ISSN 2282-1767
an ipcm magazine
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GRIN LUZ joins the Redox excellence network of approved applicators of corrosion protective coatings
page 08
Fatigue corrosion and its prevention
page 26
ISSUE 5 JANUARY 2024
Development of novel and costeffective corrosion resistant coatings for high temperature geothermal applications
page 46
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08 ISSUE 5 - JANUARY 2024
01 FROM THE EDITOR 02 WHAT'S NEW 08 COVER STORY GRIN LUZ joins the Redox excellence network of approved applicators of corrosion protective coatings
14 ADVANCEMENTS Flame Spray thermoplastic powders and their corrosion protection performance
20
20 ADVANCEMENTS
CONTENTS
Sherwin-Williams launched the new thermal insulative coating Heat-Flex® 7000
22 RESEARCH BREAKTHROUGH Drones protect wind turbines from ice
26 SCIENCE OUTLOOK Fatigue corrosion and its prevention
22
34 ADVANCEMENTS Oil & Gas goods receipt: the hidden killer of preservation planning?
36 VOICES People I met
46 RESEARCH BREAKTHROUGH Development of novel and cost-effective corrosion resistant coatings for high temperature geothermal applications
26
52 ADVANCEMENTS Hempel launches leading intumescent coating estimation software
54 MEETING THE INDUSTRY
46
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FROM THE
EDITOR
L
ast year saw the publication of the
an attractive look and style far removed from
first issue of Corrosion Protection,
those of traditional technical magazines,
the new ipcm®-branded technical-
and capable of combining the advantages of
scientific magazine devoted to
digital circulation with the practicality of its
corrosion prediction, prevention, protection,
printed version, in order to reach all players in
and mitigation – a journal designed to
this sector in a capillary manner.
illustrate the product, process, technology,
I am pleased to share some feedback we
and service-related challenges the corrosion
have received from our readers this year and
protection industry faces every day.
I am sure that the upcoming publishing year,
I remember questioning the rebranding
starting with this January issue, will be just as
project of our old ipcm®_Protective Coatings
fruitful.
magazine several times: we wondered how the
Alessia Venturi Editor-in-chief
In the space of twelve
market would react, having been accustomed
“I applaud your very elegant editorial
to receiving a magazine with very precise
style. Thank you for your dedicated, active
characteristics and with a familiar name,
attention.”
graphics, and editorial style for about ten
Prof. Pierluigi Bonora
years. We were afraid that all the promotion and distribution work we had done over time
“Good job and valuable
would have gone lost.
magazine. Congratulations. You are
However, we decided to go ahead with the
publishing a good magazine and if I can do
rebranding. And today, a year later, we are
anything, I will do it for you and your good
very pleased to have done so. In the space
team.”
of twelve months, Corrosion Protection
Prof. Hadi Beirami
has established a very good reputation in the market, attracting new advertisers,
“I am honoured that Corrosion Protection
numerous scientific reports from professors
magazine has found value in our content.
Protection has
and researchers around the world, and media
We, at INSPENET, are pleased to be
established a very
partnerships with many new international
featured in your magazine and see no
events, all extremely relevant to the industries
issue with sharing information. I want to
good reputation in
in which corrosion control is involved.
extend a congratulation for your site and
the market, attracting
We went all the way to Asia-Pacific, more
magazine. I visited your website and it has a
precisely to Indonesia, for the Pacific Coatings
lot of important values to the corrosion and
Show and next February we will participate
coating sector.”
for the first time in MECOC - Middle East
Antonio Zavarce, Director of Operation,
Metallurgy Corrosion & Coatings EXPO in Abu
INSPENET
months, Corrosion
new advertisers, numerous scientific reports, and media
Dhabi.
partnerships
It goes without saying that such a wide
“Congratulations on the successful
with many new
distribution is an added value for our content
transformation of ipcm into Corrosion
and for our advertisers, who can find in
Protection magazine!”
Corrosion Protection a refined journal, with
Heiko Reski, Sales Manager, Blastman
international events.
