Corrosion News

Excerpt: Here are the Corrosion news across the world

Sujit Sinha President Paint division Grauer & Weil (India) honoured with Lifetime Achievement award

For his contribution in promoting corrosion protection through specialised coatings

Mr Sujit Kumar Sinha, President, Paint division, Grauer & Weil (India) Ltd was recently honoured with the Lifetime Achievement award by Indian based Society for Protective Coatings (SSPC). Mr Sinha received the award for his seminal contribution in promoting corrosion protection through specialised coatings and growing the business to a higher scale. He has also been recognised for his efforts in bringing about improvements in paint systems in the country with new technology.

As President at Grauer & Weil (India), Mr. Sinha has been responsible for spearheading the company's growth strategy by working on the areas of brand building and placement along with managing the sales networks and marketing channels and key account management.

Prior to joining Grauer& Weil (India) Ltd, he headed the Sales and Marketing team at Shalimar Paints in the industrial segment and was responsible for generating an annual turnover ofRs.220 crore for the company. He has also headed the Sales and Marketing division at Asian Paints Ltd where he was known to provide valuable inputs for growth in the changing market scenario and new emerging markets for active diversification to gain the market share and profitability. In 2001, while working as General Manager-Sales and Marketing at Jenson & Nicholson (I) Ltd, Mr. Sinha was responsible for developing Steel guard –Protective coating & Megatuff, a powder coating that went on to become the number 2 powder coating brand in the country.

President Mr. Sinha is the profit centre head of the Paint Division and is responsible for the Sales and Marketing portfolio along with Production and R&D. He leads his team in identifying the market segments, selecting target markets for business growth and working towards improving the company's existing as well as new range of products.

Mr. Sinha holds to his credit a rich experience of more than four decades in the industry encompassing the prime areas of planning, sales, brand and business development. He holds a B.Tech from Harcourt Buttler Technological Institute, Kanpur.

Newark begins corrosion control to reduce lead in drinking water

NEWARK city in the USA has plans to treat its city water system with a new chemical designed to stop corrosion from chewing up lead pipes and leaching the potent neurotoxin into drinking water.

Since 2017, lead levels have spiked. This spring, out of 159 homes tested, almost half showed elevated lead levels, particularly across the western portion of Newark served by its Pequannock reservoir system when the old anti-corrosion treatment apparently failed.

“The new chemical, orthophosphate, a food-grade additive, forms a coating on the pipes, and then that coating on the pipes acts as a physical barrier to prevent the water from being in contact with the walls of the lead pipe,” said Sandy Kutzing, principal of engineering company CDM Smith.

But experts warn it will take at least six months to start working, if not longer. So environmental officials urged Newark residents to keep using the free filters handed out by the city — 36,000 so far.

“We have, and are introducing, the corrosion control inhibitor into the water. As of today, we are introducing it and in a few months we are prayerful that we will begin to see the lead levels begin to drop,” said Newark

Mayor Ras Baraka. In addition to the $75 million service line replacement project, the treated water will flow from a new $700,000 chemical feed in Montclair downstream to some 500,000 customers.

Ship coatings project wins SSPC Award

ANNOUNCED at the tail end of April, SSPC: The Society for Protective Coatings awarded Barton International (Glens Falls, New York, USA) and Mid-Atlantic Coatings Inc. (Chesapeake, Virginia, USA), in addition to the U.S. Navy and Sherwin-Williams Protective & Marine Coatings, USA with its SSPC Military Coatings Project Award of Excellence.

The award was given for the exceptional coatings work and collaboration completed on nuclear-powered aircraft carrier USS George Washington (CVN 73).

The ship is 1,092 feet long, 257 feet wide and 244 feet high. As part of the vessel's multi-year midlife refueling and complex overhaul, the coating project took place at the Huntington Ingalls Industries shipyard in Newport News, Virginia. Work on the project began in August 2017, with development plans already in the works two years prior. Work Completed

Specifications for the USS George included preserving and coating the freeboard, main deck, topside and more than 100 interior tanks. The work also involved the preparation and maintenance of the underwater hull surfaces.

