Anti-Corrosion Coatings for Different

Service Exposures
By Shivananda Prabhu, July 16, 2014
Takeaway: Corrosion engineers need to study service exposures, the variability of the conditions
and the limitations of the site to find the best possible anti-corrosion coating.

Source: Andrej Antic/Dreamstime.com

According to the most recent estimates available, corrosion carries a $276 billion cost for the U.S.
economy. This cost includes critical failures, property losses, repair and restoration costs, downtime
losses, and even loss of life. The loss estimates are indicative of losses suffered worldwide,
particularly by advanced economies. The good news: A big chunk of these losses can be prevented
by planning and implementing proactive and systematic corrosion prevention practices and
programs. Because the process of corrosion begins due to the electrochemical reaction of a surface
with corrosive environments, one of the most effective strategies is to effectively isolate a substrate's
surfaces from electrochemical (corrosive) attack by covering it with a protective barrier, or coating.
Different types of coatings are used to create and maintain this type of protective barrier on the
surface, and a large number of different types of coatings are continuously being developed and
offered in the market. In this article, we'll look at some of the most widely used coatings, the criteria
used to select a particular coating, and the surface preparation required for the application of the
coatings.

What Is an Anti-Corrosion Coating?

Anti-corrosion coatings are primarily applied for the protection of solid metal surfaces and,
occasionally, some non-metals. When selecting a suitable corrosion protection system, we must
consider the nature of the corrosive environment faced by the assets to be protected, such as
pipelines, structures, vehicles, ships, bridges, plant equipment and buildings. That environment
could be urban or rural, buried under soil, underground tunnels, and open atmospheres, marine,
mining or industrial - all are subject to corrosion. However, coatings must be selected to be
compatible with the substrate material, its composition and the conditions the material will face in the
field. So, first let's examine the major factors corrosion engineers must consider.

Service Exposure
In order to select a suitable corrosion protection system, corrosion engineers must consider the
impact of environmental factors (service exposures) such as:

Soil chemistry (the presence of reactive salts, acids and alkalis), electrical resistance and
moisture

Corrosive airborne contaminants (indoor or outdoor)

Temperature range and peak levels, fog, storm and snowfall, radiation (UV exposure)

Humidity, condensation, splash exposure

Exposure to salt water or natural water in case of partial, complete or fluctuating immersion

The reactivity of the type of product to be transported, processed or handled, and the hazard
associated with leaks

Proximity to any electrochemical activity such as cathodic or anodic protection, high voltage
lines, grounding stations, or railway system causing flow of unintended induced stray
currents, and availability of mitigation techniques

Exposure to UV radiation, sunlight and chemicals such as solvents

Expected lifespan of operation of the project, if available

Likely exposures to reactive acids and alkaline substances, smog from industry, acid rain
and sewage

Site considerations and limitations applicable to surface preparation, priming, coating and
curing process requirements

Materials
Cathodic protection and surface coatings techniques are concurrently used in most critical protective
applications. The main function of the surface coatings is to act as an insulating barrier that
eliminates the likelihood of contact between a substrate and electrolytes in the working environment,
thus preventing the likely electrochemical reaction that can cause corrosion.
Thin coatings made up of metals and certain nonmetallic substances can form an effective barrier
between the solid substrate to be protected and its working environment. In some cases, a metallic

coating may work as a sacrificial coating as in the case of zinc coatings.

Metallic Coatings
Metal coatings have the advantage of an inherent formability and provide a durable barrier against
any attack of corrosive substances. However, any surface defect such as porosity can lead to
localized corrosive failure. Different metallic coatings can be used for various substrates to prevent
corrosion. Sometimes they are used for aesthetic as well as decorative purposes. Metal coatings are
applied using the following techniques:

Hot dipping

Electrodeposition or electroplating

Thermal spray

Mechanical plating

Zinc Coating
Zinc coating by electrodeposition (as per ASTM A591) provides a coating that's less than 0.2 mil
thick and is suitable for indoor appliance panels (limited to light duty indoor usage).Procedure ASTM
B 633 covers electroplating of zinc on steel for similar applications with coat thickness less than 1.0
mil.
The hot dip process of zinc coating on steel is covered by ASTM A653, ASTM A123, ASTM A153,
and provides a coat thickness up to 5.0 mi. It's used for for outdoor and indoor structural items,
roofing, auto body parts and nut bolts.
Peening or mechanical plating (ASTM B695) provides a coating thickness of 0.2 to 4 mil, which is
useful for be kept in mind for design calculations. This loss of fatigue strength can be minimized by
nitriding the steel components prior to the plating process.
Chrome plated steel is extensively used in process industries. It is applied for a very wide range of
geometries ranging from superfine bores, to cylindrical rollers, to holes and close-tolerance
curvatures. It provides ultra-high wear resistance compared to the best heat-treated metals. It has a
bright, decorative finish, responds to polishing, and is ideally suited for the textile and paper industry.
Chrome plated steel is suitable for the exposure of organic acids and gases (with the exception of
chlorine), hot oxidizing or reducing environments, and in processes that produce and handle brine,
gas fuel, molten glass, oils and liquid fuels.