JANUARY 2024 | CORROSION PROTECTION
01
W H AT ’ S
NEW Belzona successfully provided thermal insulation protection for an oil and gas company The international provider of corrosion protection solutions Belzona
from corroding further. Belzona 5871 is designed to be applied to
has recently announced that it has collaborated with a global oil and
metal pipework, ducting and other industrial equipment in order
gas company in order to provide thermal insulation for a metal tank
to ensure thermal insulation, provide protection against contact-
at one of its lubricant plants. Belzona offered its two-component
burn injuries and eliminate corrosion. It can be applied by brush,
polymeric solvent-free system Belzona 5871 to lower the
cartridge or plural spray, expanding upon application to produce
temperature of the metal surface, prevent burns and halt corrosion.
a lightweight closed-cell foam. Moreover, since it only needs two
The upper surface of the tank, that reaches a temperature of 110° C
coats, the system developed by Belzona enables quick turnaround
(230° F), serves as a walkway for operators, causing a hazard for
times.
the employees that risk receiving contact burns from the hot metal
The surface of the metal tank has been prepared by vapor blasting
substrate. According to the guidance set forth by the Occupational
the substrate to meet SSPC-SP10 (Near-White Metal) standards
Safety and Health Administration (OSHA)1, the maximum
and degreased. Then, the personnel applied Belzona 5871 using a
temperature for exposed surfaces that a person could come into
short-bristled brush at the target thickness of 1000 µm (39 mil) wet
contact with is 60° C (140° F), in line with ASTM C1055. In addition,
film thickness, which results in 3000 µm (118 mil) dry film thickness.
the tank surface had been experiencing pitting corrosion, so it also
The second coat has been applied six hours later. Twelve hours
required pit filling and a protective coating that would prevent it
later, the tank was back to full service.
https://www.osha.gov/laws-regs/standardinterpretations/1998-08-19
www.belzona.com
1
DÖRKEN Days successfully concluded This year’s DÖRKEN Days took place in Essen on 23rd November.
reported on the topic of coating thickness measurement.
The traditional event has been a staple in the event calendar for
The event concluded with a presentation on “Digital
over ten years. It is a meeting point for customers, market partners
Transformation” by Marvin Urban. Urban is one of two managing
and experts along the entire value chain.
directors of DÖRKEN Digital Ventures GmbH, which is addressing
Christos Tselebidis, Vice President Sales Industrial Coatings at
the market challenges of the future.
DÖRKEN Coatings, welcomed the participants to the ATLANTIC
Christos Tselebidis brought the informative day to a close and
Congress Hotel Essen. After an overview of what’s new at DÖRKEN
transitioned to the joint dinner. Not only there, but also during the
and on the global market, Christian Rabe & Markus Nowak, both
day between the speeches, the participants were able to network
from Product Engineering, gave a follow-up to last year’s event.
and talk about all sorts of things.
Throughout the day, DÖRKEN employees provided interesting
“We are delighted that we were able to welcome numerous partners
insights into current topics. For example, they talked about the
of DÖRKEN live on site again this year - and in even greater
influence of the planned PFAS ban on product development, the
numbers than usual,” says Christos Tselebidis. “We would like to
DELTA-PROTEKT® TC 502 GZ topcoat, which was presented in
express our gratitude for the trust placed in us and the exciting
2023, and room-temperature curing corrosion protection solutions.
input we received from personal discussions. I’m already looking
But business partners also had the opportunity to share their
forward to next year!”
experiences. Beatrice Occhionero from A. AGRATI S. p. A. gave a presentation entitled “Enhancing of Testing Insights: A Deep Dive into massive Data Analysis”. Geoffrey Bruno from Enovasense
02
CORROSION PROTECTION | JANUARY 2024
www.doerken.com
WHAT'S NEW
AMPP Named Michio Kaku as Annual Conference Keynote Speaker
Sherwin-Williams won the Vaaler Award for CUI-mitigation coatings
The Association for Materials Protection and Performance
The international paints and coatings manufacturer Sherwin-
(AMPP) has announced that Michio Kaku will be the keynote
Williams has won the Vaaler Award with its new line of Heat-
speaker at its upcoming annual conference and exposition. He
Flex® CUI-mitigation coatings.
