Abstract
The effect of environmental loads on the propensity for failure of automotive coating systems was evaluated for both the United States and China. Population weighted climate distribution functions were created for both nations and applied to various failure modes including yellowing or color change, gloss loss, delamination, and cracking. The effect of process variability on specific failure modes was captured through the use of minimum and maximum film builds measured on vehicles produced in a commercial automotive assembly plant. The U.S. was shown to be a significantly harsher environment for most failure modes driven by UV radiation and high temperatures. China was shown to be a harsher environment for failure modes driven by liquid water and cold temperatures. The use of these models allowed for the prediction of regional failure rates given the time to failure of a coating of known thickness in a different location.
Similar content being viewed by others
References
Gerlock, JL, Kucherov, AV, Nichols, ME, “On the Combined Use of UVA, HALS, Photooxidation, and Fracture Energy Measurements to Anticipate the Long-Term Weathering Performance of Clearcoat/Basecoat Automotive Paint Systems.” J. Coat. Technol., 73 (918) 45 (2001)
Smith, C, Gerlock, J, Carter, R, “Determination of Ultraviolet Light Absorber Longevity and Distribution in Automotive Paint Systems Using Ultraviolet Micro-spectroscopy.” Polym. Degrad. Stab., 72 89–97 (2001)
Nichols, M, Darr, C, Smith, C, MD, T, Fischer, E, “Fracture Energy of Automotive Clearcoats—I. Experimental Methods and Mechanics.” Polym. Degrad. Stab., 60 (97) 291–299 (1998)
Bauer, DR, “Perspectives on Weatherability Testing of Automotive Coatings.” J. Coat. Technol., 74 (1) 33–38 (2002)
Chin, J, Nguyen, T, Byrd, E, Martin, J, “Validation of the Reciprocity Law for Coating Photodegradation.” J. Coat. Technol. Res., 2 (7) 499–508 (2005)
Chin, JW, Byrd, E, Embree, N, Martin, J, Tate, JD, “Ultraviolet Chambers Based on Integrating Spheres for Use in Artificial Weathering.” J. Coat. Technol., 74 (6) 39–44 (2002)
Gerlock, J, Kucherov, A, Smith, C, “Determination of Active HALS in Automotive Paint Systems II: HALS Distribution in Weathered Clearcoat/Basecoat Paint Systems.” Polym. Degrad. Stab., 73 (2) 201–210 (2001)
Kucherov, A, Gerlock, J, Matheson, R, Jr, “Determination of Active HALS in Weathered Automotive Paint Systems: I. Development of ESR Based Analytical Techniques.” Polym. Degrad. Stab., 69 (1) 1–9 (2000)
Nichols, ME, Ford, CAD, Company, M, “Effect of Weathering on the Stress Distribution and Mechanical Performance of Automotive Paint Systems.” J. Coat. Technol., 70 (885) 141–149 (1998)
Nichols, M, Boisseau, J, Pattison, L, Campbell, D, Quill, J, Zhang, J, Smith, D, Henderson, K, Seebergh, J, Berry, D, Misovski, T, Peters, C, “An Improved Accelerated Weathering Protocol to Anticipate Florida Exposure Behavior of Coatings.” J. Coat. Technol. Res., 10 153–173 (2013)
Bauer, DR, “Predicting In-service Weatherability of Automotive Coatings: A New Approach.” J. Coat. Technol., 69 (1) 85–96 (1997)
Kiil, S, “Model-Based Analysis of Photoinitiated Coating Degradation Under Artificial Exposure Conditions.” J. Coat. Technol. Res., 9 (4) 375–398 (2012)
Kiil, S, “Mathematical Modeling of Photoinitiated Coating Degradation: Effects of Coating Glass Transition Temperature and Light Stabilizers.” Prog. Org. Coatings, 76 (12) 1730–1737 (2013)
Pickett, JE, Sargent, JR, “Lifetime Predictions for Hardcoated Polycarbonate,” Service Life Prediction of Polymeric Materials, pp. 153–169, 2009
Pickett, JE, Sargent, JR, Blaydes, Ha, Babbie, N, “Effects of Temperature on the Weathering Lifetime of Coated Polycarbonate.” Polym. Degrad. Stab., 94 (7) 1085–1091 (2009)
