PROTECTION FROM CORROSION BY ORGANIC COATING

SUBMITTED TO: MS. KULJEET KAUR

SUBMITTED BY: AMARDEEP TIRKEY

REG. NO.:10802977 ROLL NO.:R190B54 SECTION: B COURSE CODE: 104 COURSE: DIPLOMA + B.TECH INTEGRATED [M.E.] YEAR/SEMESTER: 2 ND / 3RD

PROTECTION FROM CORROSION BY ORGANIC COATING

INTRODUCTION The corrosion is a phenomenon which is widely observed with almost all metals. The most common and convenient method of protecting a metal against corrosion is by a coating, especially an organic coating. The main function of an organic coating is to serve as a protective barrier against corrosion besides having an aesthetic appeal.

DFINITION Organic coating are inert organic barriers like paint varnishes, lacquers and enamels. Plied on metallic surfaces and other constructional materials for both corrosion protection and decoration. The protection value of such coating depends on:
1. 2. 3. 4.

Its Its Its Its

chemical inertness to the corrosive environment good surface addition. impermeability to water, salts and gases proper application method.

PAINTS Paint is a mechanical dispersion mixture of one or more pigments in a vehicle, the vehicle is a liquid consisting of non volatile film forming material drawing oil and highly volatile solvent, thinner .When a paint is applied to a metal surface usually by brushing or spraying, the thinner evaporates while the drawing of oil slowly oxidized forming a dry pigmented film. Paint is used to protect, preserve and decorate (such as adding color), or add functionality to an object or surface by covering it with a pigmented coating. An example of protection is to retard corrosion of metal. An example of decoration is to add festive trim to a room's interior. An example of added functionality is to modify light reflection or heat radiation of a surface. Another example of functionality is the use of color to identify hazards or to identify the function of equipment, such as pipelines or military ammunition. Paint can be applied to almost any kind of object. It is used, among many other uses, in the production of art, in industrial coating, as a driving aid (road surface marking), or as a barrier to prevent corrosion or water damage. Paint is a semi finished product, or intermediate good as the final product is the painted article itself.

CHARACTERISTICS OF GOOD PAINT

It should b fluid enough to be spread easily over the protected surface It should possess high covering power It should form a quiet tough uniform adherent and impervious film Its film should not get cracked on drawing It should protect the painted surface from corrosion effects of environment It should form film, the colour of which is quiet stable to the effect of atmosphere and other agencies Its film should be glossy Its film should be stable It can be prepared in such a consistency as to be easily applicable with brush or spraying device and that it yields a smooth and uniform surface. It should possess high addition capacity to the material over which it is intended to be used

CONSTITUENTS OF PAINT

PIGMENT It is a solid substance which Is an essential constituent of paint. Its functions are to: provide capacity to paint provide strength to the paint provide desired colour to the paint give aesthetical appeal i.e. pleasing to look at to the paint film give protection to the paint film by reflecting harmful ultraviolet light provide resistance to the paint against abrasion/wear
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 improve the impermeability of paint film to moisture increase weather resistance of the film

Pigment used as whites (such as white lead, zinc oxide, lithophone, titanium oxide) or coloured:

Red - red lead, ferric oxide, venetian chrome red Green - chromium oxide Blue - Persian blue Black-carbon black Brown-brown umber etc.

CHARACTERISTICS OF GOOD PIGMENT

Opaque Chemically inert so that paint film has stability and longer life. Non toxic so that there is no bad effect on the health of painter as well as inhabitants Freely mixable with film forming constituents, oil Cheap

VEHICLE OR DRYING OIL

It is a film forming constituent of paint, these are glyceryl esters or high molecular fatty acids generally present in animal and vegetable oils. CH2COOR CHCOOR CH2COOR

FUNCTIONS OF DRYING OIL

Main film forming constituents Vehicle or medium Toughness Adhesions Durability Water proofness

FATTY ACID PRESENT IN OIL AND FATS

NAME OF THE ACID Caproic Caprylic Cpric Lauric Myristic Palmitic Stearic Archidic Behenic Lingoceric Cerotic Oleic Linoleic Linoenic Eleostearic

FORMULA C5H11COOH C7H15COOH C9H19COOH C11H23COOH C13H27COOH C15H31COOH C17H35COOH C19H39COOH C21H43COOH C23H47COOH C25H51COOH C17H33COOH C17H31COOH C17H29COOH C17H29COOH

POSITION OF THE UNSATURATION Saturated Saturated Saturated Saturated Saturated Saturated Saturated Saturated Saturated Saturated Saturated Unaturated Unaturated Unaturated Unaturated

REACTION IN DRYING OILS

The oil film after it has been applied on the protected surface, absorbs oxygen(of the air at the double bonds, forming peroxides, diperoxide and hydro peroxide which isomerise ,polymerize and condense to form a characteristic tough, coherent, hard, elastic, insoluble, infusible, highly cross linked structure macro molecular film. The final hardened product actually resembles thermosetting resin in chemical structure.

