Improving corrosion resistance on aluminium alloy by using organic coating

IMPROVING THE CORROSION RESISTANCE BY USING ORGANIC COATING ON ALUMINUM ALLOYSGUIDED BY PREPARED BY Mr.K.RAJALINGAM, M.Sc.,(Engg.) SANJAY KUMAR.K Professor Roll No:-12MEED05Dept of mechanical engineering Reg No:-921312408007 PSNA CET1CONTENTSABSTRACTINTRODUCTIONLITERATURE VIEWPROBLEM DEFINITIONMETHODOLOGYCONCLUSIONREFERENCES2ABSTRACT3INTRODUCTION

CORROSION Corrosion is the deterioration or destruction of metals and alloys in the presence of an environment by chemical or electrochemical means. (0R) Corrosionis the gradual destruction of materials, (usuallymetals),chemical reaction with its environment.4Generally what is corrosionBut v have a proper definition in mech terms and they r so4Corrosion in terms of money relatedLosses due to corrosion could be around Rs.2.0 lakh crores per annum in India. It can be a minimum of 3.5% of the nations GDP. Corrosion costs manifest in the form of premature deterioration or failure necessitating maintenance, repairs and replacement of damaged parts.

55WHY DO THEY CORRODEMetals corrode because we use them in environments where they are chemically unstable. Only copper and the precious metals (gold, silver, platinum, etc.) are found in nature in their metallic state. All other metals, to include iron-the metal most commonly used-are processed from minerals or ores into metals which are inherently unstable in their environments.

6TYPES OF COROSSIONGalvanic corrosion,Uniform corrosion,Pitting, Dezincification,Atmospheric corrosion, Erosion corrosion, Fretting, Crevice corrosion-cavitation, Stress corrosion, Corrosion fatigue.

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8ALUMINUMAluminum is an abundant element in Earth's crust it is believed to be contained in a percentage from 7.5% to 8.1%. Aluminum is very rare in its free form. Aluminum contribute greatly to the properties of soil, where it is present mainly as insoluble aluminum hydroxide.Abundant element on earth crust are normally found in oxide forms (Al2O3), i.e., bauxite, kaolinite, nepheline and alunite.

9History of aluminumAncient Greeks and Romans used aluminum salts as dyeing mordants and as astringents for dressing wounds; alum is still used as a styptic. In 1761, Guyton de Morveau suggested calling the base alum as alumine. In 1808, Humphry Davy identified the existence of a metal base of alum, which he at first termed alumium and later aluminum.The name aluminum is derived from the ancient name for alum (potassium aluminum sulphate), which was alumen(Latin, meaning bitter salt). Aluminum was the original name given to the element by Humphry Davy but others called it aluminum and that became the accepted name in Europe.10PHYSICAL VIEWSAluminum is a relatively soft, durable, lightweight, ductile and malleable metal with appearance ranging from silvery to dull gray, depending on the surface roughness. It is nonmagnetic and does not easily ignite. A fresh film of aluminum serves as a good reflector (approximately 92%) of visible light and an excellent reflector (as much as 98%) of medium and far infrared radiation. The yield strength of pure aluminum is 711 MPa, while aluminum alloys have yield strengths ranging from 200 MPa to 600 MPa. Aluminum has about one-third the density and stiffness of steel. It is easily machined, cast, drawn and extruded.Aluminum atoms are arranged in a face-centered cubic(fcc) structure. 11PROPERTIESLight Weight:-Aluminum is a very light metal with a specific weight of 2.7 g/cm3, about a third that of steel. For example, the use of aluminium in vehicles reduces dead-weight and energy consumption while increasing load capacity.Corrosion Resistance:-Aluminum naturally generates a protective oxide coating and is highly corrosion resistant. Different types of surface treatment such as anodizing, painting or lacquering can further improve this property. It is particularly useful for applications where protection and conservation are required.Electrical and Thermal Conductivity:-Aluminum is an excellent heat and electricity conductor and in relation to its weight is almost twice as good a conductor as copper. This has made aluminium the most commonly used material in major power transmission lines.Ductility:-Aluminum is ductile and has a low melting point and density. In a molten condition it can be processed in a number of ways. Its ductility allows products of aluminium to be basically formed close to the end of the products design.Recyclability:-Aluminum is 100 percent recyclable with no downgrading of its qualities. The re-melting of aluminium requires little energy: only about 5 percent of the energy required to produce the primary metal initially is needed in the recycling process.

