Multi-Analytical Study of Damage to Marine Ballast Tank Coatings After Cyclic Corrosion Testing

Seawater ballast tanks in vessels are subject to severe service conditions caused by repeated filling/emptying, as well as temperature variation. Consequently, relatively thick, barrier-type coatings are used for corrosion protection of their internals. These are generally formulated with solvent-based epoxy binders and contain a range of flake pigments designed to limit environmental entry. Here, we report on a detailed study of damage processes in order to understand the mechanisms of failure after hygro-thermal cyclic corrosion testing. Similar formulations were cured using variant phenalkamine cross-linkers. Visual observation after corrosion testing shows minimal changes and no sign of corrosion damage. However, high-resolution analytical microscopy and nanoscale tomography reveal the onset of microstructural and chemical damage processes inside the coating. Thus, kaolin and talc pigments in the coating remained stable under hygro-thermal cycling; however, dolomite and barium sulphate dissolved slightly, causing voids. Galvanic protection of the substrate by aluminium flake pigments was disproven as no electrical connection was evident. Vibrational spectroscopy revealed a decrease in residual epoxy functionality after exposure for the coating cured with the more stable phenalkamine. This was correlated with an increase in glass transition temperature (Tg) and no observable corrosion of aluminium flakes. In contrast, the less stable phenalkamine cross-linker caused the binder Tg to decrease and aluminium flakes and substrate corrosion to become evident.