DRYING OF PAINT FILM

THINNER

Reduce the viscosity of the paint to suitable consistency so that it can easily handled and applied: dissolve vehicle and the additives in the vehicle suspend the pigments increase the penetrating power of the vehicle increase the elasticity of the paint film help the drawing of paint film as they evaporate
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Common thinners used are turpentine(produced by the distillation of resinous exudation of some kind of pine trees),minerals spirits(from petroleum)benzene,dipentene,naphtha,toluol,xyrol,carosene ,methylatd naphthalene etc.
DRIERS

Driers are oxygen carrier catalystthey accelerate the drawing of oil film through oxidation, polymerization and condensation. Thus there main function is to improve the drawing quality of the oil film. The most effective driers are resonates, linoleates, tungstates and naphthenates of Co, Mn, Pb and Zn. Cobalt substances are the most efficient of all and are surface drier. Lead substances are bottom driers. Manganese substances are thorough driers.

EXTENDERS OR FILLERS

They are low refractive indices material generally of white colour added to reduce the cost increase durability of the paint provide negligible covering power of the paint help to reduce the cracking of dry paint film and sometimes help to keep the pigments in suspension surf to fill voids in the film increase random arrangement of the pigment particles act as carriers of the pigment colour Important extenders used are barites (BaSo4) talc, asbestos, ground silica, gypsum, ground mica, slate powder, china clay, whiting (CaCo3), magnesium silicate, diatomite clay, calcium sulphate etc.
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PLASTICIZERS

Sometimes plasticizers are incorporated in the paint: To provide elasticity to the film To minimize the cracking Common plasticizers used are tricresyl phosphate, triphynyl phosphate, tributyl phthalate, diamyl phthalate and dibutyl tartarate.
ANTISKINNING OF OILS

They are sometimes added to some paints with the object to preventing gelling and skinning of the paint. Important antiskinning agents are polyhydroxyl phenols.

FORMULATION OF THE PAINTS Manufacture of paints depends upon composition of paint to meet specific requirements. These requirements are: Hiding power Colour fastness Weather resistance Consistency

The requirements are met by proper choice of pigments, vehicles, and extenders by paint formulator. The most important concept for modern paint formulator is:
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PIGMENT VOLUME CONCENTRATION [P.V.C.]:

PVC is the concentration by volume of the pigments expressed as a percentage of the total volume of nonvolatile constituents of the paints.

It is mathematically expressed as: P.V.C. = Volume of the pigment in paint

____________________________________________________ Total volume of non volatile constituents of the paint

IMPORTENCE OF P.V.C.:

The P.V.C. largely controls such factor as gloss, washability, adhesion and durability. Thus:

When the P.V.C. is increased, the gloss decreases, until paint becomes flat. With the increase in P.V.C., the relative quantity of binder decreases, therefore, film formed loses cohesion and hence durability. So, with the increase in P.V.C., the adhesion and durability of the paint-film decreases. With the increase in P.V.C., the washability of paint film decreases. Extenders when added to a paint, amount to increases in P.V.C., and thus, decreases washability, durability and adhesion. So, in case of the pigment is costly and its covering power is high a portion of the pigment massy economically be replaced by extenders, without sacrificing the covering power of the pigment. Opacity of the white paint is created by the difference in the refractive indices of the pigment and vehicle. It is
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also influenced by the size of the dispersed pigment particles and P.V.C.

FAILURE OF THE PAINT FILM:

Paint is considered to be failed in the following cases:

1.

CHALKING : It is the progressive powdering of the paint film on the painted surfaces. This occurs due to improper dispersion of pigment in vehicle or destruction of binder by continuous exposure of light.

2.

FLAKING : It is the peeling of the paint film on the painted surface. This is due to the presence of dust particles or greasy matters in the paint. These foreign matters result in poor adhesion of the paint.

