METALLIC COATINGS FOR CORROSIONPREVENTION
Corrosion: =
It is termed asdeterioration of the material when it comes in contact with the environment.
=>it happens due to the chemical attack from the surrounding environment and envolves transfer of electrons.
*TYPES OF CORROSION*
(1)Generator or uniform corrosion(2)Galvanic corrosion(3)Selective leaching(4)Pitting(5)Crevice corrosion(6)Stress corrosion cracking(7)Intergranular corrosion(8)Erosion corrosion
*Methods for RESTRICTING CORROSION*
(1)Alter the environment(2)Proper material selection(3)Alter design to optimize geometry(4)Employ cathodic protection(5)Use organic coatings such as paints or powder coatings.(6)Use conversion coatings such as chromates or phosphates(7)Use inorganic coatings such as zinc rich paints or phosphates(8)Use metallic coatings(i)Electroless deposited metals e.g NiCl
–
mechanically applied zinc as in mechanicalplating or Sheoridizing(ii)Electrolytically deposited metals,zinc for functional purpose or decorative Ni/Cr or decorative purposes.
*COROSSION PREVENTION BY COATINGS*
(1)Inorganic coatings(2)Metal coatings(3)Organic coatings
(i)Inorganic coatings: =
This can be applied by chemical acion, with or without electricalassistance.-The treatments change the immediate surface layer of metal into a film of metallic oxide or compound which has better corrosion resistance than the natural oxide film and provides aneffective base as key for supplementary protection such as paints.Various techniques are: =
Anodizing
Chromate filming
Phosphatizing
Nitriding
Passive films
Metallic coating
(1
)Cladding(2)Flame spraying(3)Electro-deposition(4)Hot-dipping(5)Vapor-deposition(6)Diffusion(7)Chemical conversion(8)Surface modification(9)Ion implantation
(a)Cladding
Metal on which coating is done is known as substrate.
Its corrosion resistance is improved by metallurgical binding it with asusceptible care alloy having Good corrosion resistance.
The cladding metal is passive to work-atmosphere and in cases of scratches if
the substrate is open to atmosphere acts as “Sacrificial anode”.
The difference in potential is 80 to 100 mV.
Cladding is prevalent at mill stage by manufacturers of sheet, plate or tubing.
Cladding by pressing, rolling, or extrusion can produce a coating in which the thicknessand distribution can be controlled over wide ranges, and the coatings produced are freeof porosity.
Coatings of wide range of thickness are produced.
They are generally thin in comparison to the substrate.
For example, Nickel and Steel sheet are rolled together giving a compositesheet of LINCH Steel, 1/8 inch Ni.
Ni, Al, Cu, Ti, Stainless Steel and other metals are cladded over steel.
Among principal uses Al cladding in the air-craft industry, Lead, Sheathing for cables etc;
In Cladding inexpensive material is coated with expensive material havingvery thin layer.
In cladding, inexpensive metal is coated with expensive metal moving verythin layer.
Thus, we get lower cost metal with good corrosion resistance
.
In roll bonding, layers of two metals are mated by heavy rolling in a mill after the surfaceshave been thoroughly cleaned and treated.
Clad thicknesses of 5 to 10 percent of the base steel thickness are common. Some smallareas of unbonded metal will be present. Two metals may also be coextruded through adie.
Cladding can also be accomplished by other methods such as arc or gaswelding in which relatively thick layers of weld metal are deposited either by manual or machine methods on surfaces.
Application:
The interior of pulp digesters or other pressure vessels requiring an alloycomposition to resist the chemical conditions can be constructed in thismanner.
Vapour deposition
(1)
This is accomplished in a high vacuum chamber. The coating metal is vaporized byelectrically and vapor deposits on part to be coated.(2)
It is very expensive and generally used in coating of high strength parts of
ROCKETS ANDMISSILES
.(3)
V.D alters mechanical, optical, electrical, thermal, corrosion resistance of the material.(4)
There are two categories of VD process:=a.
Physical vapor deposition:-Work piece subjected to plasma bombardmentb.
Chemical vapor deposition:-Thermal energy heats gases in coating chamber anddrives the deposition reaction.
The most useful CVD coatings are nickel, tungsten, chromium, and titanium carbide. Titanium carbide is used for coating punching and embossing tools to impart wear resistance.
Flame or thermal spraying
-Also known as metallizing.
Four methods based on the form of the coating material are generally used:(1) The coating material is in the form of rod which is melted by an oxyacetylene flame andblown onto the surface to be coated.(2) The coating material is in the form of a powder which is heated by an oxyacetylene frame,atomized and blown onto the surface.(3) The coating is in the form of a wire. The wire is fed into the central orifice of a nozzle.It passes through an oxyacetylene flame and sprayed to the metal surface.
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