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    The effect of surface roughness on corrosion resistance of machined and epoxy coated steel

    Year: 2019

    Journal: Prog. Org. Coat., Volume 130, MAY, page 17–23

    Authors: Hagen, C. M. H.; Hognestad, A.; Knudsen, O. O.; Sorby, K.

    Organizations: Research Council of Norway [235239/O70]; Brunvoll; Omya Hustadmarmor; Triplex; AquaMarine

    Keywords: Organic coatings; Cathodic disbonding; Underfilm corrosion; Steel

    By incorporating periodic micro-patterns on steel substrates, the effect of surface roughness on corrosion resistance of a two-component polyamine cured epoxy mastic coating has been studied. Machining was employed to pattern the surfaces with periodic peaks of varying peak-to-valley heights, Rz. The focus of the study was to find the surface parameter that contributes most to the stability of an organic coating in corrosive environment, and to evaluate if machining can be comparable to blast cleaning with respect to coating durability. A strong correlation between roughness (Rz) and corrosive delamination of coated surfaces was seen. Increasing Rz from 57 mu m to 252 mu m on surfaces with triangular peaks, increased the effective contact area by 40% and decreased delamination by 30%. By introducing tilted asperities at Rz = 224 mu m while keeping the effective contact area in general unchanged, delamination decreased another 55%. Hence, an increased Rz is found to be only partially beneficial, and the profile shape is more significant than the roughness value per se. The results suggest that mechanical interlocking has a substantial influence on the interfacial stability of protective coatings in corrosive environments. By optimal selection of cutting parameters, machining can give surfaces where protective coatings have long lifetime.
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