Advanced Coatings for Wear and Corrosion Protection: Session II
Program Organizers: Evelina Vogli, Flame Spray Inc.; Virendra Singh, Schlumberger
Monday 2:00 PM
October 18, 2021
Room: A220
Location: Greater Columbus Convention Center
Session Chair: Evelina Vogli, LM Group Holdings; Virendra Singh, Schlumberger
2:00 PM
The Effects of Graphene in Composite Polymer Coatings Against Inorganic Scales: Manuel Marya1; Virendra Singh1; Alireza Zolfaghari1; 1Schlumberger
The effects of minor graphene additions to high-temperature thermoplastic coatings has been investigated to establish if of any practical benefits to both abrasion resistance, friction, and general inorganic scale deposition. Using a variety of controlled tests, coating hardness, friction coefficients under varying contact stresses, anti-galling, anti-scaling behaviors with carbonate and barium sulfates, and CO2 corrosion resistance were all measured and discussed. The investigation demonstrates that graphene additions ( in the proper range and with the selected thermoplastic) can substantially harden the thermoplastic coating without detrimental consequences on the other properties. Scale nucleation and growth is also briefly discussed in relation to the presence of graphene.
2:20 PM
Direct Electrodeposition of Corrosion Resistant Coatings onto Aluminum Alloys: Rajeswaran Radhakrishnan1; Timothy Hall1; Maria Inman1; Earl Jennings Taylor1; Stephen Snyder1; Cory Crowley2; 1Faraday Technology Inc; 2Fermi National Accelerator Laboratory
Faraday will describe our recent work on the development of corrosion resistant coatings directly applied to aluminum alloys (6061/4047) after one-step electrochemical surface pretreatment process. Conventional aluminum coating application processes commonly require extensive surface pretreatment processes prior to deposition, owing to aluminum’s reactive nature and affinity for oxygen. In this study we will discuss a simple pretreatment process that enables direct deposition onto Al alloys and can dramatically reduce the cost and challenges associated with the surface preparation of Al. Furthermore, we will discuss the corrosion performance of the Ni, and NiP coatings applied directly to 6061 Al and 4047 Al surfaces.
2:40 PM
Improved Coating Performance of REACH Compliant Trivalent Chromium Plating Process for Functional Applications: Andrew Moran1; Tim Hall1; Rajeswaran Radhakrishnan1; Stephen Snyder1; Maria Inman1; EJ Taylor1; Kamyar Ahmadi2; Stanko Brankovic2; George Bokisa3; Mark Feathers4; 1Faraday Technology Inc.; 2University of Houston; 3Coventya International; 4U.S. Army Aviation and Missile Command
Faraday will discuss recent research work on the development of functional REACH compliant trivalent chromium plating process to replace hard hexavalent chromium plating. Hexavalent chromium plating has been used for many years to provide hard, durable coatings with excellent wear and corrosion resistance properties. However, hexavalent chromium baths have come under increasing scrutiny due to the toxic nature of the bath, effects on the environment, and workers’ health. Faraday has demonstrated that the chrome coatings prepared using the FARADAYIC® Process have similar functional properties to the coatings produced with a hexavalent chromium bath. Faraday will present results from its development of a trivalent chromium bath to specifically include the effects of bath chemistry and pulse electrodeposition process parameters on the wear resistance of a functional chrome coating from a hexavalent chromium free plating process.
3:00 PM
Galvanic Corrosion Mitigation of CFRP-AZ31B Dissimilar Joint: Yong Chae Lim1; Jiheon Jun1; Jong Kahk Keum1; Yuan Li1; Donovan Leonard1; Michael Brady1; Zhili Feng1; 1Oak Ridge National Laboratory
Advanced high specific strength materials such as magnesium alloys and carbon fiber reinforced polymer (CFRP) can be employed to increase fuel efficiency for lightweight vehicles. However, joining and corrosion (especially galvanic corrosion) of such multi-materials joints are steep technical hindrances for transportation applications. In this work, we employed a friction self-piercing rivet process to spot join a CFRP to magnesium alloy AZ31B at a laboratory coupon scale. Different surface coatings/modifications were applied to the different rivet materials to mitigate galvanic effects at the rivet/multi-material interfaces. Corrosion behavior of CFRP-AZ31B joints was evaluated by 0.1 M NaCl immersion testing with increasing times. Post corroded joints were evaluated by corrosion depth assessment, optical and electron microscopy analysis. Surface coatings including oxide layer and PTFE polymer coating on the rivet material showed reduction of galvanic corrosion of the AZ31B compared to the untreated rivet case.