will address the topic “The Impact of AI on the Workforce” during
The reward was granted thanks to the ability to mitigate the
his presentation, scheduled for March 4th 2024 at the Great Hall A
dangerous condition of corrosion under insulation (CUI). Among
of the Ernest N. Morial Convention Center in New Orleans (United
all currently available coating formulations that have been
States of America). “We are honoured to have Michio Kaku as
tested, the Heat-Flex® ACE (Advanced CUI Epoxy) offers the
our 2024 conference keynote speaker. His extensive expertise in
best performance in mitigating CUI. The ultra-high-solids epoxy
the realms of science and futurism, coupled with his adeptness
novolac features a functional chemical enhancement for CUI
at conveying complex ideas in an accessible manner, positions
mitigation. In addition, the Heat-Flex 650, Heat-Flex 750 and
him perfectly for our event. Attendees can anticipate a thought-
Heat-Flex 1200 Plus feature a high concentration of micaceous
provoking and engaging address that explores the future of work
iron oxide (MIO) pigment for significantly improved CUI-
in the era of artificial intelligence, seamlessly integrating insights
mitigation performance.
relevant to the corrosion prevention and coatings protection
“CUI is a lurking danger in any petrochemical plant that could
industries,” has stated Alan Thomas CEO of AMPP.
potentially lead to catastrophic events. In the interest of safety,
Kaku is the author of five New York Times bestsellers and has
we are constantly looking for new ways to address the problem
been recognised as “one of the most influential physicists in the
and have developed surprisingly effective options with the new
world today” by Academic Influence. His weekly science radio
range of Heat-Flex CUI-mitigation coatings. To be awarded for
program reaches audiences in 100 cities nationwide, including
these efforts is an honour, as well as a testament to our product
hosting numerous science specials on networks such as the
development and research teams, which continue to seek new
Discovery Channel and BBC-TV as well as popular programs
and better ways to combat CUI,” has stated Neil Wilds, Global
such as the David Letterman Show.
Product Director CUI at Sherwin-Williams Protective & Marine.
www.ampp.org/home
https://industrial.sherwin-williams.com
The Hempel foundation celebrates its 75th anniversary The international supplier of paints and coatings Hempel celebrates
shows us that we can make a difference by doing what we do best:
the 75th anniversary of the Hempel Foundation.
deliver trusted solutions that protect assets, beautify spaces and
Over 7,500 Hempel collaborators are celebrating the 75
enhance lives,” has commented Michael Hansen, Group President
anniversary of the Hempel Foundation, founded in 1948 by J.C.
and CEO of Hempel A/S.
Hempel with the aim of ensuring the future development of his
The Hempel Foundation has laid the foundations for a world-
company, Hempel A/S. The Hempel Foundation drives change
leading education, research and innovation centre at the Technical
on some of the world’s most pressing issues. For example, last
University of Denmark, in order to make coatings and surface
year it spent €21 million on philanthropic activities in the areas of
protection more effective and sustainable. In addition, Hempel
Education, Biodiversity and Science.
experts are invited each year to participate in an ‘iWitness tour’ to
“By working at Hempel, all colleagues contribute to the work of the
experience the Foundation’s global work firsthand.
th
Hempel Foundation through their daily work. The Foundation’s work is a great source of pride and inspiration for all of us at Hempel. It
www.hempel.com
JANUARY 2024 | CORROSION PROTECTION
03
WHAT’S NEW
AkzoNobel supports delivery of China’s first domestic large cruise ship
Carboline launches new urethane mastic coating for emergency maintenance
The first large cruise ship ever to be built in China has set off on
Global protective coatings manufacturer Carboline recently
its maiden voyage, having been coated with International® paint
launched Carbothane DTM Mastic, a one-coat hybrid
supplied by AkzoNobel’s Marine, Protective and Yacht Coatings
urethane formulated for emergency maintenance or
business. Constructed over a period of more than three years,
quick-turn coating projects.
the 5,246-passenger Adora Magic City features the company’s
Carbothane DTM Mastic is intended for direct-to-metal
Intersmooth® fouling control technology. The high-performance
application and adheres very well to minimally prepared
brand was specified on the hull of the milestone vessel due to
surfaces including tightly bound rust. Mastic qualities provide
its high durability, low VOC content and excellent application
excellent corrosion protection while its urethane technology
properties.
offers long-term color and gloss retention.
