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Damage morphology and force-deflection curves for impact loading of thick multilayer organic protective coating systems

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Abstract

The response of organic coatings to mechanical impact is crucial to their corrosion protection performance, particularly under offshore conditions. The paper categorizes and discusses four different types of response during the high-energy (3 to 20 J) impact of a falling ball-shaped weight on 14 multilayer organic offshore coating systems. The response types include plastic deformation, brittle (compressive) crushing, radial crack formation, and lateral delamination. Threshold and transition conditions are analyzed based on contact mechanics relationships. For the first time, complete force-deflection curves for this type of coating are recorded with an instrumented impact tester. The curves feature four characteristic points, namely a first local force maximum (FFS), the respective deflection at this force level (δFS), a maximum force (Fmax), and the respective deflection at this maximum force (δmax). These characteristic parameters are discussed in terms of coating system composition. Empirical equations for these parameters as well as for the damage size are derived. The results offer opportunities to quantitatively rank organic coatings with respect to their impact resistance.

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Abbreviations

a:

Contact radius

AC :

Contact area

AD :

Damage area

cL :

Lateral crack length

D:

Coating thickness

EC :

Young’s modulus coating material

ED :

Impact energy

EI :

Young’s modulus drop weight material

ES :

Young’s modulus substrate material

F:

Contact force

FA :

Anode area

FC :

Cathode area

FL :

Threshold force for lateral crack formation

FM :

Threshold force for median crack formation

Fmax :

Maximum force

FPL :

Threshold force for plastic deformation

g:

Gravity acceleration

H:

Height of fall

HC :

Hardness coating material

KIc :

Mode-I fracture toughness

rcorr :

Corrosion rate

RD :

Radius drop weight

t:

Time of measurement

vD :

Drop weight velocity

α:

Recovery angle

δ:

Deflection

δmax :

Deflection at maximum force

νC :

Poisson’s ratio coating material

νI :

Poisson ratio indenter material

νS :

Poison ratio substrate material

ρC :

Coating density

σC :

Flexural strength

σY :

Yield strength

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Acknowledgments

The investigations were funded by the German Federal Ministry of Education and Research (BMBF) in the frame of the innovation initiative “Wachstumskerne-Unternehmen Region”, sub-program: “OWS-MV: Offshore Wind Solutions-Mecklenburg-Vorpommern”.

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Authors and Affiliations

  1. Muehlhan Holding GmbH, Hamburg, Germany

    A. W. Momber

  2. Fraunhofer-Institut für Großstrukturen in der Produktionstechnik, Albert-Einstein-Straße 30, 18059, Rostock, Germany

    M. Irmer, D. Kelm & V. Cherewko

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Appendices

Appendix

Damage morphologies and force-deflection curves

See Figs. 16, 17, 18 and 19.

Fig. 16
figure 16

Failure/damage modes in coating system 5 (scale bars: 5 mm) and force-deflection curves for three impact intensities (energies). (Note the different axis scalings.) (a) Impact energy: 3 J (plastic response with permanent depression and wall formation); see Fig. 6. (b) Impact energy: 7 J (plastic-elastic response with central damage, plastic deformation and radial cracks). (c) Impact energy: 20 J (plastic-elastic response with central damage and radial and lateral cracks). Lateral cracks lead to coating delamination; see Fig. 10

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Fig. 17
figure 17

Adhesive failure in the intermediate layers (system 12) and force-deflection curve at high impact energy (20 J). (Scale bar: 5 mm)

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Fig. 18
figure 18

Transition from radial cracking to lateral cracking (scale bars: 5 mm) with increasing impact energy and force-deflection curves (system 10). (Note the different axis scalings.) (a) Impact energy: 7 J (plastic-elastic response with radial cracking). (b) Impact energy: 20 J (plastic-elastic response with lateral cracking and coating delamination)

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Fig. 19
figure 19

Adhesive failure after impact loading (scale bars: 5 mm) and force-deflection curves (system 8). (Note the different axis scalings.) (a) Impact energy: 7 J (plastic-elastic response with radial cracking and partial lip/wall cracking). (b) Impact energy: 20 J (plastic-elastic response with intra-layer delamination)

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Momber, A.W., Irmer, M., Kelm, D. et al. Damage morphology and force-deflection curves for impact loading of thick multilayer organic protective coating systems. J Coat Technol Res (2023). https://doi.org/10.1007/s11998-023-00829-9

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