3:20 PM Break
3:40 PM
Novel Spray-on TBC Coating with Outstanding Wear and Corrosion Protection: Paul Curtis1; 1Applied Thin Films, Inc.
Thermal barrier ceramic coatings are typically deposited using expensive equipment such as plasma spray or EBPVD. This presentation will address a novel, easy-to-apply TBC coating based on a patented aluminophosphate material. The coating incorporates a novel ceramic microballoon additive in pre-ceramic polymer slurry formulations for low thermal conductivity and sprayed onto metal or ceramic substrates with conventional HVLP spray equipment while achieving ceramic conversion below 300 °C. These coatings are deposited directly on metal substrates with excellent adhesion without needing a primer or bondcoat pretreatment. These coatings exhibit ultra-low thermal conductivity (< 0.5 W/m*K at 25 °C) and are suitable for large-scale industrial applications. Experimental efforts to assess performance on various metal substrates and under thermal shock, wear, and corrosive environments with related material characterization results will be discussed.
4:00 PM
Now On-Demand Only - Polymeric Coatings Embedded with Green Anti-corrosive Pigment for Corrosion Inhibition of Steel: Muddasir Nawaz1; Abdul Shakoor1; Ramazan Kahraman1; M. F. Montemor2; 1Qatar University; 2Universidade de Lisboa
Natural Gum Arabic (GA) used as a corrosion inhibitor and loaded into cerium oxide nanoparticles (CONPs) to develop an environment-friendly anti-corrosive pigment used in the epoxy formulation for corrosion protection of steel in the marine environment. Epoxy coatings containing CONPs, without GA, were also prepared as reference. High-Resolution Transmission Electron Microscopy (HR-TEM) and Fourier Transform infrared spectroscopy (FTIR) revealed the successful loading of GA into the CONPs. Thermogravimetric analysis (TGA) and Brunauer-Emmett-Teller (BET) techniques confirmed approximately ⁓30.0 wt. % loading of GA into the CONPs. Electrochemical impedance spectroscopy (EIS) demonstrated the anticorrosion properties of the epoxy coatings modified with the GA loaded CONPs when compared to reference coatings. Corrosion protection mechanism demonstrates that GA loaded CONPs (anti-corrosive pigment) act as a filler material for epoxy coating and it can also aid the recovery of the protective properties of the epoxy coating leading to the formation of a stable protective layer.
4:20 PM
Controlled Release of Corrosion Inhibitors by Microencapsulation for Protection of Steel Reinforced Concrete: Jacob Ress1; David Bastidas1; Ulises Martin1; Juan Bosch1; 1University of Akron
Encapsulation of corrosion inhibitors using smart technologies is an emerging trend in concrete corrosion. In this study, controlled release corrosion inhibitors were developed by microencapsulation of sodium nitrite by colophony pine rosin using the double emulsion synthesis method. The inhibitor release was studied in different pH environments: simulated pore solution (12.6), carbonate buffer solution (9.1), and deionized water (6.8). For greater pH values, the release was found to be significantly higher, concluding that the release of inhibitor is controlled by diffusion through the pores of the microcapsule. The dissolution of colophony at pH values above the pKa (7.2) increases shell porosity, thus inhibitor release. The microcapsules showed favorable performance at higher pH over extended periods of time. Therefore, the smart microcapsules have proven to be a promising method for delivering corrosion inhibitors in reinforced concrete and may be useful for encapsulation and release of a variety of active agents.
4:40 PM
High-performance Chrome Coatings to Protect Against Wear and Corrosion: Borys Sereda1; Dmytro Sereda1; 1Dneprovsky State Technical University
The SHS-technology gas transportation for the production of protective coatings made of borides alloyed with titanium and chromium on steel is considered. The results of studies of their structure and properties are shown. Methods of mathematical modeling have been developed, optimal compositions of SHS mixtures have been developed for applying wear-resistant coatings to machine parts in self-propagating high-temperature synthesis. The results of testing steel specimens for wear under friction conditions on a friction machine SMT-1 indicate a significant increase in wear resistance of the treated samples. When tested in sliding friction, titanium coatings doped with boron (their strength is 6 times higher than in uncoated samples), the wear resistance of titanium coated coatings is 1.8-2.1 times higher in comparison with control samples.