The ship – which is 323.6 meters long and has a 1,292-person crew
“The value of Carbothane DTM Mastic in the market is clear:
capacity – was built by Shanghai Waigaoqiao Shipbuilding Co., Ltd
better corrosion protection and great visual appeal in a single
and the launch heralds a new beginning for the Chinese cruise
coat. It performs exceptionally even over marginal surfaces,
ship new-build sector. “We’re proud that our trusted coatings
so it’s ideal for unplanned spot maintenance or emergencies,”
technology and expertise played an important role and were
said Jeff Anderson, Executive Vice President of Quality, R&D,
extremely impressed during a recent visit to see the final fitting out
and Commercial Resources.
of this landmark vessel,” says Simon Parker, Director of AkzoNobel’s
In July 2023, Carbothane DTM Mastic was trialed on
Marine, Protective and Yacht Coatings business, who adds that
an emergency coating project at a liquid terminal in
the company is also contributing to the new-build of Adora Magic
Philadelphia (United States of America) to address corrosion
City’s sister ship. “We hope to be involved in similar projects in
and discoloration which were not compliant with U.S.
the future and remain committed to supporting the application
Environmental Protection Agency (EPA) rules. The product
and development of advanced coatings that will help propel our
was applied by hand in tough conditions, including a minimally
customers and the industry to a more sustainable future.”
prepared surface, the presence of moisture and very hot
The newly launched ship, which weighs 135,500 tons, contains
summer temperatures. Coating application proceeded
more than 25 million different parts and was produced with the
smoothly and EPA authorities affirmed the piping was back in
cooperation of more than 30 countries and over 8,000 specialized
compliance.
suppliers. “Our ability to support global projects and supply chains
“This field trial, and other recent success stories like it,
provides value for customers of our Marine Coatings business,”
demonstrate the immediate impact Carbothane DTM
continues Parker. “Our International brand has been meeting
Mastic has had on unplanned or emergency coating project
customer needs in this respect for more than 140 years. We’re
outcomes. Every product we develop is intended to solve
constantly innovating to keep pace with evolving requirements, with
specific problems, so the market’s response to Carbothane
a clear focus on supporting customers in yard efficiency, boosting
DTM Mastic so far as a great sign,” said Justin Manuel,
lifetime performance and reducing both fuel consumption and CO₂
Director of Global Product Line.
emissions in operation.” The company’s International brand offers a leading portfolio of
https://www.carboline.com/products/product-details/
coatings that protect and enhance vessel performance when
Carbothane-DTM-Mastic
facing different challenges, such as impact and abrasion, chemical resistance and biofouling accumulation. In this area, the product range helps to reduce biofouling build up and mitigate drag over time – which helps to improve fuel efficiency and cut CO2 emissions. Owners and operators can also benefit from the company’s Intertrac software, which uses big data to support underwater hull scheme selection and predict and maximize lifetime performance, while considering key industry regulations. www.international-marine.com
04
CORROSION PROTECTION | JANUARY 2024
WHAT'S NEW
I-Tech AB signed a license agreement to provide antifouling agents to Paints Korea I-Tech AB has recently announced that it has signed a license
around 33% of the global newbuilding market of all ships.
agreement with International Paints Korea Ltd, the South Korean
“The agreement once again proves the very strong position of
subsidiary of the Protective Coatings division of the international
Selektope in the global antifouling industry. That we deliver our
paints and coatings manufacturer AkzoNobel. The company
substance to so many of the paint manufacturers active in the
now passed the technical hurdles for a future commercial use of
South Korean market is a very good testament to our product
Selektope in IPK products.
and something that benefits our continued global expansion.
