Corrosion is one of the common issues with structural components and equipment made of various materials. You can use corrosion protection coatings to reduce maintenance needs, minimize replacement costs, and increase your equipment’s lifespan. To choose the right coating, it is essential to find the type of corrosion affecting the surface.
Different categories of corrosion–
Galvanic corrosion occurs when 2 metals with various electrochemical charges have a connection through a conduction path. The movement of metal ions to the cathodic metal from the anodic ones can result in corrosion. So, you can choose corrosion-resistant metal spray coating to prevent this issue.
Stress-corrosion cracking causes irreparable damage to your component. High stress may be caused by thermal treatment, welding, and cold work. It will intensify stress-cracking issues, and you will find minor stress corrosion.
General corrosion, which results from rust, is found in steel rust. Premium-quality stainless steel coatings are effective in preventing this corrosion.
Localized corrosion turns up when your component is affected by corrosion-causing stresses. As it is localized, it corrodes only a small or local part.
Caustic agent corrosion is the result of impure liquids, solids, and gases, which wear down a material. Though most impure gasses cannot affect a dry metal, they dissolve and produce corrosive droplets.
Best coatings to prevent steel corrosion–
Corrosion-resistant coatings for steel are of different types.
Epoxy– This coating can fight against rust, and its thickness ranges from 4 to 6 mm. But, you can also apply a thicker layer (around 8mm) for the parts prone to rust. Moreover, epoxy reduces the effect of chemical erosion.
Inorganic Zinc– Zinc coatings are an effective anti-rust coating, which ensures protection against saltwater, rust, and weather elements. Refineries and chemical plants use this type of coating to protect equipment parts from deterioration. The combination of polyester coatings and zinc-rich primers makes the surface corrosion-resistance.
Corrosion-resistant coatings can be categorized in different ways-
Anodized coatings– Anodisation is a way to improve the corrosion-resistant capacity of aluminum. It is done by immersing the materials in a conductive solution. When dyed, you can achieve the desired color effects. It is better to keep the thickness of the coating to 20μm.
Plasma electrolytic oxidation coating– It involves using plasma discharges for the metallic surface transformation. It also develops an adhesive oxide layer, which is dense and hard. It is best for coating magnesium, titanium, and aluminum.
Chromate conversion coating–
As governmental regulations regarding manufacturing processes have become stricter, chromate conversion coating has become a perfect solution. This coating has unique chemistries, such as sodium, chromic acid, and potassium chromate. The presence of additives leaves a passive film that contains hydrated compounds and chrome oxide. It not only ensures high corrosion resistance but also maintains coatings. Chromium compounds can reform quickly when the surface gets damaged.
So, these are some corrosion-resistant coatings that can be applied on various metal surfaces. Choosing the right coating to ensure a long-lasting value from it.
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