3.

CRACKING : Cracking of the paint film is due to the unequal expansion or contraction of different coats of the paint, caused by variation of the temperature of the exposed film.

4.

COLOUR CHANGE OF THE PAINT FILM Colour change of the paint film after some time is due to the chemical effect of atmospheric gases on the paint.
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PREVENTION:

Scientific mixing and proportioning of the ingredients of proper characteristics. Using only suitable and selected paint for particular job. Preparing carefully the surface, before application of the paint. Applying a suitable primer coat. Properly applying the paint evenly Allowing each paint coat to dry sufficiently, before the newer or next coat is applied. VARNISHES

Varnish is a homogeneous colloidal dispersion solution of natural or synthetic resin in oil or thinner or both. It is used as protective and or decorative coating of suitable surfaces and dries by evaporation, oxidation and polymerization of its constituents; leaving behind a hard, transparent, glossy, lustrous and durable film. There are two main types of varnishes:
OIL VARNISH [OR OLEORESINOUS VARNISH]:

It is a homogenous solution of one or more natural or synthetic resin in a drying oil and a volatile solvent. The presence of oil reduces the natural brittleness of the pure resin film. This type of varnish dries up by the evaporation of the volatile solvent, followed by oxidation and polymerization of the drying oil. Consequently such varnishes take comparatively longer period [about 24 hrs.] for drying, but the film produced hard, quiet lustrous and durable. An example is copal varnish [prepared by dissolving copal linseed oil and mixing a quality of turpentine]. They are used for exterior as well as interior works.

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Drying of an Oleoresinous

SPRIT VARNISH:

It contains a resin dissolved in completely volatile solvent. Such a varnish dries by evaporation of the solvent. Sprit varnish dries quiet rapidly, leaves behind a film which is brittle and, so has a tendency to crack or peel off. Moreover, the film is easily affected by weathering. An example is spirit varnish. Such varnish are used, usually, for polishing wooden furniture.

CHARACTERISTICS OF VARNISHES:

It should be.. Be should soft and tender Adapt itself to the contraction/ expansion of coated material like wood due to temperature variation. Dry quickly Produce a protective film (a hard, tough, durable and quiet resistance to wear and tear) Produce glossy and shining film on drying
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 Yield aesthetical appealing film Yield elastic film, which does not crack or peel off on drying Yield film, whose colour does not fade or change on exposure to atmosphere weather. Not shrink or crack after drying
CONSTITUENTS OF VARNISHES
I.

Resin in use are: Natural resin (like shellac, kauri, rosin, copal, dammar, manila etc.) Synthetic resin (like phenol-aldehyde, alkyds, urea-formaldehyde, terpene polymer etc.) The resin, in general, are characterized by high resistance to weathering and chemical action, elasticity of film, good adhesion, high luster and in certain cases, high colour, stability to heat and light. Thus resin in varnish provides an element of hardening, resistance to weathering, durability, resistance to chemical action and water proofness.

II. Drying Oils Principal oils used are linseed oil, tung oil, dehydrated castor oil, soyabean oil, oticia oil, perilla oil, fish oil etc They dry by oxidation and polymerization. III. Solvent or Thinners They are usually employed are turpentine, petroleum spirits , coal-tar-nephtha, kerosene, xylol, tolyl, butyl and ethayl alcohol, amyl acetate acetone etc IV. Driers They are added to enhance the drying rate of oil constituents. These include Pb, Co and Mn linoleates nephthanates resonates etc.
V.

Antiskinnig Agent
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It is like tert- amyl phenol, guiacol, etc.. Uses: for the protection of the articles against corrosion as a brightening coat to a painted surface For improving the appearance and intensifying the ornamental grains of wood surfaces.

ENAMELS Enamel paint is a paint that air dries to a hard, usually glossy, finish. In reality, most commercially-available enamel paints are significantly softer than either vitreous enamel or stoved synthetic resins.With respect to paints enamel is a fanciful term, implying that an ordinary latex or oil-based paint has the same properties as true, fired vitreous enamel. Some enamel paints have been made by adding varnish to oil-based paint. The term sometimes refers to oil-modified polyesters that were introduced in the early 1930s. The oil is required to stop or enhance the cross linking of the paint in order to achieve sufficient flexibility of the paint film. Typically the term "enamel paint" is used to describe oilbased covering products, usually with a significant amount
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of gloss in them, however recently many latex or waterbased paints have adopted the term as well. The term today means "hard surfaced paint" and usually is in reference to paint brands of higher quality, floor coatings of a high gloss finish, or spray paints.