I-Tech is a biotechnology company that has developed the
Selektope has proven to be very successful in combating marine
product Selektope®, an active agent that prevents barnacle
fouling of barnacles on ships. Earlier this year, we show that the
attachment on submerged surfaces such as ships and boat hulls,
hospital ship Global Mercy, whose hull was treated with Selektope,
but also other marine installations. By increasing the resistance
remained free from barnacle growth even after being laid idling for
to barnacle growth in marine paint systems, fuel and maintenance
extensive periods over a 22 month operational timeframe in warm
costs are reduced. With the new partnership, the company has
waters” has stated Philip Chaabane, the CEO of I-Tech AB.
now a deal with all the six major paint and coatings producers operating in the South Korean market, which alone accounts for
https://www.i-tech.se
WHAT’S NEW
Hexigone will sign a distribution partnership with Adizol
The ecosparc® graphene product range from Sparc Technologies received commercial evaluation authorization
The corrosion inhibitor manufacturer Hexigone has announced
Sparc Technologies has recently announced that its ecosparc®
a new distribution partnership with Adizol, a specialty chemical
graphene product range for protecting against cracking and
distributor based in Santiago (Chile). The collaboration will
corrosion has received the Commercial Evaluation Authorization
bring Hexigone’s ion exchange corrosion inhibitors to the
(CEA) from the Australian Industrial Chemicals Introduction
Chilean coatings industry. “We are thrilled to partner with
Scheme (AICIS). In addition, Sparc has had completed fully
Adizol to bring our Intelli-ion technology to the Chilean market.
independent lifecycle assessment (LCA) with significant cost
This collaboration is an exciting opportunity, especially given
savings and also CO2 emissions which are in-line with the
the substantial mining and construction industries in Chile
company's broader ESG thematics. “We are delighted to announce
that require anti-corrosion coatings to safeguard equipment
that ecosparc has received governmental regulatory approval from
and infrastructure. A sustainable alternative that excels in
AICIS to enable commercial evaluations to occur. This milestone
performance will be welcomed in this region!” commented Ella
allows Sparc to progress into the next stage of its commercial
Newington, Marketing Manager at Hexigone. Adizol is a specialty
growth, where we can concentrate on the development, marketing,
chemical distributor with a vast experience in supplying
production and sales of ecosparc,” has stated Stephen Hunt, the
technical products to the Chilean coatings market. Their efforts
executive chairman of Sparc Technologies. The CEA allows Sparc
for improving the sustainability of the sector aligns perfectly
to conclude the trials phase in the laboratory, so the company
with Hexigone and its commitment to create environmentally-
will now be able to manufacture larger quantities of its new
friendly solutions. “Our partnership with Hexigone signifies our
graphene product for commercial tests on steel infrastructure
joint commitment to sustainability and cutting-edge solutions in
assets in Australia, while the regulatory approval process for both
the coatings industry. Hexigone’s corrosion inhibitors are unique
Europe and North America has also started. Furthermore, Sparc
and we know our customers are going to be excited to start
Technologies is currently engaged in discussions with several
testing and utilizing something new within our market,” added
industrial asset owners to test the use of ecosparc in protective
Bernardo Bollmann, Development and Technical Manager at
coatings, aiming to improve their crack resistance and corrosion
Adizol. Alongside Adizol and MCassab, Hexigone also had a
mitigation properties. “This is an exciting progression in the
strong presence at the last ABRAFATI event, where they met
business which will see the realisation of ecosparc being used
numerous coatings manufacturers from South America. This
in protective coatings in real world trials which are relevant to
event offered the opportunity to learn more about Hexigone’s
our target markets. The cost savings and positive environmental
smart Intelli-ion technology and how it can improve primer
outcomes for our customers will be substantial,” has added Denis
coatings.
