corrosion and protection

– phosphating and painting

 by
p. Jayaraman
r.v. Prakash
 Iron Ore
Casting
(Iron Oxide)

Melting
Iron and
Process
Steel

Steel and
Ferro
Alloys
 topics
Session one Session two

Corrosion formation Corrosion prevention

Surface preparation
 Phosphating
 Nickel plating
 Hard Chrome
Plating
 ENP
 Metallising
 Painting
Why we need surface
protection?
to prevent

CORROSION
&
ERROSION
 Corrosion loss
 Corrosion
Corrosion loss
loss calculated
calculated app.
app.500
500 Billions.
Billions.
In
In India
India calculated
calculated around
around 36000
36000 Crores.
Crores.

 Direct
 Direct losses
losses
Replacement
Replacement of of corroded
corroded materials,
materials, use
use of
of
more
more corrosion
corrosion resistance
resistance materials,
materials, use
use of
of
coatings
coatings and
and inhibitors.
inhibitors.

 Indirect
 Indirect losses
losses

 Shut
Shut down
down
 Loss
Loss of
of product
product
 Loss
Loss of
of efficiency
efficiency
 Contamination
Contamination ofof product
product
 Over
Over Design
Design
 Corrosion Loss
 In most of the cases, indirect losses are
substantial part of the corrosion cost.

 Sometimes, due to corrosion of critical

part, may result in the loss of human
life which is very serious.
Corrosion formation
 Theory
 Corrosion may be defined as the dissolution
or oxidation of a metal due to interaction
with the environment.

 Example:
 Rusting of iron
 Discolouration or tarnishing of copper
 TYPES OF CORROSION
A. Direct Oxidation E. Bacterial
B. Atmospheric Corrosion
Corrosion F. Stress Corrosion
C. Electro Chemical G. Corrosion
Corrosion resulting from
D. Galvanic differential
Corrosion aeration. (O2
deficiency)
 TYPES OF CORROSION
 Atmospheric Corrosion:

 This Corrosion will occur when metal

directly contacts with atmosphere.

 Electrochemical Corrosion:

 This Corrosion will occur due difference the

emf valves of steel and contact substance.
 TYPES OF CORROSION
 Stress Corrosion:

 This Corrosion will occur due to more stress

when two metal directly contacts with each
other.
(e.g. Bolt , screw fitting)
606934 – 10”x8” CS valve
Why we required surface
preparation?
 To remove the loose particles
like rust, carbon shoot, etc.
Selection of soil preparation
 mechanical  chemical

• Hand cleaning  solvent wiping

• Power Tool
cleaning  Degreasing
• Flame cleaning  Pickling
• Abrasive  Electrolytic
cleaning
cleaning
 ABRASIVE CLEANING

 Grits, shots, sand, Garnets – are

used in abrasive cleaning.
 Pressurised abrasive will release
from the nozzle which will come
and hit the surface.
 This continuous hits will create
anchor profile.
Blasting Standard
 SURFACE PREPARATION STANDARDS

SIS (ISO
S.No. QUALITY NACE SSPC 850 REMARKS
1-1)

White Metal Blast When viewed without magnification, the surface shall be free from
1 No. 1 SP-5 Sa 3
Cleaning millscale, rust, paint coatings and foreign matter.

When viewed without magnification, the surface shall be free

from millscale, rust, paint coatings and foreign matter,
except for staining as noted below.
Near White Blast Random stainging sall be limited to no more
2 No.2 SP-10 Sa2 1/2
Cleaning than 5% of each unit area of surface as defined in section
2.6 and may consist of light shadows, slight streaks, or
rust stains of mill scale, or stains of previously applied
coating

When viewed without magnification, the surface shall be free from

Commercial Blast visible oil, grease and dirt, and from most of the millscale, rust,
3 No.3 SP-6 Sa 2
Cleaning paint coatings and foreign matter. Any residual contamination
shall be firmly adhering.

