Selection Of Coating Systems Research Articles

Steel Bridge-Coating Systems and Their Environmental Impacts: Current Practices and Future Trends

Coatings are essential for protecting structural steel bridges from corrosion in harsh environmental conditions. The selection of a suitable coating system can significantly impact the performance and longevity of a bridge as well as its environmental footprint. This study investigates the U.S. and Canada’s environmental ISO corrosivity map and the general environments to which bridges are exposed. Additionally, environmental data and road maintenance practices of transportation departments and the use of de-icing salts were investigated to examine the impact of micro-corrosive environments on bridge elements. The study reviews commonly examined coating systems and their expected service life in moderate and highly corrosive environments. This sheds light on factors influencing coating system selection, such as life-cycle cost analysis and maintenance practices for bridge elements. For the first time to our knowledge, an environmental life-cycle evaluation of one of the most commonly used coating systems with theoretical maintenance scheduling for a bridge project’s expected service life is presented to encourage the use of a quantitative tool for environmental impact assessment of coatings in terms of global warming potential (GWP). Additionally, perspectives on patented state-of-the-art and future steel-protective technologies and their potential role in bridge engineering are reviewed.

Selection of Organic Coating Systems for Corrosion Protection of Industrial Equipment

The most important element of corrosion protection in industrial conditions is the protective coating system. However, selecting the right coating can often be a real problem due to the sheer number of coating manufacturers and their products on the market. A quantitative approach based on the data mining technique used to analyze the obtained multi-site exposure data has been proposed. This was demonstrated by the example of the selection of a coating system to protect an industrial ball mill located in a hall for the enrichment of copper ore at the Polish company KGHM Polska Miedz S.A. A collection of 21 two-layer coating systems from different manufacturers was tested for one year. Multiple areas on the industrial ball mill, subjected to varying degrees of vibrations and abrasion, were painted. In addition, sets of samples that can be detached from the mill housing were mounted, as well as the set exposed in the hall without vibrations. The condition of the coatings after exposure was assessed using impedance spectroscopy. The obtained data from many different exposure areas were analyzed using principal components analysis (PCA). In this way, the most advantageous coating systems for the specific conditions in the hall were indicated. Additionally, on this basis, the contribution of various destructive factors, including vibrations and abrasion, to the protective properties of the tested coatings, was estimated.

Micro-scale impact resistance of coatings on hardened tool steel and cemented carbide

Micro-impact, a novel accelerated test method for assessing coating durability under repetitive contact, has been developed to concentrate impact-induced stresses close to the interfaces in coating systems. Test results are described for carbon coatings on hardened tool steel and nitride-based coatings on cemented carbide. At higher load it was possible to show the increasing contribution of the substrate properties (load support and ductility) to the coating system response whilst retaining high sensitivity to the coating properties. Hard and elastic carbon coatings on hardened tool steel displayed very low impact resistance under these conditions. Relatively soft carbon-based coatings with more metallic character and high plasticity (low H/E) deposited on hard but tough tool steel were resistant to radial cracking and lateral fracture at high load. Lateral fracture at high load and extensive substrate cracking was observed at higher load for hard nitrides on cemented carbide. The micro-impact test has the potential to significantly speed up the pace of coating system selection for durability under highly loaded repetitive contacts, as occur in coatings applications in engine components and in discontinuous cutting operations.

APPLICATION OF ARTIFICIAL NEURAL NETWORK IN THE PROCESS OF SELECTION OF ORGANIC COATINGS

The structure of the artificial neural network (ANN) to support the selection of organic coatings was developed and verified, and its learning process was carried out. A simulation of the operation of the network was also carried out, which showed that programming of the coating system selection process can be much faster and more accurate, which is important for a system used in industrial conditions.

Surface protection of Mg alloys in automotive applications: A review

Mg alloys find widespread applications in transportation industries especially in cars and trucks because of their edges in light-weight design, which can greatly help improve the fuel efficiency and decrease the gas emissions of vehicles; However, Mg alloys’ high sensitivity to the corrosive environments limit their penetration in automotive applications. Surface coating is one of the most effective and economic ways to protect Mg alloys from corrosion. Presently, the currently researched and commercial coatings that are specifically applied to Mg alloys in the automotive industry are reviewed in this paper. With some Mg automotive components subjected to corrosion and repeated load simultaneously, corrosion fatigue of coated Mg alloys are reviewed as well. Additionally, a part of attention in this review is given to the assessment approaches of corrosion and corrosion fatigue performance of coated Mg alloys for the purpose of material/surface coating system selection. Finally, some corrosion-related challenges for the growth of Mg alloys, future developments and research directions on surface coatings and corrosion fatigue testing approaches are discussed.

Atmospheric corrosion map of an oil refinery

PurposeThe purpose of this paper is to draw up an atmospheric corrosion map for an industrial zone to determine the best coating system for each location.Design/methodology/approachThe outdoor atmospheric corrosion rate was measured at eight locations distributed in an oil refinery during a year. Corrosion rates were measured by weight loss of carbon steel coupons, according to ISO Standard 9223. Weathering conditions, including temperature, time of wetness, and atmospheric pollution such as chloride precipitation and sulfur content also were measured. The results were analyzed using “Surfer 8” software and the corrosion map of the refinery was derived.FindingsAn atmospheric corrosion map was derived for the oil refinery. By this approach, coating system for equipment can be selected based exactly on where the plant item is located.Originality/valueExterior coating systems for equipment now can be selected based on their application, regardless of their position in any refinery. In this article, an atmospheric corrosion map was developed for a refinery for the first time. The position of equipment on the corrosion map is a new parameter that should be considered for coating system selection.

Protective Coatings Offshore: Introducing a Risk-Based Maintenance Management System—Part 2: Framework Establishment

Abstract This paper describes a risk-based maintenance management system for protective coatings and how it might influence offshore maintenance processes. Maintenance of protective coatings is one of the more resource-demanding and, hence, costly operations on offshore installations. On older platforms, typically about 5% of all man-hours are related to coating maintenance (including scaffolding). The cost is strongly influenced by initial coating system selection and maintenance strategy, together with the required lifetime. A new, risk-based maintenance management system is being developed, and Part 1 of this series discussed the risk analysis methodology. Parameters influencing the risk related to coating maintenance have been identified, and a framework for control and monitoring of these parameters has been established. This framework aims to optimize maintenance and inspection programs through risk evaluations, and may affect: —inspection methodology and intervals, —priority-assignment during maint...