Wright, the general manager of Sparc Technologies.
www.hexigone.com
www.sparctechnologies.com.au
Elementis launched NALZIN FA 180 to prevent flash rust in aqueous paint systems Elementis has recently presented NALZIN® FA 180, a new solution
undergoes a transformative process during film drying, converting
specifically developed to prevent flash rust in aqueous paint
into a non-water dispersible and insoluble zinc compound – providing
systems, which is a common occurrence during the drying process
lasting rust protection and a durable finish.The international provider
of waterborne coatings on iron-containing substrates. Additionally,
of specialty chemicals for paint and coatings has designed NALZIN FA
it enhances the resistance of the dried film, effectively preventing
180 for compatibility with a broad spectrum of waterborne coatings
in-can corrosion during storage. The new NALZIN FA 180 product
systems, so it can be incorporate into several applications, such as
exhibits a distinctive composition of organic zinc complex with low
water-dilutable alkyds, acrylics, epoxies and dispersion paints.
nitrite content that offers extended protection against rust and corrosion. Initiated as a water-dispersible solution, the product
06
CORROSION PROTECTION | JANUARY 2024
www.elementis.com
INDUSTRIAL COATINGS Graco opened a new application center in Dubai The international producer of fluid handling equipment Graco has recently opened its new Application Center in Dubai
I N D U S T R I A L C OAT I N G S
(United Arab Emirates). The new facility will be a major hub for supporting local contractors, distributors and material manufacturers, offering comprehensive training programs and facilitating material validation. The new structure features an innovative spray booth, workbenches and a demonstrative area for texture applications as well as several meeting rooms. In addition, the hub will serve as a unit to test and validate materials in different applications, such as architectural painting, protective coatings or healthcare applications. “This new facility reinforces our commitment to the region and our esteemed network of distributors and material manufacturers. It serves as an avenue for our partners to showcase our comprehensive equipment range, organize training sessions, and collaborate on material testing and validation,” has stated Caroline Chambers, President of Graco for the EMEA region. Lastly, Graco will hold a range of training modules aimed at optimising the use of its equipment. As a matter of fact, a team of specialists will be available to pass on their knowledge and assist distributors, material manufacturers and customers in material demonstrations and validations.
w w w .m iro du r.c om
www.graco.com
Waterborne Solventborne High solid
COVER
STORY
GRIN LUZ joins the Redox excellence network of approved applicators of corrosion protective coatings by Alessia Venturi, ipcm®
GRIN LUZ serves a wide variety of sectors and handles parts with very different dimensions, all with the need for high-quality coatings in common.
08
CORROSION PROTECTION | JANUARY 2024
COVER STORY
Craftsman quality, careful control of all process steps, and fast delivery: it is often thought that these three elements cannot coexist in the same sentence and thus within the same industrial philosophy. GRIN LUZ’s history and growth journey in the powder coating field proves otherwise, as also confirmed by its entry into AkzoNobel’s Redox Excellence network, recently established in Spain.
G
RIN LUZ was founded in June 1972 by Féliz Herrero together with four other partners who, after some time, chose to leave
the company. As its name itself suggests, GRIN LUZ started out as a manufacturer of lighting equipment: cleaning, galvanic coating with nickel, chrome, and gold, but also liquid coating were the finishing operations performed by GRIN LUZ – which, in the boom years for the lighting industry, mainly produced special designer lamps featuring high-quality finishes obtained through technically and operationally perfect processes. Thanks to the experience gained in the finishing of such peculiar products, GRIN LUZ then decided to change its core business and focus exclusively on contract surface treatments.
Exterior view of the automatic shot blasting machine.
“Learning from our history and the evolution of the market, we have become what GRIN LUZ is today: the company that offers the largest range of surface treatments in the Madrid area,” says Marta Herrero, the founder’s daughter and the current owner of the company. “Shot blasting, vibratory finishing, electro-cleaning, pickling, passivation, and liquid and powder coating are the treatments we now offer to a wide range of industries, including automotive, railway, food, pharmaceutical, recreational, and decorations production. We serve many different sectors and handle very differentsized parts: what they all have in common is their required finishing quality. We have chosen to work in market niches that are interested in the highest quality degree, but to which we can assure very
Automatic shot blasting of stainless steel parts.
