Cracks and defects, as a result of internal stress during
curing,
can accelerate the degradation and failure of protective epoxy coatings
for essential infrastructures. To reduce, or eliminate, this so-called
premature crack formation, it is essential to understand the underlying
mechanisms. The present work investigated the simultaneous development
in internal stresses, the degree of conversion of reactants (i.e.,
cross-linking), the volumetric shrinkage, and the elastic modulus
of a solvent-based novolac epoxy cured with a cycloaliphatic amine.
In addition, the crack susceptibility of the coating was quantified
from a stress–strain curve (tensile mode), and the effects
of film thickness, solvent content, pigment volume concentration,
and flat versus 90-degree angle geometry were mapped. Finally, digital
microscopy, in combination with a nondestructive scanning acoustic
microscope (SAM) analysis, proved efficient for characterization of
the crack morphology. Residual solvent, due to plasticization, promotes
a low crack susceptibility. Later in the process, however, the solvent
plasticization contributes to a high reactant conversion, and when
the solvent finally evaporates, an increased internal stress is established.
This, in turn, leads to an associated higher probability for crack
initiation and growth. The crack susceptibility method provides insight
and input to guidelines on how to modify formulations and curing conditions.