Nnuclear-powered aircraft carrier USS George Washington (CVN 73). “From the beginning, we knew this project would require looking beyond the usual horizons—not just in terms of engineering a strategy, but in effectively communicating our innovations and ideas, and collaborating with the right teams,” said Mark Schultz, Government Marine Manager for Sherwin-Williams Protective & Marine Coatings.

“Since several aspects of the project were groundbreaking, not only were we challenged to assemble this complex arrangement of features and benefits, we also had to demonstrate how these technologies and teams would come together to deliver on our promise.”

In terms of surface preparation, MAC and Sherwin-Williams joined forces with Greener Blast Technologies and Barton garnet abrasives in order to introduce Naval contractors to vapor blasting. This form of preparation was chosen by the team for its water-like medium properties and known reduction in dust levels.

After witnessing the technique remove miscellaneous exterior built-up materials and the outermost coatings prior to applying secondary direct-to-steel blasting, the Navy created a new SSPC/NACE specification for vapor blasting. In taking steps to “improve sustainability and reduce environmental impact,” the vapor blasting aided in lowering the amount of waste, reducing fuel emissions in using water-powered pressure washers and recycling the remaining slurry upon vapor blast completion. Other abrasive blasting processes used recycled steel grit in the tanks as well.

Remaining materials and paints slated to be removed were done so with the use of garnet in dry-blasting techniques. Barton and MAC representatives worked together to ensure that the garnet would meet the project's requirements. . When assessing the freeboards, Shultz went on to explain that instead of using a two-coat system, Sherwin-Williams' Fast Clad ER was used on about 70% of the boards. By using this product, the team was able to achieve a four-hour cure time, allowing for accelerated coating schedules, in addition to eliminating the possibility of missing recoat windows.

For the other 30% of the freeboards, the team used Sherwin-Williams' SeaGuard 5000HS Epoxy with a Sherwin-Williams Polysiloxane XLE-80 HAPS Free Epoxy Siloxane applied as a topcoat over the whole area. The polysiloxane included a new and approved Naval Research Lab low solar absorption pigment package, enhancing the paint's signature “Navy Gray” while achieving a reduced solar temperature load on the vessel.

Within the ship, the tanks designed to hold various chemicals, ballast, water and waste were also coated with the Fast Clad ER, a coating that offers immersion for up to 15 years.

Schultz explained the change in coating choice by saying, “We started with 98% solids Dura-Plate tank coatings more than a decade ago, and we're seeing those tanks hold up very well during inspections with no required rework. We'll see even more success down the road when they re-inspect tanks featuring Fast Clad ER.”

The coatings were applied using plural-component sprayers and utilized cartridge technology from V.O. Baker Co. developed for plural-component materials. During the project, more than 95% of touchups and repairs following initial spray applications were completed entirely with cartridges.

India metal treatment chemical market research report – Forecast to grow at 5% cagr by 2023

THE Indian metal treatment chemical market is likely to witness a substantial growth at a CAGR of 5.68% and is projected to reach USD 378.4 million by the end of 2023. Rising demand for metal components in industrial machinery, electronics & electrical, construction and transportation industry are anticipated to augment the market growth. Moreover, rising government initiatives to boost the production of machine tools namely in automotive and railway sector are expected to drive the market growth.

Metal treatment chemicals are used for removing scale, stain and inorganic contaminants. These chemicals are a part of surface treatment chemicals used mainly for cleaning, anodizing and smooth bonding paints on any metal substrate. Based on various metal treatment chemicals types, the anodizing & platting is leading the segment, which held 32.6% market share in 2016. Anodizing & platting is set to emerge as the preferred choice in metal treatment chemicals owing to easy penetration of anodizing hard coating for numerous application such as electrode coating, anodized layer formation, and electroless plating. Cleaning chemicals segment witnessed a substantial growth and is expected to reach USD 75.4 million by 2023. These chemicals are the first stage of surface metal treatments as they are used to remove scale, contaminants, and dust from the metal substrate thereby, providing a durable and hygienic environment for metal. However, to maintain luster and smooth finish under extreme temperature, corrosion protection chemicals are gaining high importance and are expected to grow at a CAGR of 5.81% during the forecast period.

