Attachment 1: Team Project Activities

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TEAM PROJECT ACTIVITIES

Project Discussion with industrial partners and members of academia to seek additional input, develop Technical Advisory Panel Team, including Peer Review members. Kick-Off Team meeting and modify the research program, if necessary. Use analytical and finite element analysis to calculate residual stresses in a multi-layer pipeline coating systems. Identify critical coating material properties to the development of residual stresses. The residual stress calculation includes: (a)Stress distribution along longitudinal direction of a coated pipe joint, particularly at the cutback (b)Stress distribution at the metal-coating interface and across the thickness direction. Evaluate the existing residual stress measurement techniques – cantilever beam, instrumented ring, and others – and select the most appropriate method for this research; Make residual stress measurement Identify the impact of manufacturing parameters, such as processing temperatures and coating thickness on residual stresses. The 3L polyolefin coating systems are:
I.3L High-Density Polyethylene (HDPE)
1.FBE-4 mil / adhesive-10 mil / HDPE-140 mil
2.FBE-10 mil / adhesive-10mil / HDPE-140 mil

II.3L PP

1.FBE-4 mil / adhesive-10 mil / PP-140 mil
2.FBE-10 mil / adhesive-10mil / PP-140 mil
Identify and measure the basic coating material properties to be used in the calculation of residual stresses.

Compare the calculated residual stress values with the experimental values and refine the analytical modeling to match with the experimental results on residual stresses. Prepare Adhesion test panels. The following surface preparations will be applied: I.Anchor profile height – 3 mil, 2 mil, and 1.5 mil
II.Anchor profile shape – angular and round
III.Peak density – 60, 80, 100 peaks/inch
IV.Chloride contamination, 20, 30, 40, 50 mg/m2,
V.Dust level – Rating 1, 2, 3 in ISO standard 8502-3
VI.With and without phosphoric acid wash
VII.Chromate treatment.
Determine the adhesion degradation rate by immersion of test panels in: (a)3 percent salt solution at 60 °C for 1 year
(b)Dry/wet cycling.

Identify the effect of various surface treatments on adhesion durability; Prepare free films of single layer FBE, adhesive, and multi-layer coating;

Immerse free films in 60 °C, 3 percent salt water to measure their ageing stability, weight, and dimensional change versus time. The total immersion time is one year.

Immerse residual stress samples in 3 percent salt water at 60 °C and measure the residual stress relaxation rate.