Coatings fogging

The initiation of development in the activator solution is more rapid than in conventional processes because the developer molecules need not diffuse into the light-sensitive layers from the processing solution. In spite of the low activity of the coated developer, some unintentional reduction sensitization may occur, which produces unwanted fog. Therefore, coating the developer in a separate layer usually is preferred. Because of simplicity, rapid access, and solution stabihty, incorporated developer papers have been used for office copying appHcations. 

Formulation of effective corrosion-resistant coatings is made difficult by the lack of a laboratory test that can provide rehable predictions of field performance. The most widely used test is exposure in a salt fog chamber. It has been shown repeatedly, however, that the results of such tests do not correlate with actual performance (125). Outdoor exposure of panels can provide useful data, especially in locations where salt spray occurs, but predictions of performance are not always satisfactory (126). 

A good sensitizing dye does not interfere with other system properties. Sensitizing dyes can sometimes influence the intrinsic response of a chemically sensitized emulsion, leading to desensitization or additional sensitization. The dye can also interfere with development rate, increase or decrease unwanted fog density, and remain as unwanted stain in the film after processing. The dye should have adequate solubihty for addition to the emulsion, but should not wander between layers in the final coating. 

Sa.lt Spray Tests. One of the older accelerated corrosion tests is the salt spray test (40). Several modifications of this imperfect test have been proposed, some of which are even specified for particular appHcations. The neutral salt spray test persists, however, especially for coatings that are anodic to the substrate and for coatings that are dissolved or attacked by neutral salt fog. For cathodic coatings, such as nickel on steel, the test becomes a porosity test, because nickel is not attacked by neutral salt fog. Production specifications that call for 1000 hours salt spray resistance are not practical for quahty acceptance tests. In these cases, the neutral salt spray does not qualify as an accelerated test, and faster results from different test methods should be sought. 

Standard method for evaluation of painted or coated specimens subjected to corrosive environments Standard test method of salt spray (FOG) testing... 

The most common of the spray tests is the salt-spray or salt-fog test which was developed originally by Capp in 1914 for studying the protective values of metallic coatings on steel under conditions that he hoped would simulate exposure to a sea-coast atmosphere. Since then the test has been used for a number of purposes, for many of which it is not well suited Although there is no standard size or shape of salt-spray box certain other features of the test have been standardised in ASTM B117 1990. Various... 

Organic coatings are commonly evaluated using salt water immersion, salt fog or spray, modified salt exposure tests (e.g., salt fog with added SO2), and various cyclic exposure tests. Humidity exposure and water immersion, and, for many applications, physical resistance tests (adhesion, impact resistance, etc.) are widely used preliminary tests. Standard methods for most of these tests are given in compilations of standard tests such as the Annual Book of ASTM Standards (16). Test methods have been extensively reviewed (e.g., 17-23). 

Metallic corrosion is an electrochemical process associated with the flow of current between surface sites having a difference in electrochemical potential. The assessment and evaluation of organic coatings to prevent metal corrosion has traditionally been accomplished through salt fog testing (ASTM B-117) and long term exposure tests in particular service environments. Electrochemical techniques have often been considered (, but are not routinely employed in practice. 

Absolute correlations between service performance and electrochemical measurements do not appear frequently in the literature. Based on 300 test systems. Bacon and coworkers (, correlated electrochemical resistance with exposure time. Recently, Mills ( also observed a correlation between salt fog corrosion and electrochemical resistance. We have found open circuit potential measurements to be extremely useful for the routine evaluation of high-nitrile polymer-based photocured coatings. 

The effect was more pronounced at the starting potential than at the finish potential. Leidheiser suggested that the best performance is obtained when the cathode/anode surface area ratio is the same as the uncoated metal. Inadequate performance is obtained when the cathode/anode area ratio becomes larger. Qur work agrees with Leidheiser s hypothesis. The B210/GBL coatings have rest potentials less noble than the B40 coated steel panels and perform best in the salt fog environment. 

Accelerated Corrosion Tests. There are as many as a dozen methods (salt fog, Kesternich, etc.) that are currently being used to investigate corrosion resistance of coating systems and a need to develop a better and more dependable method to predict in-use service. A severe drawback of all these tests is that their results often compare unsatisfactorily with practical experience. One reason for the discrepancies is assumed to be the variability of natural exposure conditions. Accordingly, cyclic testing procedures have been developed with which exposure conditions, especially temperature and humidity. 

In all the paint systems tested in the atmosphere, the presence of the chloride contaminant at its highest concentration, causes the appearance of small blisters. Such blisters may in time burst due to the oxide built-up inside them, as was seen in the case in the CR system ("Table III.") In the P system ("Table III."), the blistering seen with the third level of chlorides continues after two years outdoor exposure, without rust coming through the coating. This same effect is also seen in salt fog test panels, but it does not appear in those test specimens subjected to accelerated weathering tests. 

Recent studies on monitoring of a carrier environment( 3 ) have shown that its corrosion severity parallels to a laboratory cyclic environment of 5% NaCl spray (fog) with 30ppro of SO2. The development of a new chemical conversion coating which is also resistant to this environment would be of great inportance. 

Panels of high strength aluminum alloy (7075-T6) were used in this study. The panels were approximately 10 x 3 x 0.032 inch (25 x 7.5 x 0.08 cm) in size. The test environments for coating evaluation were (1) a 5% NaCl spray (fog) chamber according to ASTM Standard Method of Salt Spray (Fog) Testing (B117-73), and (2) a modified 5% NaCl/S02 spray (fog) chamber with SO gas introduced periodically - ASTM Standard Practice for Modified Salt Spray (Fog) Testing (G85-84(A4)). In the latter case, a constant spray of 5% NaCl was maintained in the chamber and SO2 was introduced for one hour four tines a day (every 6 hours)( ). Coated test panels were examined for corrosion after one- and two- eek exposure periods. 

Salt Spray Test Panels coated with the standard chromate conversion coating and CMT were compared with each other in their corrosion resistant properties in several ways. The conventional 5% NaCl/S02 fog chamber tests showed excessive corrosion and pitting within one week on chromate conversion coated (COC) 7075-T6 A1 alloy panels. The CMT coated panels were almost uncorroded and without any pits. The plates in Figure 1 show the conditions of the panels after 7 and 14 days exposure in this environment. Even after 14 days exposure the CMT panels were still far better than COC panels. 

Table 1 - Corrosion test results of coated 7075-T6 A1 alloy exposed to salt/S02 fog environment.

Figure 1. Effect of 5% NaCl/S02 fog exposure on corrosion resis properties of chemical conversion coatings on 7075-T6 aluminum a...

Slides coated with fused zinc stearate were exposed with the cages to furnish records of the fog deposits, which might be correlated with the kills. 

The combined (S + Au)-sensitization usually is applied during the manufacture of the emulsion, but sensitization can be achieved also by bathing a coated S-sensitized emulsion in an aurous thiocyanate solution before exposure (161). Reduction sensitization can be combined with (S + Au)-sensitization under some conditions. Collier (162) found that reduction sensitization either before or after (S + Au)-sensitization increased both sensitivity and fog in a l-ym octahedral grain silver bromide emulsion. The largest increase in sensitivity and lowest increase in fog were achieved when reduction sensitization was applied after the S+Au. Hydrogen hypersensitization likewide is effective (108) and can produce large increases in sensitivity for some emulsions. 

Rusting and blistering of high solids polyester coatings on metal substrates. Salt fog resistance (300 h)... 

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