Laboratory accelerated and field exposure testing of MgRP and MgORP on AA2024-T351: Chemical and electrochemical protection effects

Abstract

Two Mg-based coatings consisting of Mg-rich primer (MgRP) and MgO-rich primer (MgORP) with and without topcoat were exposed to laboratory accelerated lifecycle testing (LALT) and outdoor field environments. The coatings were tested in parallel exposure studies utilizing ASTM B117, modified ASTM B117 (cyclic wet-dry, dark-UV exposure in ASTM synthetic ocean water), rural inland (Charlottesville, VA), and coastal marine (Kennedy Space Center) field exposure. Several characterization and electrochemical diagnostic techniques were used to continuously assess coating performance as a function of time in various exposures, enabling comparison of LALT to field exposures. The coating systems were evaluated with respect to the intact coating and to a machined scribe defect. The fate of Mg2+ upon dissolution of Mg and MgO with respect to pigment depletion, corrosion product formation, and repartitioning from the coating into the scribe was monitored with XRD and EDS. The capacity for MgRP and MgORP to provide barrier, cathodic, and chemical corrosion protection to AA2024-T351 substrate was evaluated. The ultimate ability of these coatings to protect the AA2024-T351 substrate both in the scribe and under the coating was gauged with optical profilometry assessment of corrosion damage. The Mg and MgO-based coating systems exhibited several desirable aspects of a corrosion preventative coating. The corrosion damage quantified both under the intact coating and within the scribe was much less than the corrosion damage measured on uncoated controls. Within a given exposure, the reduction of corrosion damage in the scribe correlated with the amount of Mg2+ which was released from the coating and repartitioned into the scribe. The open circuit potential of the coated substrate was depressed to more negative potentials than the bare substrate in 5 wt% NaCl, with non-topcoated samples establishing more negative potentials. The barrier properties remained high throughout the exposures for topcoated samples, which also better preserved the pigment from depletion. Comments are made regarding differences between the Mg and MgO-based coatings and the various laboratory and field exposures.