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Raising a new Generation of Leaders

CHE 431 CORROSION OF

METALS AND ALLOYS
Week 4
Lecturers: OLAYEMI ODUNLAMI
AND AJIBOLA OGUNBIYI

www.covenantuniversity.edu.ng

Raising a new Generation of Leaders

ASSIGNMENT
Corrosion in automobile, chemical and
petroleum industry

PROTECTIVE COATINGS

Olayemi Odunlami

TYPES OF COATINGS

Metallic coatings
Inorganic coatings
Organic coatings
Olayemi Odunlami

Methods of application of coatings

Hot dipping
Electroplating
Thermal spraying
Cementation
Diffusion

Methods of application of coatings

Hot dipping is carried out by immersing the metal
on which the coating is to be applied, usually steel,
in a bath of the molten metal that is to constitute the
coating, most commonly zinc, but also aluminum
and aluminum zinc alloys.
Hot dipping can be either a continuous process, as
in galvanizing steel sheet, or a batch process for
example, galvanizing fabricated parts, nuts, bolts,
and fasteners .
Olayemi Odunlami

Methods of application of coatings

In electroplating , the substrate, or base, metal
is made the cathode in an aqueous electrolyte
from which the coating is deposited.
A wide of variety of coatings can be applied by
electroplating for example, zinc, cadmium,
chromium, copper, gold, nickel, tin, and silver,
as well as alloys, such as tin zinc, zinc nickel,
brass, bronze, gold alloys, and nickel alloys.
Olayemi Odunlami

Methods of application of coatings

In thermal spraying of metal coatings, a gun is
used that simultaneously melts and propels small
droplets of metal onto the surface to be coated.
The material that is to form the coating is called
the feedstock.
Olayemi Odunlami

Methods of application of coatings

Cementation consists of tumbling the work in a
mixture of metal powder at elevated
temperatures, allowing the metal to diffuse into
the base metal.
Aluminum and zinc coatings can be prepared in
this way.
Olayemi Odunlami

Methods of application of coatings

Diffusion coatings of chromium, nickel, titanium,
aluminum, and so on, can be prepared by
immersing metal parts, under an inert
atmosphere, in a bath of molten calcium
containing some of the coating metal in
solution.

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Specific metal coatings

Nickel coatings
Lead coatings
Zinc coatings
Cadmium coatings
Tin coatings
Chromium plated steel for containers
Aluminium coatings
Olayemi Odunlami

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Nickel coatings
Nickel coatings are usually prepared by electroplating.
The metal is plated either directly on steel or sometimes
over an intermediate coating of copper.
The copper underlayer is used to facilitate buffing of the
surface on which nickel is plated, because copper is
softer than steel, and also to reduce the required
thickness of nickel (which costs more than copper)
for obtaining a coating of minimum porosity.
The automotive industry uses nickel as an underlayer for
microcracked chromium to protect steel
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Lead Coatings
Lead coatings on steel are usually formed either by hot dipping or
by electrode position.
In the hot - dipping operation, a few percent tin are usually
incorporated to improve bonding with the underlying steel.
When 3 15% tin is incorporated, the resulting lead tin alloy is
called terne . Terne, which means dull, .
Coatings of lead or lead tin alloy are resistant to atmospheric
attack,
Lead coatings are not very protective in the soil.
Lead coatings must not be used in contact with drinking water or
food products, because of the poisonous nature of small
quantities of lead salts.
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Zinc Coatings
Coatings of zinc, whether hot - dipped or electroplated, are called
galvanized coatings, and the term electrogalvanized is used to differentiate
electroplated from hot - dipped coatings.
The electroplating process has been used to explore new zinc alloy coatings,
such as Zn Fe, Zn Co, and Zn Ni .
The coating produced by hot dipping is bonded to the underlying steel by a
series of Zn Fe alloys, with a layer of almost pure zinc on the outside
surface.
The coating produced in the batch process is thicker than that produced
in the continuous process, and it has clearly distinguishable alloy layers.
The continuous process results in a thinner coating with a very thin alloy
layer at the coating steel interface .

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Zinc Coatings Continued

Zinc coatings are relatively resistant to rural
atmospheres and also to marine
atmospheres, except when seawater spray
comes into direct contact with the surface.
In aqueous environments at room temperature,
the overall corrosion rate in short time tests is
lowest within the pH range 7 12.
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Tin Coatings
Tinplate is a low - carbon steel strip product coated on both sides
with a thin layer of tin.
Several million tons of tin plate are produced each year, and most of
it is used to manufacture many billions of food containers. The
nontoxic nature of tin salts makes tinplate ideal for use with
beverages and foods. Because electrodeposited tin is more uniform
than is hot - dipped tin and can be produced as thinner coatings,
tinplate is now produced universally by electrodeposition.
After electroplating the tin on the steel substrate, the tinplate is
given a heating cycle that melts the tin coating, creating a layer of tin
iron intermetallic compound at the tin steel interface.