12APPLICATION OF ALUMNIUMTransportation (automobiles, aircraft, trucks, railway cars, marine vessels, bicycles, etc.) as sheet, tube, castings, etc. Packaging (cans, foil, frame of etc.). Construction (windows, doors, siding, building wire, etc.).A wide range of household items, from cooking utensils to baseball bats, watches. Street lighting poles, sailing ship masts, walking poles, etc. Outer shells of consumer electronics, also cases for equipment e.g. photographic equipment, MacBook Pro's casing. Electrical transmission lines for power distribution. Super purity aluminum (SPA, 99.980% to 99.999% Al), used in electronics and CDs. Heat sinks for electronic appliances such as transistors and CPUs. Powdered aluminum is used in paint, and in pyrotechnics such as solid rocket fuels and thermite. A variety of countries, including France, Italy, Poland, Finland, Romania, Israel, and the former Yugoslavia, have issued coins struck in aluminum or aluminum-copper alloys.

13Various prevention methodEnvironmental Modification, Metal Selection and Surface Conditions, Cathodic Protection,Corrosion Inhibitors,Coating,Plating.

14VARIOUS COATING TYPESMetallic,Inorganic,Conversion, Organic coatings.15ORGANIC COATINGOrganic coating provides protection either by the formation of a barrier action from the layer or from active corrosion inhibition provides by pigments in the coating. Surface condition of metal converted to more stable state by coating with organic compounds. These coatings delay the generation of electromotive force, causing the corrosion of the substrate. Cathodic deposition of organic coatings has gained worldwide acceptance as a coating process for automotive, appliance and general industrial coatings which has been adopted in technology to provide the first prime coat to a variety of products.

16VARIOUS ORGANIC COATING PROCESSPainting,Powder coating, E-coating,Solgel process, Electro active conducting polymer.

17SOL-GEL COATING PROCESSThe sol-gel technique is deposition method to create protective coatings, optical coatings or ceramics. This technique starts with the hydrolysis of a liquid precursor (sol) which undergoes polycondensation to gradually obtain a gel. This gel is a bi-phasic system containing both a liquid phase (solvent) and a solid phase (integrated network, typically polymer network). Step by step, the proportion of liquid is reduced. The rest of liquid can be removed by drying and can be coupled with a thermal treatment to tailor the material properties of the solid.

