Faculty of Engineering and Technology

Ramaiah University of Applied Sciences

Department Chemistry Programme B.Tech. in AS/Civil/ECE / EEE/Mech.

nd
Semester / Batch 2 /2020
Course Code 20CHB111A Course Title Engineering Chemistry
Course Leader(s) Dr. Jyotsna Kumar, Dr. Anantharamaiah P.N., Dr. Sumy Joseph, Dr. Rashmi Prashanth
and Dr. Deepak

Assignment - 01

Register No 20ETEC004004 Name of Student ANSAR K M HIMBRAN

First
Sec Max Second
Examin
tio Marking Scheme Mark Examiner
er
ns s Marks
Marks
1.1 Introduction to Electrophoretic coating 1

1.2 Working principle and types of e-coating 4

1.3 Compare and contrast of e-coating and powder 4

Par coating
t-A Significance and future opportunities of E-coating in auto
1.4 3
industry
1.5 Conclusion 1

Part-A Max Marks 13

2.1 Identification of type/s of corrosion and causes for failure 5
Discussion on general preventative measures to control such
2.2 5
Par types of corrosion in aerospace vehicle alloys
tB 2.3 Recommendation of any two alternate steel alloys 2

Part-B Max Marks 12

Total Assignment Marks 25

Course Marks Tabulation

Component – 1 (B) First
Remarks Moderator Remarks
Assignment Examiner
A

Marks (Max 25 )

Signature of First Examiner Signature of Moderator

1
 PART – A
“Electrophoretic coatings are used in surface finishing processes in the auto industry”.

1.1) Introduction to Electrophoretic coating:

Ans: Electrophoretic coating is also known as E- coating, Electro-coating, Electroplating. Is a high-tech process
that has been developed over the last fifty years. The E-coat process was originally developed for applying an
anticorrosive coating over steel car bodies. E-coats such as clear cad processes are used for coating a wide range
of consumer goods including hardware, jewellery, eyeglass frames, giftware and many other items.
E-coating is a technique where charged particles in a stable colloidal suspension are moved through the
liquid due to electric field and deposited on an oppositely charged conductive substrate, forming the intended
material or device. E-coating enables fabrication of a wide range of structures from traditional to advanced
material, from nano-metric thin films to a fraction of 1mm thick films, and from porous scaffolds to highly
compact coatings. These structures includes different compositions with complex shape and structures which can
be formed in a relatively short experimentation time by simple apparatus.

2.3) Working principle and types of E-coating:

Ans: E-coating is a process by which a metal gets deposited over the other in the presence of salt (in aqueous
solution). In this process, the water molecules is given out as the end product. Hence the principle behind E-
coating is hydrolysis.
E-coating is process by which electrically charged particles are deposited out of a water suspension to a
coat conductive part. During E-coating process, paint is applied to a part at a certain film thickness, which is
regulated by the amount of voltage supplied. The deposition is self-limiting and slows down as the applied
coating electrically insulates the part, Electrocoat solids initially deposit in the areas closest to the counter
electrode and as these areas become insulated to current, solids are forced into more recessed bare metal areas
to provide complete coverage. This process is known as throwpower and is a critical aspect of the electrocoat
process.

Types of E-coating:
1) Anodic epoxy electrocoating: This is the most corrosion-resistant anodic electrocoat that can be cured at less
than 200F. The low cure attributes of anodic apoxies makes this electrocoat products an excellent finish for
astings, engines, and temperature- sensitive substrates or assemblies.

2) Anodic acrylic electrocoatings: This offer a single-coat application used for both interior and exterior
environments and are available in numerous colours and glosses. These coats are used as a one-coat finish on
toolboxes, air diffusers, hangers and other indoor and mild exterior environments.

3) Cathodic epoxy electrocoatings: These are the best benchmark for the corrosion resistance. Widely used in
the automotive and automotive parts industries, they provide superior salt spray, humidity and cyclic
corrosion resistance. Aromatic epoxy-type coatings are particularly prone to chalking and degradation by the
UV components of sunlight.
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 4) Cathodic acrylic electrocoatings: These are available in a wide range of glosses and colours to maximize
exterior durability, gloss retention, colour retention and corrosion protection. These products are used as a
one-coat finish in the agricultural, lawn and garden, appliance, and air-conditioning industries. Cathodic acrylic
electrocoatings are typically used in applications where both UV durability and corrosion protection on
ferrous substrates are desired.