4 Brush-off Blast Cleaning No. 4 SP-7 Sa 1 Light Blast cleaning

5 Solvent Cleaning   SP-1   Cleaning the substrate by solvent

6 Hand Tool Cleaning   SP-2 St2 Through hand and power tool cleaning

7 Power Tool Cleaning   SP-3 St3 Very through hand and power tool cleaning

Mineral and Slag

9   AB-1    
Abrasives
 Key Points to Check

 Nozzle
 Pressure
 Moisture free air
 Temperature of air
Blasting Profile
CORROSION PREVENTION
 OILING

 PHOSPHATING

 ACID PICKLING

 PLATING

 PAINTING
PHOSPHATING
Degreasing

Rinse

De-Rusting
Organic
coating

Rinse

Refiner/
Pre-dipping Phosphating Rinse
 DEGREASING
 Step-1 :
the degreasing part will attack the oil
surface.
 Step-2 :

the degreasing part will reduce the

contact angle between the oil and surface.
 Step-3 :

the oil completely removed from the

surface
 DEGREASING
¶ Degrease chemical
Stage I

Θ
Stage II

¶
¶ ¶ ¶ Stage III
¶
¶
¶
¶ ¶
CHECK

• Total alkalinity
• Free alkalinity
• Oil content (emulsified)
 Water Rinse

Enough water rinse is required to

remove alkali carry over.

General requirement is 4-7 times

of dilution is required.
 De-rusting

 to remove loose rust (iron oxides )

 to remove loose carbon particles
CHECK

1. Acidity
2. Iron Content
 Water Rinse

Enough water rinse is required to

remove acid carry over.

pH shall be always 7.0.

 PRE-DIP / REFINER

 Pre-dip is a two pack system.

 One is water softener
 Another one is activator
 PRE-DIP / REFINER

 Activator:

– Activator will create active centers

– More active centers will control Coating
thickness and Crystal size
 PRE-DIP / REFINER
Activator Function:

Secondary PO42+
Active Centre

Without Activation With Activation

(No Secondary
Phosphate Observed)
CHECK

• No Direct Checking for bath content

• pH
• Alkalinity
• Bath frequency will be changed
based on Coating Weight
 Phosphating

 Zinc phosphate

 Manganese phosphate

 Cold Zinc Phosphate

 Zinc Phosphate

 etching:
– Phosphoric acid attack on the substrate
 deposition:
– Zinc phosphate deposited on the substrate
 completion:
– Iron Phosphate sludge formation
 Mechanism of Phosphate

 etching / primary reaction:

Fe2+ + 2H3PO4  Fe(H2PO4) + H2

 deposition / secondary reaction:

Fe(H2PO4)2  Fe(HPO4) + Fe2PO4

 completion / tertiary reaction:

3FePO4  Fe3(PO4)3 + H3PO4
CHECK
• Total Acidity
• Free Acidity
• Iron Content
• Toner level for Zinc Phosphate
• Coating Weight
• Sludge – Visual Check
 Rinses

Rinse 1: D.M Water Rinse to

remove excess
acidity

Rinse 2: D.M Water Rinse

 OILING

 After D.M. water rinse the

component shall be dipped in
dewatering oil, to remove water
from the component.
Machined Plug
Cold Phosphating
Cold Phosphated Body
7- Tank Hot Phosphating
Hot Zinc Phosphated Component
Mn Phosphate with LoMU
Tectyl-506 oiled component
Hot Zinc Phosphated with RP Oil
PHOSPHATING
DEFECTS
Patchy Coating
Rough Coating
 defects counter measure
• Patchy Coating • Roughness
Coating
1. After degreasing 1. Bath
water Breaks Concentration
should be checked. should be checked.
2. Iron content in 2. Running time
the bath should be should be checked.
checked.
 Inspection

 Visual Inspection.
 Coating Colour
 Coating Weight
 Coating Thickness
 Salt Spray – test
 90-120 Hrs. for Mn Phosphate
 72 Hrs. for Zn Phosphate
PAINTING
 What is meant by paint?
 Paint is a homogeneous
mixture of rinse in which
solid particles are blended
 PAINT
 Paint normally contains

– Binder
– Pigment
– Solvent
– Additives
 Binder

– Binder or resin forms the bulk of the

dried paint film. It gives of its
mechanical and weathering properties.

 Pigment

– Pigment is the colored part of the

coating. It is dispersed into fine particles
with the binder.
 Solvent

– Solvents are used to dilute the Binder. There

are normally several solvents in one coatings,
each performing a different task.

 Additive

– Additives are chemicals which when used in

small quantities can improve certain properties
of a wet paint or a cured film.
 Type of Paints
Organic Inorganic
 Epoxy  Silicone

 Phenolic  Ethyl Zinc

Epoxy Silicate
 Poly
Urethane
 Acrylic
COATINGS DEFECTS
APPLICATION
DEFECTS
SAG: (RUNS or CURTAINS)

 Cause:
1. Spray gun too close.
2. More thin.