India metal treatment chemicals are used in various application such as automotive & components, metalworking, industrial machinery, electronics & electrical, construction & infrastructure, aerospace & transportation. The prominent application automotive & OEM components segment is anticipated to reach USD 124.8 million by 2023 at a CAGR of 6.14% during the forecast period 2017-2023. Growing production and sales of automobile in India are likely to boost the market growth further. To maintain the smooth surface finish and optimum paint adhesion, auto components are treated with chemicals for long-term corrosion protection. Thus, this segment is anticipated to retain its dominance over the forecast period. Rising concern over continual repair of warranty parts has led to high demand for the product in various applications, especially electrical & electronic products. Construction & infrastructure segment is projected to witness a considerable CAGR of 5.81% during the review period due to growing government expenditure to boost tourism activity. Furthermore, development in metal work industry such as minimal complex process and technology advancement has led to the positive growth.

Regional analysis

India metal treatment chemicals market is further segregated into four sectors such as North, East, West, and South. The northern sector offers a lucrative opportunity to the automakers and its suppliers owing to close proximity to the raw material manufacturers and policymakers such as ACMA and SIAM. Major automotive companies such as Bajaj Auto, Hero Moto Corp, Honda, JCB, and Maruti Suzuki capture a major share in this sector. Growing automotive sales in North sector is valued at USD 88.0 million in 2016 which accounts for highest CAGR of 5.72% during the assessment period. Moreover, the rapid growth in the industrial machineries and government initiatives such as 100% FDI in the automotive industry are driving the growth of the metal treatment chemicals market. The western region of India emerged as a huge potential sector due to the presence of considerable market participants and favorable climatic condition. Moreover, growing infrastructure activities and rise in the SME's (small-medium enterprise) in Southern region are likely to propel the growth of India metal treatment chemicals market.

Segmentation

India metal treatment chemical market is segmented into types and application. Based on the type, the market is segregated as anodizing & platting, corrosion protective, cleaning, paint stripers. On the basis of the application, the market is divided into automotive & components, metalworking, industrial machinery, electronics & electrical, construction & infrastructure, and aerospace & transportation.

Key Players

Some of the key players in the India metal treatment chemical market are BASF India Ltd., Henkel Adhesives Technologies, Metalguard Pvt. Ltd., Chemtex Speciality Limited, CMP PVT. LTD, Dimetrics Chemicals, KCH India PVT. LTD, Olivine Mercantile Pvt. Ltd., Prime Laboratories and GTZ India Private Limited among others

Further information from:. Nishi Sharma, Report Ocean Classic Tower, Rajnagar Extension, Ghaziabad, 201017 – India Tel: +91-9997112116 Email: sales@reportocean.com URL: www.reportocean.com

KPMG report finds F-35 joint strike fighters susceptible to 'intergranular corrosion'

AUSTRALIAN defence officials have been urged to consider round-the-clock dehumidification systems at an Air Force base near Newcastle to curb the corrosion risk for its fleet of Joint Strike Fighter jets.

Auditing and consulting firm KPMG was tasked with doing a report on the "intergranular corrosion mitigation options" for the 72 F-35A fighter jets, bought by the Australian Defence Force for $17 billion.

Concerns over the risk of metal stress and cracking were raised in 2017, the year before the next-generation fighters were due to come to Australia. The FOI report obtained by the ABC said of the three bases where the jets would be based, only Williamtown, near Newcastle, had been identified as having potential problems.

