open access publication

Article, 2024

Delamination of thermally sprayed ZnAl15/organic duplex coating systems on structural steel for offshore wind applications

Surface and Coatings Technology, ISSN 1879-3347, 0257-8972, Volume 485, Page 130796, 10.1016/j.surfcoat.2024.130796

Contributors

Li, Ziyou 0000-0002-1498-4501 [1] Bi, Huichao 0000-0003-0418-0355 (Corresponding author) [1] Gunnarsson, Sverrir [2] Weinell, Claus Erik 0000-0001-7178-4808 [1] Dam-Johansen, Kim Dam- 0000-0003-1658-6176 [1]

Affiliations

  1. [1] Technical University of Denmark
    2. [NORA names: DTU Technical University of Denmark; University; Denmark; Europe, EU; Nordic; OECD];
  2. [2] Hempel A/S, Lundtoftegårdsvej 91, 2800 Kgs. Lyngby, Denmark
    3. [NORA names: Denmark; Europe, EU; Nordic; OECD]

Abstract

Duplex coating systems incorporating both thermally sprayed metal (TSM) and organic coatings have demonstrated excellent corrosion protection performance in highly corrosive offshore applications. However, the present work showed extensive delamination of organic coatings from the TSM (ZnAl15) layer during ISO 12944-9 cyclic ageing test. A positive correlation was uncovered between cathode-to-anode ratio and the extent of the delamination, which was further verified by delamination measurement on samples with varying artificial scribes. A depletion of aluminum at the tip of propagating cracks in the TSM layer was detected by scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS), suggesting the occurrence of local acidification driven by hydrolysis of Al3+. X-ray diffraction (XRD) analysis confirmed ZnO, Zn5(OH)8Cl2·H2O, and AlO(OH) as the main corrosion products in the artificial scribe. Careful considerations and supplementary real-field assessment were recommended when employing ISO 12944-9 cyclic ageing test for a robust anticorrosive performance evaluation of this type of duplex coating system.

Keywords

Al3+, AlO(OH, ISO, X-ray, X-ray diffraction, X-ray spectroscopy, ZnO, acidification, aging test, aluminum, applications, artificial scribe, assessment, cathode-to-anode ratio, coating, coating system, considerations, correlation, corrosion, corrosion products, corrosion protection performance, crack, cyclic aging tests, delamination, delamination measurements, depletion, depletion of aluminum, diffraction, dispersive X-ray spectroscopy, duplex, duplex coating system, electron microscopy, energy, energy dispersive X-ray spectroscopy, evaluation, excellent corrosion protection performance, hydrolysis, hydrolysis of Al3+, layer, local acidification, measurements, metal, microscopy, occurrence, offshore applications, offshore wind applications, organic coatings, performance, performance evaluation, positive correlation, production, protection performance, ratio, samples, scanning electron microscopy, scribes, spectroscopy, steel, structural steel, system, test, thermally, thermally sprayed metals, tip, tips of propagating cracks, wind applications

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