USES

Guitars - may be used as a DIY solution to dead and scurfy guitar. Floor enamel - May be used for concrete, stairs, basements, porches, and patios. Fast dry enamel - Can dry within 10-15 minutes of application. Ideal for refrigerators, counters, and other industrial finishes. High-temp enamel - May be used for engines, brakes, exhaust, and BBQs. Enamel is also used on wood to make it resistant to the elements via the waterproofing & rot proofing properties of enamel. Generally, treated surfaces last much longer and are much more resistant to wear than untreated surfaces. Nail-enamel - Used to polish the nails

LACQUERS

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In a general sense, lacquer is a clear or coloured varnish that dries by solvent evaporation and often a curing process as well that produces a hard, durable finish, in any sheen level from ultra matte to high gloss and that can be further polished as required. The term lacquer originates from the Portuguese word for lac, a type of resin excreted from certain insects. Regardless, in modern usage, lac-based varnishes are referred to as shellac, while lacquer refers to other polymers dissolved in Volatile Organic Compounds (VOCs), such as nitrocellulose and later acrylic compounds dissolved in a solvent generally referred to as lacquer thinner. While both lacquer and shellac are traditional finishes, lacquer is more durable than shellac.

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EMULSION PAINTS An 'emulsion' [IPA]: is a mixture of two immiscible (unbendable) liquids. One liquid (the dispersed phase) is dispersed in the other (the continuous phase). Many emulsions are oil/water emulsions, with dietary fats being one common type of oil encountered in everyday life. Examples of emulsions include butter and margarine, milk and cream, and vinaigrettes; the photo-sensitive side of photographic film, magmas and cutting fluid for metal working. In butter and margarine, fat surrounds droplets of water (a water-in-oil emulsion). In milk and cream, water surrounds droplets of fat (an oil-in-water emulsion). In certain types of magma, globules of liquid NiFe may be dispersed within a continuous phase of liquid silicates. Emulsification is the process by which emulsions are prepared. Emulsion is also a term used in the oil field as untreated well production that consists primarily of crude oil and water. [citation needed] Emulsions tend to have a cloudy appearance, because the many phase interfaces (the boundary between the phases is called the interface) scatter light that passes through the emulsion. Emulsions are unstable and thus do not form spontaneously. Energy input through shaking, stirring, homogenizing, or spray processes are needed to form an emulsion. Over time, emulsions tend to revert to the stable state of the phases comprising the emulsion. Surface active substances (surfactants) can increase the kinetic stability of emulsions greatly so that, once formed, the emulsion does not change significantly over years of storage. Vinaigrette is an example of an unstable emulsion that will quickly separate unless shaken continuously. This phenomenon is
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called coalescence, and happens when small droplets recombine to form bigger ones. Emulsions can also suffer from creaming, the migration of one of the substances to the top of the emulsion under the influence of buoyancy or centripetal force when a centrifuge is used. Emulsions are part of a more general class of two-phase systems of matter called colloids. Although the terms colloid and emulsion are sometimes used interchangeably, emulsion tends to imply that both the dispersed and the continuous phase are liquid. There are three types of emulsion instability: flocculation, where the particles form clumps; creaming, where the particles concentrate towards the surface (or bottom, depending on the relative density of the two phases) of the mixture while staying separated; and breaking and coalescence where the particles coalesce and form a layer of liquid. Whether an emulsion turns into a water-in-oil emulsion or an oil-in-water emulsion depends on the volume fraction of both phases and on the type of emulsifier. Generally, the Bancroft rule applies: emulsifiers and emulsifying particles tend to promote dispersion of the phase in which they do not dissolve very well; for example, proteins dissolve better in water than in oil and so tend to form oil-in-water emulsions (that is they promote the dispersion of oil droplets throughout a continuous phase of water). The basic colour of emulsions is white. If the emulsion is dilute, the Tyndall effect will scatter the light and distort the colour to blue; if it is concentrated, the colour will be distorted towards yellow. This phenomenon is easily observable on comparing skimmed milk (with no or little fat) to cream (high concentration of milk fat). Micro emulsions and nano emulsions tend to appear clear due to the small size of the disperse phase.

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