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Test methodologies for protective coatings of aircraft are analyzed and evaluated in a variety of conditions. Mechanisms and kinetics of damage progression are quantified using in situ measurements of coating system properties.
The most effective means to control atmospheric corrosion of aircraft is through the use of protective coatings. In addition to combating corrosion, which represents a risk to the safe operation of an asset, there are strong economic and environmental drivers to extend the service life of aerospace coatings. Repair and replacement of exterior coating systems that no longer meet protective requirements generate a significant volume of environmentally hazardous waste, which includes the coating material, media used for coating removal, as well as the waste materials generated in surface preparation and reapplication of the coating system. Development and use of the most durable coatings systems has often been limited by the ability to predict service performance in accelerated tests. Existing accelerated test techniques do not adequately employ the chemical, thermal, or mechanical stressors that produce relevant damage mechanisms, such as cracking at structural discontinuities in coated airframes. Additionally, single coating layers may be qualified individually rather than as part of a representative multilayer stack-up. As a result, current test methods cannot be used for accurate quantification of coating performance and service life. In this work, test methodologies previously described that employ combined environmental and mechanical loading modes are utilized to excite relevant failure modes of a multilayer system, such as coating cracking at sealant-filled lap joints. The mechanisms and kinetics of damage progression are quantified throughout static and dynamic atmospheric tests using in situ measurements of coating system properties. It is observed that the coating barrier properties and resistance to cracking at a lap joint are dependent upon both the individual effects of stress, temperature, and humidity as well as the combined interaction effects of these stressors.
Key words: Coating performance, coating cracking, accelerated testing, in situ monitoring, mechanical stress
Corrosion behavior of carbon steel in an in-house solvent was investigated in a pilot-scale post combustion CO2 capture process. Carbon steel specimens were placed where corrosion problems were previously found in the stripper column and the CO2-rich amine piping.
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Case histories will be presented that illustrate the exfoliation corrosion mechanism and the problems that occur in plastics manufacturing systems. Methods for control of corrosion in these systems will be proposed.
Static exposure tests of pre-oxidized stainless steel and carburized chromium were conducted in the molten fluoride salt, LiF-NaF-KF (46.5-11.5-42 mol %), FLiNaK to simulate the corrosion environment typical of some advanced nuclear reaction concepts.