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• W611439286 abstract "Subsea 7 is experiencing corrosion and coating degradation on their remotely operated vehicles (ROV) and tether management system (TMS). The structure consists of steel, stainless steel and aluminium, and is protected with sacrificial anodes of zinc and magnesium in addition to organic coating. This does not give the required protection needed for the environment it is exposed to, which is alternating conditions between seawater immersion and marine atmosphere. The problem is pitting corrosion on the aluminium parts and cathodic disbonding of the paint film. Another protection system should be suggested. During this work, nine different coating systems have been investigated in the lab with respect to degradation in seawater and marine atmosphere. Standardized test methods for investigation of cathodic disbonding (ISO 15711), filiform corrosion and other degradation mechanisms (EN 3665) have been performed. Two of the coating systems have been given special attention. These are thermally sprayed zinc (TSZ) duplex coating and thermally sprayed zinc-aluminium (TSZA) duplex coating. The zinc-aluminium alloy contains 15% Al. Such systems have shown very good performance in marine field testing. It provides protection as a barrier against the environment, and also works as a sacrificial anode at damages in the coating. A cyclic test (ISO 20340) has been performed to evaluate the performance of these duplex coatings. A scanning electron microscope (SEM) was used to investigate the results. The results show that both TSZ and TSZA experience degradation in form of corrosion and blisters along an artificial scribe. However, TSZA looks a lot worse than TSZ. The suggested explanation is that the Al-content in the TSZA sample increases the under-film corrosion rate of the metal coating due to acidification of the electrolyte. Formation of HCl, from AlCl3, increases the dissolution rate of both aluminium and zinc. The large amount of corrosion products lifts the paint film from the substrate. The corrosion creep is measured to be 3-4 mm on the TSZ samples, and 9mm on the TSZA sample, after 14 weeks of exposure. Results from the immersion test show a large diversity in the extent of cathodic disbonding on the different samples. Hot dip galvanized zinc with phosphate conversion coating and polyester powder coating showed really bad performance, with no adhesion after exposure. A steel sample coated with zinc-rich primer, epoxy intermediate layer and polysiloxane topcoat showed blisters around the artificial holiday, resulting in some adhesion loss. Two other coating systems, polyester and epoxy coatings with aluminium pigments and glass flakes, performed very well. Most of the TSZ and TSZA duplex coatings performed well regarding cathodic disbonding. A deviation was however seen on the TSZA duplex sample with 100 &#61549;m zinc-aluminium coating, which experienced some adhesion loss due to cathodic disbonding. None of the coating systems showed any degradation after exposure to the climate chamber used in the test standardized in EN 2665. Thermally sprayed duplex coatings with zinc and zinc alloy have proven to be suitable for seawater immersion. Previous work has also shown excellent results in real marine atmosphere. Testing in the lab however, shows poor resistance to degradation, especially for TSZA. Hence, only TSZ duplex coatings should be used in alternating environment before further research concerning TSZA duplex coatings is done. TSZ duplex coating is however evaluated to be an expensive solution for Subsea 7 compared to the level of degradation experienced on the existing solution. The ROV and TMS are not very difficult to maintain. Local damages can be fixed at site. Hence, the best solution for Subsea 7 is to change the sacrificial anode material for protection of aluminium parts. Anodes of Al/Zn/In alloys should be used to avoid pitting corrosion. Polyester and epoxy coatings, containing aluminium and glass flake pigments, should be used on steel components. When the periods between operations are expected to be longer, the ROV and TMS should be flushed with fresh water to remove salts." @default.
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• W611439286 date "2012-01-01" @default.
• W611439286 modified "2023-09-22" @default.
• W611439286 title "Protective coatings for alternating immersed and atmospheric exposure" @default.
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