Mechanical integrity and tribological properties of cargo hold coatings: Investigation of polymeric materials and commercial coating systems

• Coal cargo simulation enables multi-parameter durability assessment of coatings • Wear, surface damage, and cleanability were evaluated in a unified testing framework • Single-property metrics fail to predict coating performance under cargo-hold conditions • Co-optimization of bulk wear resistance and surface properties is critical for durability • Silicone-modified epoxy shows superior abrasion resistance and water-only cleanability This research investigates the durability and performance of commercial epoxy-based coatings, termed Epoxy-1 and Epoxy-2, alongside millimeter-thick polymeric panels within a simulated cargo hold environment. To replicate real-world mechanical stresses and contaminations, a coal cargo experimental simulation was employed, allowing for a controlled evaluation of material degradation, cleaning efficiency, and resistance to surface damage. Surface damage and bulk properties were analyzed thoroughly, revealing key interactions at both levels. Rather than reliance on isolated material properties, the findings demonstrate that optimal cargo hold coatings require a synergistic balance of mechanical durability, wear resistance, and cleanability. Epoxy-2 and an acrylic panel with a scratch-resistant surface treatment (ACSR) were identified as the most durable materials, exhibiting minimal surface damage, low weight loss during abrasion test (Taber), and superior cleanability. Conversely, despite favorable individual properties like hardness and coefficient of friction (COF), the Epoxy-1 coating, as well as polycarbonate (PC), and polytetrafluoroethylene (PTFE) panels showed considerable wear and poor cleaning performance. The results highlight the need for multifactorial optimization of mechanical integrity and tribological properties in coating design, emphasizing that durability in cargo hold applications depends on integrating multiple material properties to ensure structural integrity, abrasion resistance, and ease of maintenance.