The risk is posed by salt and other climatic conditions. Intergranular corrosion occurs as a chemical reaction between metal and the environment. "It can degrade the material properties causing stress cracking and cause tensile stress which can impact adjacent components", the report said.

The report points to Aluminium Alloy 7085, used in the construction of the F-35 — the first time the material had been used in widespread production of a military aircraft. AA 7085 is reported to have increased susceptibility to intergranular corrosion," the report said.

The jets will also be based at Luke Airforce Base in the US state of Arizona, and the RAAF base at Tindall in the Northern Territory.

As a result, KPMG recommended the full-time use of mobile dehumidification units, in conjunction with other systems. The projected costs for the infrastructure have been redacted in the KPMG report released through FOI.

“Smart” Corrosion Inhibitor from Hexigone

HEXIGONE Inhibitors Limited (Swansea, Wales) has developed a corrosion inhibitor that substitutes harmful chemicals for “chemically intelligent” pigments. Independent research confirms that this corrosion inhibitor, Intelli-ion, can protect end products up to ten times longer than other chrome-free options. According to Hexigone, the research was performed “by a global leader in industrial coatings.” After 1,000 hours of aggressive prohesion, and 4,000 hours of salt spray and humidity testing, Intelli-ion was found to have 0.04 in (1.0 mm) of corrosion, as opposed to 0.40 in (10 mm) of corrosion in the control sample.

Last month, the European Union (EU) banned the use of hexavalent chromate, a highly toxic corrosion inhibitor that has been linked to increased risk of lung cancer and other serious health conditions. The non-toxic, environmentally friendly alternative offered by Hexigone replaces chromate with a safer, smarter alternative that uses disruptive micro/nano reservoir technologies.

Through these intelligent micro reservoirs, Intelli-ion inhibitors are released “on demand” in reaction to environmental stimuli. This method of anti-corrosion protection could result in longer life spans to end products in the construction, automotive, and aerospace industries.

Patrick Dodds, founder and chief executive officer (CEO) of Hexigone, says that the goal of the Intelli-ion research was to “use chemicals that were previously incompatible with coatings. Now, we are offering a potentially game-changing inhibitor to the coatings industry; a higher performing product that can be easily added to existing production processes, at a price that matches the market.”

Founded by researchers and scientist from Swansea University (Swansea, Wales), Hexigone has received an investment from the Development Bank of Wales and Innovate UK, and partnered with 20 industry partners in order to scale up Intelli-ion for commercial distribution. Says Phil Buck, former CEO of Spencer Coatings Group, “In my forty years in the industry, we have been searching for a comparable anti-corrosion pigment that delivers the same results as lead and chromate complexes. None of the new developments have given that. Now at last we have a corrosion inhibitor that provides the level of performance that our clients need to protect their assets from premature failure. Hexigone is now able to offer the corrosion industry what they have been looking for—a search which has spanned a generation.”

Further information from: www.hexigone.com.

Metal oxide can deform into liquid-like anticorrosion coating

ALUMINUM oxide, a chemical compound commonly used as a protective coating for metals, can deform into a thin, liquid-like substance that can fill cracks and prevent leakage of corrosive or radioactive materials. This was the finding of a research team consisting of researchers from the Massachusetts Institute of Technology (MIT) (Cambridge, Massachusetts, USA), Xi'an Jiaotong University (XJTU) (Shaanxi, China), and Brookhaven National Laboratory (Upton, New York, USA), and their work was supported by the National Science Foundation (Alexandria, Virginia, USA).

Most metals tend to oxidize when exposed to air and water, resulting in cracks and structural failure over the long term. However, aluminum is one of three elements (along with silicone and chromium) that produce an oxide that can protect metals against abrasion and corrosion. With that in mind, the researchers wanted to determine why aluminum oxide and silicon dioxide offer excellent corrosion resistance.

