyclic Salt-Spray (w/ 5% NaCl)

-ND

-0.046

KTA Envirotest Type 1

-0.485

-ND

KTA Envirotest Type 2 (w/UV)

-0.481

-0.213

KTA Envirotest Type 3

-0.043

-ND

KTA Envirotest Type 4 (w/UV)

-0.619

-ND

Prohesion Test

-0.065

-0.091

ASTM D5994 Cyclic Salt-Fog/UV-Exposure

-0.699

-0.459

     

ND = Not Determined

   
 

 

The above data represents results obtained in independent studies conducted by the Society of Protective Coatings (SSPC) and the Cleveland Society of Coatings Technology (CSCT).  In these studies the statistical correlation of accelerated test results and outdoor exposure were compared in the testing of a wide variety of water and solvent based coatings, including alkyd, epoxy, latex and polyurethane systems.  Correlation coefficients were averaged based on outdoor testing conducted at 10 industrial and marine test sites located throughout the U.S. and Canada.

References:
(1) Journal of Protective Coatings and Linings, Vol. 11, No. 10, 1994, p.51.
(2) Journal of Coatings Technology, Vol. 65, No. 837, 1994, p.49.

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