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The free flood areas of underwater vehicles pose a significant and expensive corrosion problem to operating forces. These areas undergo an alternating cycle of wetting and drying in a closely confined area that has regions of relatively stagnant seawater and other regions of high turbulence. The corrosion induced damage requires constant upkeep by ship’s force and frequent expensive maintenance action by depot personnel to effect periodic full restoration.
The free flood areas of underwater vehicles pose a significant and expensive corrosion problem to operating forces. These areas undergo an alternating cycle of wetting and drying in a closely confined area that has regions of relatively stagnant seawater and other regions of high turbulence. The corrosion induced damage requires constant upkeep by ship’s force and frequent expensive maintenance action by depot personnel to effect periodic full restoration. Modifications to the superstructure area of underwater platforms are contemplated that will reduce the accessibility of this region for periodic maintenance. An improved coating system is therefore needed to increase the longevity of the current system from about 5 years to 20 years, corresponding to the midlife major overhaul availability. A three-phase program of coating evaluation was developed to address this need. This report provides the results of the first two phases of the program. The first phase consisted of the development of key attributes necessary for an improved coating system and the screening of available commercial coating products. The second phase consisted of a series of mechanical properties testing and corrosion testing to select out the best candidates for a final phase of at sea and long-term corrosion performance testing.
Due to very severe conditions at offshore, conventional coatings do not work as they require multicoats to acquire high thickness and their curing times are rather high, giving chances for the contamination by severe environment (high RH and salt) in the intermediate layers. Thus, modern coatings which can give larger thickness in just one single coat and cure in a few minutes time are required for critical applications such as splash zone which is marred by continuous dry and wet spell.
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Improved selection of testing protocols for corrosion coatings, along with proper interpretation of the results, allows for a better representation of how coatings will perform in service. A review of several types of corrosive service environments is presented, including the testing normally performed, along with a more in depth look at how to quantify performance variables in a rating system based on individual test results.
Two-Coat zinc-rich primed systems with a fast-dry topcoat were evaluated for their potential to replace the conventional three-coat zincrich/epoxy/polyurethane bridge coating systems for rapid field deployment.