They used an environmental transmission electron microscope (E-TEM) to examine how samples of these oxides would react on metal surfaces that are exposed to an oxygen environment and placed under stress. The E-TEM enabled researchers to study the effects of certain gases or liquids on the samples to see if they would exhibit signs of stress corrosion cracking (SCC). Whereas other metals corrode quickly under SCC, the researchers found that aluminum oxide was not only able to protect the metal surface but could also penetrate between the metal grains, thereby preventing deep-set corrosion.

Because it had been impossible to observe how metal oxides behave at room temperature, it was assumed they were too brittle to assume a flowing, crack-resistant form. But thanks to the E-TEM donated by the Brookhaven National Laboratory—one of only about 10 such devices in the world—the team learned that aluminum oxide can, even at room temperature, be made into a liquid-like layer about 2 to 3 nm thick. As a result, a flowing layer of aluminum oxide coated onto an aluminum surface protects it from structural failure.

According to MIT professor Ju Li, an oxide-coated portion of aluminum “forms a very uniform conformal layer that protects the surface” and can be stretched to more than twice its length without signs of cracking. He adds that the liquid-like properties of this aluminum oxide coating and its ability to prevents the intrusion of cracks or grain boundaries could make it a viable material in a variety of potential applications.

Li was a senior author of a paper that details the team's findings. Entitled “Liquid-Like, Self-healing Aluminum Oxide during Deformation at Room Temperature,” the paper was published in the journal Nano Letters.

UM researchers develop ice-proof coatings for airplanes, marine vessels

RESEARCHERS from University of Michigan (UM) (Ann Arbor, Michigan, USA) researchers have developed a new class of coatings that de-ice the surfaces of large structures, including airplanes, cargo ships, and power lines.

Decades in the making, this ice-proofing spray-on coating sheds ice from surfaces with a force as minimal as a light breeze or even under the weight of the ice itself. This innovation was made possible through “a beautiful demonstration in mechanics,” according to Michael Thouless, UM's Janine Johnson Weins Professor of Engineering.

Whereas previous ice-repellent coatings failed to effectively shed ice on large surfaces, UM researchers embarked on a new strategy that's unusual to the field of icing research. “For decades, coating research has focused on lowering adhesion strength—the force per unit area required to tear a sheet of ice from a surface,” explains Anish Tuteja, an associate professor of materials science and engineering at UM. “The problem with this strategy is that the larger the sheet of ice, the more force is required. We found that we were bumping up against the limits of low adhesion strength, and our coatings became ineffective once the surface area got large enough.”

To solve this problem, Tuteja and his fellow researchers relied on a strategy of low interfacial toughness (LIT). As opposed to low adhesion strength coatings, LIT coatings cause cracks to form between the ice and the surface, resulting in a chain reaction that spreads across the entire iced surface. Thouless uses the analogy of a large rug that becomes easier to move once a wrinkle forms in that rug. “It's easy to keep pushing that wrinkle across the rug, regardless of how big the rug is. The resistance to propagating the wrinkle is analogous to the interfacial toughness that resists the propagation of a crack,” says Thouless.

Interfacial toughness is a key concept in fracture mechanics and has informed the creation of such products as laminated surfaces and adhesive-based aircraft joints. But Thouless saw its potential applications in ice mitigation and suggested to Tuteja that “the failure load would rise while interfacial strength was important.” This insight led to the “beautiful demonstration in mechanics” that Tuteja and his graduate student researchers to test the LIT theory of ice proofing. They mapped the properties of a vast library of substances, including those that relied on interfacial toughness, and mathematically predicted their individual success rates.

After devising various combinations, Tuteja's team developed a coating that balanced interfacial toughness and adhesion strength, and then they tested it on different large surfaces. They found that ice fell off the surfaces with the coating, while ice stuck to the control samples that were either uncoated or had another ice-proof coating. The team plans on improving the durability of the LIT spray-on coatings.

The results from the research project of Tuteja and Thouless, along with UM graduate students Abhishek Dhyani and Kevin Golovin, can be found in a paper entitled “Low interfacial toughness materials for effective large-scale de-icing” in Science Magazine..