18ADVANTAGES OF SOL-GEL PROCESSSolgel processing temperature generally is low, usually close to room temperature.Thus, thermal volatilization and degradation of entrapped species, such as organic inhibitors, is minimized. Since liquid precursors are used it is possible to form coatings on complex shapes and to produce thin films without the need for machining or melting.The solgel films are formed by green coating technologies. Compounds are used that do not introduce impurities into the end product as initial substances. Solgel processing is waste-free and excludes the stage of washing.19DISADVANTAGES OF SOL-GEL PROCESSHowever, a major restriction of solgel technology is the small thickness attainable with the mechanical deposition techniques, like dipping, spin-coating and spraying.Room temperature should be maintained during the process if not coating will not be uniform. 20LITERATURE VIEWS.NOPROJECT TITLEAUTHORSPUBLISHERYEAR1Anticorrosion properties of pigments based on ferrite coated zinc particlesP. Benda, A.KalendovPhysics Procedia 20132Atmospheric corrosion of Galfan coatings on steel in chloride-rich environmentsXian Zhang, Christofer Leygraf, Inger Odnevall WallinderCorrosion Science 20133Investigation of marine environmental related deterioration of coal tar epoxy paint on tubular steel pilingsA. Husain, O. A.Shamali, A.AbduljaleelDesalination200421S.NOPROJECT TITLEAUTHORSPUBLISHERYEAR4Transfer of tritium in concrete coated with hydrophobic paintsS. Fukadaa, Y. Edaoa,K. Satoa, T. Takeishia, K. Katayamaa, K.Kobayashib, T. Hayashib, T. Yamanishib, Y. Hatanoc, A.Taguchic, S. AkamarucFusion Engineeri-ng and Design20125Silicone functionalized pigment to enhance coating performance] K. Rajesh Kumar a, Swapan K. Ghosh bDyes and Pigments 20126Alkyd coatings containing polyanilines for corrosion protection of mild steelG.S. Gonc alvesa, A.F. Baldisseraa, L.F. Rodrigues Jr. a, E.M.A. Martinib, C.A. FerreiraaSynthetic Metals 20112222S.NOPROJECT TITLEAUTHORSPUBLISHERYEAR7 Biofunctionalized anti-corrosive silane coatings for magnesium alloysXiao Liu a, Zhilian Yue a, Tony Romeo a, Jan Weber b, Torsten Scheuermann c, Simon Moulton a, Gordon Wallace a.Acta Biomaterialia 20138Mixed metal oxides with the structure of perovskite for anticorrosion organic coatingsM. Kantorova, D. VeselbPhysics Procedia 20139Properties of organic coatings with nonisometric ferrite particlesMiroslav Ulbrich, Andrea KalendovPhysics Procedia 201323S.NOPROJECT TITLEAUTHORSPUBLISHERYEAR10Development of heat-resistant anticorrosion urethane siloxane paintsMoussa Tamboura, Anna M. Mikhailova,Meng Qiu JiaJ. Coat. Technol. Res201311Effect of hydrophobic paints coating for tritium reduction in concrete materialsY. Edaoa, S.Fukadaa, Y.Nishimuraa, K.Katayamaa, T.Takeishia, Y.Hatanob, A.TaguchibFusion Engineering and Design 201312Water uptake kinetics in anti-corrosion organic films with a high resolution microbalance oscillator sensorL. Rodriguez-Pardoa, A. CaoPaza, J.Farinaa, A.Covelob, X.R.Nvoab, C.PrezbSensors and Actuators201224S.NOPROJECT TITLEAUTHORSPUBLISHERYEAR13Anti-corrosion performance of waterborne Zn-rich coating with modified silicon-based vehicle and lamellar Zn (Al) pigmentsLiuyanZhanga, AibinMaa, JinghuaJiangDanSong, JianqingChenb, DonghuiYangbProgress in Natural Science: Materials International201214 Lack of adhesion of paint in galvanised steel stripNelson F. Garza-Montes-de-Oca , Rafael ColasEngineering Failure Analysis201225PROBLEM DEFINITIONAll aluminum alloys contain some copper. Alloys with what is considered a high degree of copper content (3-4%) have experienced an unacceptable rate of corrosion, especially in environments with a higher than average salt content. The proposal to resolve the unacceptable rate of corrosion is to limit aluminum alloys to those containing 1% of copper or less.26METHODOLOGYSolgel is a broad class of processes in which a solid phase is formed through gelation of a colloidal suspension (sol). Drying of the gel can then give the dry gel (xerogel) state and subsequent heat treatment can be used to remove unreacted organic residues, stabilize the gel, densify it, or introduce crystallinity.Generally, the solgel formation occurs in four stages: (a) hydrolysis, (b) condensation and polymerization of monomers to form chains and particles, (c) growth of the particles, and (d) agglomeration of the polymer structures followed by the formation of networks that extend throughout the liquid medium resulting in thickening, which forms a gel.27CONCLUSIONIn this paper the material to be coated is selected and it is aluminum alloy AA7075 plate.The coating is to be done with sol-gel dip coating process.The resin to be used in the coating process is to be silica.The efficiency of the corrosion resistance is to be improved by using various parameters (thickness of coat, withdrawal rate, temperature).With the salt spray test (or) salt fog test chamber, corrosion behavior of coated and uncoated aluminum sheets to be measured in NaCl.By using scanning electron microscopy (SEM) the morphology of the coatings to be studied in detail.