Pickett, JE, Coyle, DJ, “Hydrolysis Kinetics of Condensation Polymers Under Humidity Aging Conditions.” Polym. Degrad. Stab., 98 (7) 1311–1320 (2013)
Sargent, JR, Shuler, S, Pickett, JE, “Polycarbonate Glazing: Maximum and Effective Temperatures for Outdoor Weathering Exposure in the Desert of Arizona,” Proc. SAE, pp. 573–577, Apr 2009
Pickett, J, Webb, K, “Calculated and Measured Outdoor UV Doses.” Die Angew. Makromol., 252 217–236 (1997)
Hinderliter, B, Sapper, E, “Water Concentration Distribution in Coatings during Accelerated Weathering Protocols,” Proc. CoatingsTech Conf., 2013
Croll, SG, “Application and Limitations of Current Understanding to Model Failure Modes in Coatings.” J. Coat. Technol. Res., 10 (1) 15–27 (2012)
Hinderliter, B, Croll, S, “Monte Carlo Approach to Estimating the Photodegradation of Polymer Coatings.” J. Coat. Technol. Res., 2 (6) 483–491 (2005)
Shi, X, Hinderliter, BR, Croll, SG, “Environmental and Time Dependence of Moisture Transportation in An Epoxy Coating and Its Significance for Accelerated Weathering.” J. Coat. Technol. Res., 7 (4) 419–430 (2009)
“US Census Department.” http://www.census.gov/main/www/access.html. Accessed March 2014
“National Bureau of Statistics of China.” http://www.stats.gov.cn/english/. Accessed March 2014
“US Department of Energy.” http://apps1.eere.energy.gov/buildings/energyplus/weatherdata_about.cfm. Accessed March 2014
Ross, S, A First Course in Probability, 4th ed. Prentice-Hall, 1994
Beuth, JLJ, “Cracking of Thin Bonded Films in Residual Tension.” Int. J. Solids Struct., 29 1657 (1992)
Perera, DY, Vanden Eynde, D, “Moisture and Temperature Induced Stresses (Hygrothermal Stresses) in Organic Coatings.” J. Coat. Technol., 59 (748) 55 (1987)
Perera, T, Nguyen, D, “Hygroscopic Stress and Failure in Coating/Metal Systems,” Eurocoat Congress, 1996
Perera, DY, Schutyser, P, “Effect of Physical Aging on Thermal Stress Development in Powder Coatings.” Prog. Org. Coatings, 24 299–307 (1994)
van der Linde, R, Belder, EG, Perera, DY, “Effect of Physical Aging and Thermal Stress on the Behavior of Polyester/TGIC Powder Coatings.” Prog. Org. Coatings, 40 (1–4) 215–224 (2000)
Misovski, T, Nichols, ME, Hardcastle, H, “The Influence of Water on the Weathering of Automotive Paint Systems.” In: Martin, J, Ryntz, R, Chin, J, Dickie, R (eds.) Service Life Prediction of Polymeric Materials. Springer, New York, 2009
Nichols, ME, Gerlock, JL, Smith, CA, Darr, CA, “The Effects of Weathering on the Mechanical Performance of Automotive Paint Systems.” Prog. Org. Coatings, 35 (1–4) 153–159 (1999)
Nichols, ME, Tardiff, JL, “The Effects of Weathering on the Fracture Resistance of Clearcoats.” In: Martin, JW, Bauer, DR (eds.) Service Life Prediction Methodologies and Metrologies, pp. 373–394. ACS, Washington, 2000
Henderson, K, Hunt, R, Boisseau, J, Pattison, L, “The Importance of Water in the Weathering of Automotive Coatings.” JCT CoatingsTech, 5 (9) 50–55 (2008)
Lin, J, Nielsen, CP, Zhao, Y, Lei, Y, Liu, Y, McElroy, MB, “Recent Changes in Particulate Air Pollution over China Observed from Space and the Ground: Effectiveness of Emission Control.” Environ. Sci. Technol., 44 (20) 7771–7776 (2010)
Acknowledgments
The authors would like to thank both BASF and Axalta Coating Systems for some of the paint systems discussed in this manuscript.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Nichols, M.E., Frey, J.F. Statistical modeling of coating lifetimes in disparate environments. J Coat Technol Res 12, 49–61 (2015). https://doi.org/10.1007/s11998-014-9624-5
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11998-014-9624-5