JANUARY 2024 | CORROSION PROTECTION
09
COVER STORY
fast delivery times. The customers that rely on GRIN LUZ know we put extreme care in finishing their parts and that our coatings have a craftsman quality degree, although achieved with state-of-the-art equipment, technology, and industrial procedures.” Since the beginning, GRIN LUZ has relied on AkzoNobel Coatings, S.L.U. (Vallirana, Spain) for the procurement of powder coatings. From epoxy primers and epoxypolyester hybrids to Qualicoat Class 1 and Class 2 architectural polyesters, the range of products used by GRIN LUZ is very broad. “Working with AkzoNobel guarantees we use high-quality paint products. In turn, the fact that we know very clearly the results we want to achieve is an advantage for AkzoNobel,” notes Marta Herrero. “We are very precise and detailed in our requirements. Therefore, we have managed to establish a fruitful collaboration of mutual growth and technical exchange.” “GRIN LUZ is not the typical high-volume customer,” adds Juan José Sánchez, Sales Representative at AkzoNobel Coatings, S.L.U., “but it is a demanding customer, which sees coating quality as a competitive lever. Among the coating contractors in the Madrid area, GRIN LUZ is undoubtedly the one with the most complete surface treatment offer, while at the same time being capable of meeting adequate delivery times.”
An industrial philosophy of high-quality craftsmanship “Our main strength is our wide variety of finishes and their possible combinations, geared towards meeting any customer specifications,” adds Marta Herrero. “We shot blast some parts because they are heavily contaminated with calamine or welding residues, whereas we send the others directly to the five-stage chemical pre-treatment tunnel with a nanotechnology conversion stage by atomisation.
From top to bottom: The manual shot blasting cabinet for stainless steel components; The pre-treatment tunnel; Pre-treated parts. Next page: The workpiece blowing and masking area and masked parts waiting to be coated.
10
CORROSION PROTECTION | JANUARY 2024
COVER STORY
Using AkzoNobel powder coatings is not enough to be part of the Redox Excellence network: it is necessary to have implemented equipment and processes that, by combining surface preparation, paint application, and quality control procedures, ensure that such corrosion specifications are achieved in compliance with ISO 12944. The application of powders can be either manual or automatic, depending on the shape and size of the workpieces in the batch to be treated, in order to achieve our high coating quality standards. Our target customers are companies looking for the quality and durability levels of the corrosion classes C4 to C5H. This is what differentiates us from other types of coating and surface treatment contractors. “Our second strength is our all-round finishing service, which encompasses all the processes required to achieve perfect, durable, and functional finishes. 90% of our customers entrust us with the treatment of parts intended for outdoor use; components for indoor use also have very high durability requirements. This is why we have been specialising in functional and protective finishes. We take great care of all our customers’ parts from reception to shipping. We carry out quality tests to verify that their substrates comply with their related specifications to make sure that we are going to be able to achieve the required quality degree. We inspect both the incoming material and the end products, which has meant that we have received no complaints from our customers in recent years. It is important to be able to say “no” to customers and educate them about quality. We have also developed such thorough warranty and packaging quality procedures that many companies send the finished parts directly to their customers or installation sites without even checking them. They trust us and, in turn, most of them are very loyal to us.” “I make no secret of the fact that having AkzoNobel by our side as our main supplier of powder coatings, with its products and its daily technical support, is one of the factors that has enabled us to achieve such a high
JANUARY 2024 | CORROSION PROTECTION
11
COVER STORY
Powder coating application and inspection and mask removal after coating. reliability and finishing quality level,” states Fernando Martínez,
coatings is not enough to be part of the network: it is necessary
GRIN LUZ’s Quality Manager. The production approach of GRIN
to have implemented equipment and processes that, by
LUZ is also what earned it the approval as a certified applicator of
combining surface preparation, paint application, and quality
the Redox Excellence network established in Spain by AkzoNobel
control procedures, ensure that such corrosion specifications are
itself.