28Salt fog test, 28REFERENCES[1] P. Benda, A. Kalendov, Anticorrosion properties of pigments based on ferrite coated zinc particles, Physics Procedia 44 ( 2013 ) 185 194.[2] Xian Zhang, Christofer Leygraf, Inger Odnevall Wallinder, Atmospheric corrosion of Galfan coatings on steel in chloride-rich environments, Corrosion Science 73 (2013) 6271.[3] A. Husain*, O. A1-Shamali, A. Abduljaleel, Investigation of marine environmental related deterioration of coal tar epoxy paint on tubular steel pilings, Desalination 166 (2004) 295-304.[4] S. Fukadaa,, Y. Edaoa, K. Satoa, T. Takeishia, K. Katayamaa, K. Kobayashib, T. Hayashib, T. Yamanishib, Y. Hatanoc, A. Taguchic, S. Akamaruc, Transfer of tritium in concrete coated with hydrophobic paints, Fusion Engineering and Design 87 (2012) 54 60.[5] K. Rajesh Kumar a, Swapan K. Ghosh b,*, A.S. Khanna c, Gulzar Waghoo a, Faisal Ansari a, Kapil Yadav, Silicone functionalized pigment to enhance coating performance, Dyes and Pigments 95 (2012) 706e712.[6] G.S. Gonc alvesa, A.F. Baldisseraa, L.F. Rodrigues Jr. a, E.M.A. Martinib, C.A. Ferreiraa, Alkyd coatings containing polyanilines for corrosion protection of mild steel, Synthetic Metals 161 (2011) 313323.[7] Xiao Liu a, Zhilian Yue a, Tony Romeo a, Jan Weber b, Torsten Scheuermann c, Simon Moulton a,*, Gordon Wallace a, Biofunctionalized anti-corrosive silane coatings for magnesium alloys, Acta Biomaterialia 9 (2013) 86718677.

29REFERENCES[8] M. Kantorova, D. Veselb, Mixed metal oxides with the structure of perovskite for anticorrosion organic coatings, Physics Procedia 44 ( 2013 ) 213 223.[9] Miroslav Ulbrich*, Andrea Kalendov, Properties of organic coatings with nonisometric ferrite particles, Physics Procedia 44 ( 2013 ) 247 255.[10] Moussa Tamboura, Anna M. Mikhailova, Meng Qiu Jia, Development of heat-resistant anticorrosion urethane siloxane paints, J. Coat. Technol. Res., 10 (3) 381396, 2013.[11] Y. Edaoa,, S. Fukadaa, Y. Nishimuraa, K. Katayamaa, T. Takeishia, Y. Hatanob, A. Taguchib, Effect of hydrophobic paints coating for tritium reduction in concrete materials, Fusion Engineering and Design 87 (2012) 995 998.[12] L. Rodriguez-Pardoa,, A. Cao-Paza, J. Farinaa, A. Covelob, X.R. Nvoab, C. Prezb, Water uptake kinetics in anti-corrosion organic films with a high resolution microbalance oscillator sensor, Sensors and Actuators B 144 (2010) 443449.[13] Liuyan Zhanga,b,n, AibinMaa,b,n, JinghuaJiangb,c, DanSongb,c, Jianqing Chenb, DonghuiYangb, Anti-corrosion performance of waterborne Zn-rich coating with modified silicon-based vehicle and lamellar Zn (Al) pigments, Progress in Natural Science: Materials International 2012;22(4):326333.[14] Nelson F. Garza-Montes-de-Oca , Rafael Colas, Lack of adhesion of paint in galvanised steel strip, Engineering Failure Analysis 26 (2012) 175181.

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