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Chromium - Plated Steel for Containers

Because of price advantage, steel may be coated with a
combined thin chromium layer (0.3 0.4 in; 0.008 0.01
m), followed by chromium oxide (5 40 mg Cr/m 2 ) and an
organic top coat.
The advantages include good storage ability, resistance to
sulfide staining, good adhesion, freedom from undercutting of
the organic coating on the inside, and resistance to filiform
corrosion on the outside of the container. However, it is not
readily soldered, limiting its use in some application.
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Chromium - Plated Steel for Containers

The corrosion potential of chromium - plated
steel, which is always porous to some degree, is
more active than that of either passive
chromium or the underlying steel .
The metallic chromium layer contributes
resistance to undercutting of the organic
coating.
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Aluminium Coatings
Steel is aluminized (i.e., coated with aluminum) by hot
dipping or spraying and, to a lesser extent, by cementation.
Molten baths of aluminum for hot dipping usually contain
dissolved silicon in order to retard formation of a brittle
alloy layer.
Hot - dipped coatings are used for oxidation resistance at
moderately elevated temperatures, such as for oven
construction and for automobile mufflers.
They are unaffected by temperatures up to 480 C (900 F).
At still higher temperatures, the coatings become refractory,
but continue to be protective up to about 680 C (1250 F).
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Aluminium Coatings
The use, since 1975, of catalytic converters in
automobiles has resulted in increased exhaust gas
temperatures, up to 870 C (1600 F), with metal
temperatures up to 760 C (1400 F), as well as
increased concentrations of corrosive chemicals, such as
sulfuric acid, in the exhaust gas stream.
As a result, materials resistant to high - temperature
oxidizing conditions, such as hot dip aluminum - coated
type 409 stainless steel, are being used in automotive
exhaust systems
Olayemi Odunlami

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Aluminium Coatings
Aluminum coatings are also used for protecting against atmospheric
corrosion, an application that is limited by higher costs of aluminum
compared to zinc coatings and by variable performance.
In soft waters, aluminum exhibits a potential that is positive to steel; hence, it
acts as a noble coating.
In seawater and in some fresh waters, especially those containing Cl , the
potential of aluminum becomes more active and the polarity of aluminum
coating under these conditions is sacrificial and cathodically protects steel.
An Al Zn alloy coating consisting of 44% Zn, 1.5% Si, bal. Al has been
reported to have excellent resistance to marine and industrial atmospheres.
It also protects against oxidation at elevated temperatures.
Sprayed coatings are commonly sealed with paints to delay eventual
formation of visible surface rust.

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Inorganic Coatings
The glasses linings are composed essentially
of alkali borosilicates and can be formulated to
resist strong acids, mild alkalies, or both.
Their highly protective quality results from
virtual impenetrability to water and oxygen
over relatively long exposure times, and from
their durability at ambient and above - room
temperatures.
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Inorganic Coatings
They are used in cathodically protected hot water
tanks.
the glass coating, must be perfect and without a single
defect. This means that glass - lined vessels for the food
and chemical industries must be maintained free of
cracks and other defects.
Susceptibility to mechanical damage and cracking by
thermal shock the main weaknesses of glass coatings. If
damage occurs, repairs can sometimes be made by
tamping gold or tantalum foil into the voids.
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Inorganic coatings
Portland cement coatings have the
advantages of low cost, and ease of application
or repair.
Usual thickness ranges from 5 to 25 mm (0.2 1
in.); thick coatings are usually reinforced with
wire mesh.
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Inorganic coatings
Chemical conversion coatings are protective
coatings formed in situ by chemical reaction
with the metal surface.
They include special coatings, such as iron
fluoride, which forms when steel containers
are filled with hydrofluoric acid ( > 65% HF).
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Inorganic coatings
Phosphate coatings on steel ( Parkerizing,
Bonderizing) are produced by brushing or
spraying, onto a clean surface of steel, a cold or
hot dilute manganese or zinc acid
orthophosphate solution.
The ensuing reaction produces a network of
porous metal phosphate crystals firmly bonded
to the steel surface
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Organic Coatings
Paints
Paints are a mixture of insoluble particles of pigment
suspended in a continuous organic or aqueous
vehicle. Pigments usually consist of metallic oxides
or other compounds, such as clay.
The Painted systems require continued
maintenance to ensure integrity of corrosion
protection.
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