Electroless Plating
In electroless plating, the coat formation occurs due to a pure chemical reaction, aided by a catalyst
without the application of voltage. Nickel plating or cobalt plating is performed by this method as
well.
Mechanical Plating
In this process, a superfine metal powder is cold welded onto the metallic substrate through tumbling
the component part, the powder solution (aqueous) and a medium (glass beads, for example) with
chemical agents to facilitate the process. This process is employed to form a zinc or cadmium
coating on fasteners and other auto components.
Hot Dipping
In a hot dipping process, a thin coating of metal is formed on a component surface by dipping the
component in a hot, molten bath of the coat substance. This is a popular manufacturing process for
corrosion-resistant underbody sheet metal structural parts.
The steel plants supply hot rolled as well as the cold rolled sheets with necessary anti-corrosion
coating such as zinc, zinc-nickel, aluminum-zinc, lead-tin, or tin. Hot dipping and electroplating are
the common facilities used. Many steel plants also provide customized coatings.
Thermal Sprays
Thermal spray facilitates the development of a huge variety of coatings for different severe corrosion
and wear resistant applications. Some examples of thermal spray coatings are found in components
of jet engines, orthopedic implants, surgical applications and electrical-electronic devices.
The coat thickness here will be around 0.003 to 0.010 inch, which is advantageous for severe
chemical corrosion conditions. This type of coating also tends to provide a surface that's free of
voids and pin holes. After the coat is completed, surface finishing may be needed for a dynamic
application. However, coverage is limited to simple geometries and outer surfaces only. This method
is suitable for ferrous metals used in hostile chemical environments with oxidation and extreme
temperatures.

Non-Metallic Coatings
Most nonmetallic coatings provide protection by making an insulating barrier that is completely
impermeable to the moisture and electrolytes that are necessary for the process of corrosion. These
liquid, nonmetallic coatings are made up of a solvent, a resin and pigment. Each of these has a role
to play in its effectiveness.
Solvent
The solvent dissolves and disperses the resin material, which is the backbone of the coating. It helps

provide ease of application, adequate adhesion and overall effectiveness.

Resin
The resin of the coating is the basic film-forming component and provides corrosion protection and
other vital properties. Thus, coatings are generally known by the name of the resins used.
Pigment
The pigment constitutes the second solid part of the coating. The main function of this component is
to provide opacity to prevent the organic substance from being exposed to sunlight. Titanium is
frequently used for opacity. Pigments can also improve adhesion, color, weather resistance, or
reduce moisture ingress.
The resin with pigment remains on the surface after the solvent has volatilized, and hence
determines the film thickness of the coat.

Classification of Coatings
Based on the mechanism of the protection, nonmetal coatings are classified as:

Barrier coatings

Inhibitor coatings

Galvanic coatings

Barrier-Type Coatings
These form an insulating and physical barrier, thus stopping the contact of corrosive elements, such
as the electrolyte, with the substrate. Coal tar epoxy coatings are an example of this mechanism.
Inhibitor Coatings
Inhibitor coatings cause a chemical to be released by the pigment. This interferes with the electrolyte
and stops electrochemical reactions. Chromate-type pigments are an example of this mechanism.
Galvanic Coatings
Galvanic coatings are primer coatings rich in zinc content, which provide a sacrificial type of coat
and the cathodic type of protection to a ferrous substrate. These primers must be directly coated on
the substrate.
Generic Polymer Coatings

Some of the generic polymer coatings widely used in corrosion protection include:

Acrylic Coating: Acrylic coatings are water-based, eco-friendly, and suitable for outdoor use
with significant exposure to sunlight. They can be used as a primer or a top coat, and are
suitable for moderate to high temperatures.

Alkyd Coatings: These are based on modified natural oil, and are used as primer for the
atmospheric environment. They're not suited for an alkaline environment such as concrete.

Bitumen-Based Coating: Bitumen coatings possess a very good moisture resistance but
are not resistant to solvents. These are used for the protection of aluminum and ferrous
surfaces.

Amine Epoxy: This has good resistance to acids, solvents and alkalis, but is sensitive to
temperature, moisture and sunlight and is therefore used underground.

Polyamide Epoxy: Has resistance to salt solution and water, but is not suitable for other
chemicals. It is suitable for immersion and buried service.

Epoxy Coal Tars and Urethanes: These are widely used for large-diameter pipe-coating
systems in the petroleum industry.

Multi-Layer Epoxy or Extruded Polyolefin Systems: These multi-layer systems provide

strong adhesion under polyethylene. With the addition of an epoxy primer, these multi-layer
systems are the most popular in the U.S. and Europe for pipelines for outdoor and buried
applications.

Mill-Applied Taping System: Mill-applied tape systems are provided with a primer, an inner
layer of tape, and some outer layers for abrasion protection. Concern about a disbonded
coating due to cathodic protection has aided in the development of fused layers of tapes.
The availability, ease of on site construction, and low cost make this tape system very
popular.

