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The Futility and Folly of Seeking the Accelerated Corrosion Holy Grail

The Futility and Folly of Seeking the Accelerated Corrosion Holy Grail
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Since the dawn of mankind, or at least since the advent of the very first accelerated corrosion cabinet, it has been the goal of coatings evaluators to develop an accelerated corrosion testing protocol which reflects the real world of corrosion in totality. There have been passionate arguments promoting one or another testing protocol while demonizing others, but that one protocol has yet to be developed to everyone’s satisfaction. 

Product Number: 41215-885-SG
Author: Carl W. Reed, Kat Coronado
Publication Date: 2015
Industries: Coatings , Corrosion Monitoring and Control , Coatings and Linings
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Since the dawn of mankind, or at least since the advent of the very first accelerated corrosion cabinet, it has been the goal of coatings evaluators to develop an accelerated corrosion testing protocol which reflects the real world of corrosion in totality. There have been passionate arguments promoting one or another testing protocol while demonizing others, but that one protocol has yet to be developed to everyone’s satisfaction. While the simplistic notion of one accelerated corrosion testing protocol is appealing, it is naïve to believe this Holy Grail is actually attainable. Mother Nature, in her divine wisdom, simply will not allow it. In the natural world, there are literally millions of variables that affect the composition and rate of corrosion. Distilling these variables into a few and packaging them into the proverbial accelerated box is not possible. It is therefore incumbent on the industry to back away from such futility and folly and embrace the variations that real world corrosion has to offer by understanding what corrosion is, what is important about corrosion and its measurement, and how to deal with it from a coatings point of view. This paper will look at the history of accelerated corrosion testing and some popular accelerated corrosion protocols. Also, mechanisms of corrosion and the variables that affect the corrosion process will be discussed, especially as they relate to testing protocols. And finally, the role of coatings in accelerated corrosion testing and the variability encountered in the different test protocols will be examined.

Since the dawn of mankind, or at least since the advent of the very first accelerated corrosion cabinet, it has been the goal of coatings evaluators to develop an accelerated corrosion testing protocol which reflects the real world of corrosion in totality. There have been passionate arguments promoting one or another testing protocol while demonizing others, but that one protocol has yet to be developed to everyone’s satisfaction. While the simplistic notion of one accelerated corrosion testing protocol is appealing, it is naïve to believe this Holy Grail is actually attainable. Mother Nature, in her divine wisdom, simply will not allow it. In the natural world, there are literally millions of variables that affect the composition and rate of corrosion. Distilling these variables into a few and packaging them into the proverbial accelerated box is not possible. It is therefore incumbent on the industry to back away from such futility and folly and embrace the variations that real world corrosion has to offer by understanding what corrosion is, what is important about corrosion and its measurement, and how to deal with it from a coatings point of view. This paper will look at the history of accelerated corrosion testing and some popular accelerated corrosion protocols. Also, mechanisms of corrosion and the variables that affect the corrosion process will be discussed, especially as they relate to testing protocols. And finally, the role of coatings in accelerated corrosion testing and the variability encountered in the different test protocols will be examined.

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Accelerated corrosion test methods are regularly utilized in coating industries to predict the performance of coatings in real life exposure. The performance of coatings in these accelerated tests is a key step in the product development cycle. It is essential to understand different factors that may introduce variability in the test result. 
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A previous paper presented by the authors at SSPC 2015 demonstrated the futility and folly of attempting to use accelerated corrosion testing as a tool for predicting real world corrosion performance. The effect of corrosion was shown to be governed by the type of ions and the concentration of oxygen in the corrosion environment. By understanding these two factors, accelerated corrosion testing can, however, be used as an indicator of performance which may be encountered in the real world. 
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Field Testing – The Correlation Between Accelerated Laboratory Tests and Field Testing

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All protective coatings are thoroughly tested using accelerated laboratory tests. Accelerated testing has the advantage of providing data and results in a relatively short timeframe and the conditions of testing are pre-defined and controlled throughout the test. However accelerated testing also has disadvantages. Accelerated testing at e.g. tougher environmental conditions or higher temperatures may give different degradation mechanisms than at in service conditions.Field exposures can be used as a supplement to accelerated testing and can be utilized as a verification of the test setup.In this paper results from several atmospheric accelerated laboratory exposure tests for numerous protective coating systems have been compared to results obtained from up to nine years of field exposure testing in a marine environment corresponding to corrosion category C5 according to ISO 12944-2.The comparison shows varying correlation between accelerated laboratory tests and field exposures. This indicates that high performance of a coating system during accelerated laboratory testing is not necessarily predictive for high long term performance under in-service conditions. Potentially causing premature coating failures under in service conditions.The authors therefore propose ailormade test scheme for the various generic coatings and the in-service conditions and for the industry to accept a more holistic view on coating performance.
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