2.3) Compare and contrast the e-coating and powder coating

Ans: Among the many types of industrial coatings, e-coating and powder coating are the two types. These
two processes are similar, as they both involve applying a coating to a metal product for purposes such as
enhancing corrosion protection and wear resistance.

E-coating:
The metal is immersed in a bath consisting of paint, epoxy or other water-based solution. The coloured
particles suspended in the solution are then attached to the substrate with an electrostatic charge, attracting the
particles in the solution to the metal surface. The electrodeposition process continues until the desired level of
coating thickness is achieved. Once reaching the desired coating thickness, the substrate is removed from the
solution. The coated substrate is then oven-cured to promote cross-linking and finish “baking” the finish.

Powder coating:
Unlike e-coating, powder coating is a type of industrial coating known as “dry’ process. The
powder process uses an exact, precise combination of curing agents and epoxy resins. A coating shop uses a
specially-designed spray gun to apply the dry powder particles onto the substrate surface. Just as with the e-
coating, curing is the finishing step in the powder coating process. Curing causes the particles to melt and
catalyse a chemical reaction that produces the desired finish.

3
 Along with the aesthetics and sustainability, durability is the third pillar of a finished coating products. The
hardness achieved through the combination of the powder itself and how it is applied and cured offers unmatched
hardness and excellent weather ability – including colour and gloss retention as well as humidity and UV resistance.
Powder coating has proven time and again to outlast other coating types when it comes to exterior finishing
applications.

1.4) Significance and future opportunities of e-coating in the auto industry

Ans:
Significance of e-coating:-
• E-coating is renowned for its ability to stand up to outdoor weathering and indoor environments where harsh
chemicals may be present, as well as being chip resistant.

• E-coating works well with the complex shapes, allowing for better coverage and thinner coats than other
methods.

• E-coating can be used for higher volume production runs and uses paint more efficiently than spray techniques,
delivering a high quality finish with zero waste.

• A water-based, immersion technology, E-coating produces no hazardous air pollutants or volatile organic
compounds. So we can say this is a environment friendly.

The automotive industry is a complex sector, which relies on a huge range of other industries in order to
manufacture, finish and maintain the vehicles. From the initial design and planning department, through to the
engineering aspects to consider, the automotive industry depends on many other work sectors in order to help
to create a quality finished vehicle. The automotive industry relies on the e-coating process due to the strong,
durable and reliable e-coat corrosion resistance it provides. Vehicles require safe and dependable mechanism in
order to efficiently without posing a hazard.

1.5) Conclusion
Ans:
To conclude, e-coating is an immersion wet paint finishing process. It uses an electrical current to
attract the paint product to the metal part. The process includes many steps with rinses and coatings repeated.
The reason the parts needs to be rinsed between coats is to ensure no excess residue, bits of metal, grease or oil
is left on the part. E-coating is commonly used in the automotive sector, making a mistake with a car body could
be detrimental to finished products
4
 PART – B
2.1) Identify the type/s of corrosion and causes for failure of Nitronic 60 pin of General Dynamics F
16 aircraft.

Ans: An aircraft crash in the Netherlands was caused by disintegration of a jet engine. Fractography showed
that the chain of events started with stress corrosion cracking (SCC) of a pin attached to a lever arm of the
compressor variable vane system. Such a lever arm-pin assembly costs only a few dollars. Investigation of
hundreds of pins from the accident and a number of identical engines revealed that this was not an isolated case.
Many pins exhibited various amounts of SCC. The failed pin in the accident engine happened to be the first
fractured one. SCC requires the simultaneous presence of tensile stress, a corrosive environment and a susceptible
material. In this case the stress was a residual stress arising from the production method. There was a clear
correlation between the presence of salt deposits on the levers and SCC of the pins. It was shown that these
deposits were able to reach the internal space between the pin and lever arm, thereby initiating SCC in this space.
The corrosive environment in Western Europe explains why the problem manifested itself in the Netherlands at a
relatively early stage in engine life. The main point is, however, that the manufacturer selected an SCC-prone
material in the design stage. The solution has been to change the pin material.

Types of corrosion found on aircraft:

• Uniform surface attack. This is the most common type and is caused simply by exposing the metal to
oxygen in the air, such as when paint is worn off wing skin or the fuselage. Poor prepaint preparation at the
factory, fumes, acid, pollutants, or high humidity accelerate the decay.
• Intergranular corrosion. Normally worst on 7000-series alloys (those with an appreciable amount of zinc,
like wing spars, stringers and other high-strength aircraft parts), this is not frequently found but is a particularly
nasty type of corrosion. It can be difficult to detect, and once you see it, it’s too late: that piece of metal is toast.
• Stress corrosion. In highly stressed parts like landing gear or engine crankshafts, this type may develop from
a scratch or surface corrosion. Crankshaft failures are often due to undetected corrosion of this type.