Coal Tar Epoxy: This has moisture resistance as well as chemical resistance, but it may
become brittle with age. It is used for immersion service and is also suitable for tank lining
and industrial maintenance coating. Coal tar epoxy with glass filament reinforcement also
works at high temperature.

Fusion-Bonded Epoxy:Widely used for buried and immersion service. Now sometimes
replaced by fusion-bonded nylon. Fusion-bonded epoxy is used for moderately high
temperatures.>

Urethane and Polyurethane: Polyurethane is a type of urethane. It is cured by chemical

reaction as well as solvent evaporation. These are suitable for atmospheric exposure and
fluctuating immersion operations.

Moisture-Cured Urethane: Suitable for damp environments, this can be customized with
specific pigment formulations for a variety of service exposures such as burial, immersion,
chemicals and gases.

Extruded Polyolefin Systems: The system is used for large-diameter pipes (for pipe up to
24 in diameter). Recent improvements in the adhesive properties and availability of
polypropylene for use at wide and high temperatures (up to 190F [88C]) has made the
system effective and popular. It is able to provide holiday-free coatings.

hardware items used indoor or outdoor.

Diffusion Coating
Diffusion coating involves alloy formation by diffusion of an alloying element on the substrate. For
this reason, the process is also called surface alloying. Solid parts to be coated are packed in a
chamber and exposed to the vapor of the alloying elements. Examples are the deposition of zinc,
chromium and aluminum on steel.
This process ensures high strength with good corrosion resistance to steel, and is used for gas pipes
handling gases containing corrosive sulfur compounds. Aluminum coated steels are used in
petroleum and chemical industries that handle corrosive acids, while glass-lined steel is used for
corrosive processes in the food industry, breweries and the drug industry. (Learn more in An Intro to
Pipeline Corrosion and Coatings.)
Electroplating
In the electroplating process, the coating layer is formed on the substrate by interposing an electrical
voltage between the substrate metal (as the cathode) and an anode of the substance to be
deposited, immersed in an electrolyte. The electrolyte is normally an aqueous solution consisting of
a salt of the metal to be formed on the substrate, and other additional chemicals to facilitate the
electrochemical process.
While chrome plating and nickel plating processes provide the necessary corrosion resistance to the
parent metal, the resulting residual tensile stresses can cause a loss of fatigue strength, which
needs to

General Tips for Selecting a Coating

For acid, alkali or salt resistance, use urethane, coal tar epoxy and chlorinated rubber
coatings

For solvent resistance, use zinc inorganic, urethane or chlorinate rubber

For an oxidizing environment, use vinyl and urethane, or zinc inorganic coatings

As a general rule, polymer coatings should be avoided for metals working under high temperatures.

Reasons for Coating Failure

Apart from improper application, other factors responsible for the failure of coatings are:

Improper surface preparation

Poor adhesion of priming coat

Improper selection of top coats

An improperly cleaned and prepared substrate surface

Primer that lacks good adhesiveness, or is incompatible with the top coat

Surface preparation steps are cleaning to remove oil and dirt and roughening to get mechanical
bonding. The best way is to do this is to grit blast/sand blast a substrate's surface. Other methods
include pickling or chemical treatments and, flame cleaning and scraping.
Advantages:
excellent dispersion properties
good rheological properties
very low sedimentation
low abrasivity
fast drying
good weathering resistance
good corrosion protection
good chemical resistance, especially against acids
excellent abrasion resistance
potential for reducing the corrosion protection pigmen

ACS NEWS SERVICE WEEKLY PRESSPAC: MAY 02,

2012

'MIRACLE MATERIAL' GRAPHENE IS

THINNEST KNOWN ANTI-CORROSION
COATING
Graphene: Corrosion-Inhibiting Coating
ACS Nano
New research has established the miracle material called graphene as the worlds
thinnest known coating for protecting metals against corrosion. Their study on this
potential new use of graphene appears in ACS Nano.
In the study, Dhiraj Prasai and colleagues point out that rusting and other corrosion of
metals is a serious global problem, and intense efforts are underway to find new ways
to slow or prevent it. Corrosion results from contact of the metals surface with air,
water or other substances. One major approach involves coating metals with materials
that shield the metal surface, but currently used materials have limitations. The
scientists decided to evaluate graphene as a new coating. Graphene is a single layer of
carbon atoms, many layers of which are in lead pencils and charcoal, and is the
thinnest, strongest known material. Thats why it is called the miracle material. In
graphene, the carbon atoms are arranged like a chicken-wire fence in a layer so thin
that is transparent, and an ounce would cover 28 football fields.
They found that graphene, whether made directly on copper or nickel or transferred
onto another metal, provides protection against corrosion. Copper coated by growing a
single layer of graphene through chemical vapor deposition (CVD) corroded seven times
slower than bare copper, and nickel coated by growing multiple layers of graphene
corroded 20 times slower than bare nickel. Remarkably, a single layer of graphene
provides the same corrosion protection as conventional organic coatings that are more
than five times thicker. Graphene coatings could be ideal corrosion-inhibiting coatings in
applications where a thin coating is favorable, such as microelectronic components
(e.g., interconnects, aircraft components and implantable