CORROSION ENGINEERING

CORROSION COATINGS
 Corrosion coatings
Coatings are classified into three types:
 Metallic coatings

 Organic coatings

 Inorganic coatings

Basic mechanisms for the functioning protective coatings:

 Barrier Protection

 Chemical inhibition

 Galvanic (sacrificial) protection

Metallic coatings

Methods for applying coatings:

 Electroplating

 Electroless plating

 Hot dipping

 Thermal spraying

 Cladding

 Vapor deposition

 Ion implantation

 Laser processing
Electroplating:

1. Immersing a metal or part of the metal to be coated

in a solution of the metal to be coated and passing
direct current between the metal and another electrode.
2. Coating of desired thickness and property can be
achieved by changing temperature, current density,
time and composition of the bath.
3. Gold, Ca, Ag, Sn, Cu, Cr, Ni, Pt can be plated in this way.
Electroless metal coatings:
1. Prepared without the help of electric current.
2. It involves autocatalytic chemical reduction reactions to
deposit metal layers.
3. Nickel coatings can be achieved by this method
4. These coatings are amorphous in nature.

Hot-dipping coating:
1. Metal substrate is immersed in a molten bath of a second
metal and second metal is coated on the first one.
2. Melting temperature of first metal higher than the second
3. Metal substrates are steel, iron and coating materials are Zn, Al,
Sn, Pb.
Thermal spraying:
 The coating materials are heated to a plastic or molten state

and propelled by a stream of compressed gas onto the

substrate. When these particles strike the metal surface, they
flatten and form thin platelets and adhered to the prepared surface.
 Generally, a spray gun is used to generate the required heat for
melting through combustion of gases, electric arc or plasma.

Cladding:
It is the bonding together of dissimilar metals.
For example, a nickel and steel sheets are hot rolled to get a composite
nickel-steel sheet

Vapor deposited coatings:

The coating material is vaporized by heating electrically and the vapors
are allowed to deposit on the part to be protected.
Major vapor depositions are Physical Vapor Deposition (PVD)
and Chemical Vapor Deposition (CVD)
These vapor deposited coatings are pore free and highly dense.

Ion implantation and laser processing:

These are two surface modification methods and accomplished by high
energy beam.
Ion implantation enhance the passivation characteristics or create novel
material.
Laser processing helps to produce corrosion resistant surface layers.
 Non Metallic Inorganic coatings
 Inorganic coatings include ceramic coatings, conversion coatings,
and anodized coatings.
 Ceramic coatings provide high performance oxide layer on the
metals and alloys. Ceramic coatings such as zinc silicate, silicon
carbide, boron nitride.
 Advantages of these coatings: they increase the life time of the parts,
reduce heat on high temperature components, reduce friction.
 Disadvantages: extremely brittle and hard to repair.
 Conversion coatings are phosphate coating and chromate conversion
coatings.
 Phosphate conversion coatings are generally used to improve the
corrosion resistance and the adhesion of paints. Commonly used
phosphate conversion coatings are zinc phosphate, iron phosphates,
and manganese phosphates.
 Chromate conversion coatings are produced on the metal surface
by a chemical or electrochemical treatment of the metals or
metallic coatings in solutions containing hexavalent chromium
(Cr6+) and other components.
 Anodized coatings are used for Aluminium alloys. Aluminum
oxide (Al2O3) films are formed on the surface when aluminum
and aluminum alloys are polarized anodically in electrolyte
solutions.
Non Metallic Organic coatings
 Organic coatings such as paints, lacquers, varnishes. Coating liquid
generally consists of solvent, resin and pigment. The resin provides
chemical and corrosion resistance, and pigments may also have
corrosion inhibition functions.
 Three factors considering for applying organic coatings. (a) surface
preparation (b) Selection of primer or priming coats and (c)
selection of top coat.
 Surface preparation includes the
removal of dirt, oil, rust, grease and
other impurities.
 The primer generally contains some
inhibitive pigments and these
pigments used to passivate the
metal surface. Eg. Zinc chromate.
 Top coat the surface