• Crevice or deposit corrosion: This can occur anywhere there is an area where moisture or other pollutants
are trapped. Lapped skin joints or rivets on an oil-stained belly are examples of prime corrosion spots.

• Filiform corrosion. Particularly on aluminium surfaces poorly prepared for polyurethane paints, this type of
corrosion will show up as fine, worm-like lines of corrosion under the paint that will eventually lead to bubbling
and flaking.

Filiform corrosion

Intergranular corrosion
5
 Stress corrosion

2.2) Discuss general preventative measures to control such types of corrosion in aerospace vehicle
alloys.
Ans: Although corrosion will always be present on aircraft, especially on older ones, there are measures that can be
taken to ensure that it is kept to a minimum.
• Inspection for corrosion on a scheduled basis
• Thorough cleaning, inspection, lubrication, and preservation at prescribed intervals.
• Prompt corrosion treatment after detection.
• Accurate record keeping and reporting of material or design deficiencies to the manufacturer and the FAA.
• Use of appropriate materials, equipment, and technical publications.
• Maintenance of the basic finish systems.
• Keeping drain holes and passages open and functional.
• Replacing deteriorated or damaged gaskets and sealants to avoid water intrusion and entrapment, which leads
to corrosion.
• Minimizing the exposure of aircraft to adverse environments, such as hangaring away from salt spray.
• In order for corrosion to occur, four conditions must exist: presence of an anode, presence of a cathode,
presence of an electrolyte, and electrical contact between the anode and cathode. Since it is not usually an
option to remove either the anode or the cathode, the two ways to remove corrosion are to remove the
electrolyte or to prevent the physical contact between the anode and the cathode.

6
2.3) Recommend any two alternate steel alloys to replace Nitronic 60.
Ans: ALLOY 22:
It displays exceptional resistance to a broad range of corrosion environments. It has excellent resistance
to wet chronicle and mixtures containing nitric acid or oxidizing acids with chlorine ions. Resistance to reducing
acids such as sulphuric and hydrochloric can also be expected. Other corrosive chemicals to which the alloy has
resistance are oxidizing acid chlorides, wet chlorine, formic and acetic acid, ferric and cupric chlorides, sea water,
brine and many mixed or contaminated chemical solutions, both organic and inorganic.

INCONELL 690 ALLOY:

The Inconel 690 material is a kind of austenitic nickel-base superalloy, which has excellent
Stress corrosion cracking resistance, excellent corrosion resistance, high strength, strong antioxidation, and
favourable metallurgy stability(9 - 12). Thus the alloy is widely used in various important areas, such as
petrochemical engineering, nuclear power, and defense industries, in which numerous large scale seamless
Inconel 690 tubes have been employed.

INCONELL ALLOY 625:

INCONELL alloy 625 is known as a ‘superalloy’, or a high temperature alloy, which means that
It has certain characteristics to earn the accolade. Then includes its excellent mechanical strength, corrosion
resistance, heat resistance, thermal creep deformation and surface stability. The term was first used just after
World War II specifically to describe a group of alloys that were used in aircraft turbine engines that performed at
The inherently high temperatures. Therefore ‘superalloys’ are very much grounded in aerospace, through the
term is applied to many other applications such as gas turbines, rocket engines, and chemical processing plants.
Superalloys retain good strength even after being exposed to temperatures above 650 C
for a long period of time. Combined with their ability to exhibit low-temperature ductility and surface stability, it’s
no wonder this group of high-performance alloys is considered ‘super’.

BIBLIOGRAPHY

• https://clearclad.com/products /what-is-e-coat/

• https://pacdiecast.com/die-casting/difference-between-electrophoretic-deposition-and-powder-

coating/

• https://www.aviotionpros.com/homearticle/10387961/corossion-control

• https://aircraftmaintenancestands.com/blog/types-of-corossion-in-aircraft/

• https://doubleeaglealloys.com/products/corossion-resistant-alloys/alloy-c-276/

• https://www.corrotherm.co.uk/blog/inconel-alloy-625-in-aerospace-engineering

• https://www.aopa.org/go-fly/aircraft-and-ownership/maintainance-and-inspections/aircraft-corossion