Filiform corrosion on organic coated steel

Corrosion poses an ongoing challenge in materials science. This thesis delves into the intricate phenomenon of filiform corrosion (FFC) in organic-coated steel, investigating its mechanisms and proposing novel prevention strategies. Despite extensive empirical research and theoretical models, uncertainties persist about the precise nature of FFC on steel substrates, the causes, and the electrochemical process. This work systematically explores the electrochemical underpinnings of FFC, shedding light on the influencing factors and the complex interactions within the metal-paint interface. Advanced electrochemical methods are developed to systematically study and replicate the FFC phenomenon, providing a deeper understanding of this often underestimated issue in industrial applications. Leveraging insights from FFC research in other alloys, such as aluminum and magnesium, this thesis significantly advances our comprehension of FFC's mechanisms and underlying chemical reactions. Furthermore, the research introduces novel techniques for evaluating existing corrosion mitigation solutions and proposes innovative strategies. A breakthrough innovation is presented, involving the development and characterization of a ceramic composite pigment system based on calcium and aluminum loaded with an organic inhibitor. This promises substantial advancements in corrosion protection for steel structures. Additionally, commercially available technologies are being assessed for their effectiveness in safeguarding against FFC also using a simulated electrochemical approach, with the aim of validating this suggested methodology. In summary, this thesis aims to provide a comprehensive study of filiform corrosion for organic-coated steel substrates, offering a deeper understanding of its mechanisms, novel prevention strategies, and innovative characterization techniques.