In Situ Atmospheric Corrosion Monitoring of Coated Aluminum Alloys Exposed in Tropical Monsoon Climate

Organic coatings are the most widely utilized corrosion protection strategy for metallic materials. Nevertheless, they can degrade over time through the effects of UV, moisture, and corrosive media, compromising their protective performance. In order to monitor the coating performance for predictive maintenance, an electrochemical sensor was fabricated using 6005A aluminum alloy and coated with four coating systems: (1) epoxy primer, (2) epoxy primer/polyurethane topcoat, (3) epoxy primer/polyurethane topcoat/aluminum-powder-containing polyester resin, and (4) epoxy primer/polyurethane topcoat/aluminum-powder-containing polyester resin/acrylic coat. The sensors and corresponding coupon samples were exposed for 24 months at two sites in Thailand: Pathum Thani (PTI, suburban) and Chon Buri (CBI, mild marine). Electrochemical impedance spectroscopy (EIS) measurements were conducted at a fixed frequency of 117 Hz, synchronized with on-site meteorological monitoring. Impedance data were converted into a coating aging index (AI) to quantitatively assess the coating degradation. Coating deterioration was observed in PTI as early as at 6 months of exposure. Machine learning modeling revealed that cumulative rainfall was the dominant environmental factor influencing coating degradation. The single epoxy primer layer exhibited the poorest durability, while the incorporation of polyurethane, aluminum-pigmented polyester, and acrylic layers significantly prolonged the protective service life of the coating system.