 Remedy:
1. Control your speed
and distance of spray.
2. Add require thinner
only.
OVER SPRAY: (DRY SPRAY)
 Cause:
1. Spray out side the
pattern.
2. Dry spray.

 Remedy:
1. Control your spray
pattern.
2. Use correct quantity
and quality thinner.
BLISTER:

• Cause
Oil, moisture or
salt
contaminated
surface.
• Remedy
Contamination
free surface shall
be used for
painting.
MUDCRACK:

 Cause
1. surface finish.
2. High dft

 Remedy
1. 40-65 µm-
Anchor Profile.
2. Apply only
required DFT
FIELD DEFECTS
Abrasion Damage:

 Cause:
 Physical damage by
abrasion.
 Impact
 Remedy:
 Impact and abrasion
damage shall be avoided.
 Name plate like thing to
be fixed without
damaging the paint film.
Peeling of Paint from Substrate:

 Cause:
 Improper white metal
surface finish.
 White metal
Contamination.
 Remedy:
 Proper Surface
preparation.
 Contamination free white
metal.
PIN POINT RUSTING:

 Cause:
 More sharp edges.
surface finish.
 Pin hole in paint
surface.
 Remedy:
 Proper Surface
preparation.
 Defect free top coat
surface.
INSTRUMENTS
Testing Type

 Ford Cups F1, F2,

F3 and B4 to check
the viscosity.
 More viscous only
stable in transit.
 Thinner should be
added for
application.
Surface Tension Liquid

 Place a drop on
object.
 If it spreads (water
breaks) low ST
 No water breaks
surface tension ok
DRYING TIME RECORDER
 Place the instrument
on Wet painted
object
 The needle slowly
and freely rotates.
 If paint surface dried
the rotation got
stop.
 The running time
will give drying time.
Hardness of the Dry film Surface
 Pencil – H series
 Draw the line with
H pencil
 No Pencil mark
means hardness of
the film is more
than the pencil.
Colour Comparison

 Multi angle
comparison
 Good for Metallic
Parts
 Flip, Flap and Face
comparison
Adhesion cutter
 Class A, B, C, D
 No peel off is AIL
standard.
 Normal Paint
adhesion check will
be in mesh type.
 Zinc Silicates
adhesion check will
be X type
Blasting Standard
 SURFACE PREPARATION STANDARDS

SIS

S.No. QUALITY NACE SSPC REMARKS

(ISO
850
1-1)

White Metal Blast When viewed without magnification, the surface shall be free from
1 No. 1 SP-5 Sa 3
Cleaning mill scale, rust, paint coatings and foreign matter.

When viewed without magnification, the surface shall be free from

mill scale, rust, paint coatings and foreign matter, except for
staining as noted below.
2 Near White Blast Cleaning No.2 SP-10 Sa2 1/2 Random stainging sall be limited to no more than 5% of each
unit area of surface as defined in section 2.6 and may consist of
light shadows, slight streaks, or rust stains of mill scale, or
stains of previously applied coating

When viewed without magnification, the surface shall be free from

Commercial Blast visible oil, grease and dirt, and from most of the mill scale, rust,
3 No.3 SP-6 Sa 2
Cleaning paint coatings and foreign matter. Any residual contamination
shall be firmly adhering.

4 Brush-off Blast Cleaning No. 4 SP-7 Sa 1 Light Blast cleaning

5 Solvent Cleaning   SP-1   Cleaning the substrate by solvent

6 Hand Tool Cleaning   SP-2 St2 Through hand and power tool cleaning

7 Power Tool Cleaning   SP-3 St3 Very through hand and power tool cleaning

Mineral and Slag

9   AB-1    
Abrasives
Chloride test kit
Chloride test kit
Dew Point Meter
DFT Meter
Salt Spray Chamber
Schematic Diagram of SS
Surface Profile Gauge
Non Contact Thermometer
 IR principle
 Just hit the object
with IR
 Digital display will
give the
temperature
 Distance should be
with respect to the
model
Wet Film Gauge
 Place the comb
perpendicular on
the Wet Paint
Surface for few
seconds
 The wet film
thickness is biggest
teeth contact
Powder Coat WET FILM Gauge
DFT meter with differ Probe
DFT STD FOILS
 Standard DFT
gauge foils
 Used for
calibrations only
Pull off machine
Holiday Detector

 Holidays will be
found out easily.
 Holiday is mild gap
in the film
continuity
 Working based on
conductivity
principle.
Metal Detector

 Holiday reverse
principle almost.
 Thank You