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07639 Long Term Performance of Thermal Spray Coatings in Tropical Marine Environments

Picture for 07639 Long Term Performance of Thermal Spray Coatings in Tropical Marine Environments
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Product Number: 51300-07639-SG
ISBN: 07639 2007 CP
Author: O. Rincon, N. Romero, O. Salas, M. Sanchez, A. Valdivieso, A. Uzcategui, and A. Rincon
Publication Date: 2007
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The objective of this research is to study the long-term performance of thermal-sprayed Aluminum, Zinc and Zn/Al coatings in tropical marine environments. To that effect, carbon steel coupons (10 cm x 15 cm x 3 mm) were sprayed using two different processes (electric arc and flame spray), with and without the application of two additional layers of sealer. Three sealers were evaluated: two wash primers of different industries, and a phenol sealer. The sheets were exposed for two years in two atmospheric stations, La Voz (coastal marine atmosphere), and the Towers of the Lake Maracaibo Crossing (marine atmosphere), supplemented by laboratory-accelerated tests: Climatic Chamber and intermittent salt spray (ISO 11474). The sheets were characterized by means of initial weight, thickness, metallography, adhesion, roughness, with monthly evaluations by visual and photographic inspection for two years. The results showed that in these aggressive atmospheres, where the wind effect is high (> 11.3 km/h), the performance of the thermal sprayed Zn/Al coating is excellent, even without sealer, providing galvanic protection to the substrate. In the case of Zn and Al coatings, a phenol-based pore sealer should be used to provide a complete cover for the irregularities of this type of coating.
The objective of this research is to study the long-term performance of thermal-sprayed Aluminum, Zinc and Zn/Al coatings in tropical marine environments. To that effect, carbon steel coupons (10 cm x 15 cm x 3 mm) were sprayed using two different processes (electric arc and flame spray), with and without the application of two additional layers of sealer. Three sealers were evaluated: two wash primers of different industries, and a phenol sealer. The sheets were exposed for two years in two atmospheric stations, La Voz (coastal marine atmosphere), and the Towers of the Lake Maracaibo Crossing (marine atmosphere), supplemented by laboratory-accelerated tests: Climatic Chamber and intermittent salt spray (ISO 11474). The sheets were characterized by means of initial weight, thickness, metallography, adhesion, roughness, with monthly evaluations by visual and photographic inspection for two years. The results showed that in these aggressive atmospheres, where the wind effect is high (> 11.3 km/h), the performance of the thermal sprayed Zn/Al coating is excellent, even without sealer, providing galvanic protection to the substrate. In the case of Zn and Al coatings, a phenol-based pore sealer should be used to provide a complete cover for the irregularities of this type of coating.
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