achieved in compliance with ISO 12944. “The reason we undertook the creation of the Redox Excellence
12
Redox Excellence: AkzoNobel’s network of approved applicators
network is that AkzoNobel is increasingly involved by specifiers
Redox Excellence, which is being set up in Spain right at the time
corrosion resistance class is to be identified depending on the
we are writing this report, is a network of applicators approved
intended use of the parts and the location of the project,” explains
by AkzoNobel for the application of corrosion protection and
Juan José Sánchez. “AkzoNobel, therefore, started to rely on a
functional coatings on steel. Over the course of two years of
network of approved applicators. We verify their processes once
plant testing and validation, AkzoNobel has selected a number
a year so that we can recommend them to customers depending
of powder coating contractors capable of guaranteeing the
on where the project site is located. GRIN LUZ is currently the
application of anti-corrosion systems that meet the resistance
only Redox Excellence company in the Community of Madrid to
requirements of classes C4H to C5H. Using AkzoNobel powder
be certified by AkzoNobel with all the processes, procedures, and
CORROSION PROTECTION | JANUARY 2024
in the drafting of construction specifications, where the required
COVER STORY
Expanding its offer of processes and treatments and improving its quality and professionalism degree, combined with a great industrial culture and passion for coating, is what enabled GRIN LUZ to be among the first companies to be selected to join the Redox Excellence network.
The whole GRIN LUZ team together with AkzoNobel’s technical and sales support team, Rosa González and Juan José Sánchez (on the right in the photo).
standards needed to achieve a C5H corrosion resistance class
to leave the familiar path, even if the alternative is faster, cheaper,
according to ISO 12944.
and more sustainable and guarantees the same performance
“For now, we have selected a precise number of companies
level. Today, with the market increasingly focussing on
in Spain. AkzoNobel established the rules of access to this
sustainability, using powders also conveys the image of a company
network, assessing pre-treatment, control, and process stability
that is more committed to the environment. Finally, with the Redox
procedures. A key criterion is that the applicators carry out all the
Excellence approval, GRIN LUZ takes a further step on the path
necessary processes in-house, without outsourcing any steps. We
to quality: it puts us at a higher level than other companies and
would also like to point out that any coating applicator meeting
enables us to enter certain market niches that were previously
these requirements can apply to join the Redox Excellence
closed to us. On our part, we have the right means, plants, and
network. AkzoNobel will then assess their processes and approve
professionals to do it.”
them if they meet all the criteria. Once approved for the Redox Excellence network, these applicators will be provided with
Quality as a competitive factor to stand out
training and marketing tools for their growth, while AkzoNobel will
The Madrid market for powder coatings has always been one of
carry out annual audits to check that they continue to reach the
high volumes and adequate prices, based on fast delivery services.
set quality levels.”
Such high volumes have always been entrusted almost exclusively
“Being a Redox Excellence applicator is first and foremost a
to industrial coaters, since the share of companies that apply
matter of prestige for GRIN LUZ,” explains Marta Herrero. “It is a
paints in-house on their own or other manufactured products in
seal on fifty-one years of activity in the coating business, a mark of
this area is very low precisely because there is a very large network
quality. I do not know if it will open up new business opportunities
of powder coaters, although with limited performance capabilities.
for us or increase our production volumes, but it is certainly also
GRIN LUZ’s successful choice was to raise the bar, expanding its
a very powerful marketing lever. Not to mention that if a project
offer of processes and treatments and improving its quality and
comes up in the Madrid area that includes AkzoNobel paints in its
professionalism degree. This distinctive feature, combined with a
specifications, if the size of our plants allows it, we will be chosen
great industrial culture and passion for coating, is what enabled it
for the provision of the coating service. GRIN LUZ is also active in
to be among the first companies to be selected to join the Redox
endorsing powder coatings as an alternative to liquid paint. Being
Excellence network.
in the Redox Excellence network will contribute to our effort to promote powder coating: it is always very difficult for a customer
The future for GRIN LUZ can only be bright. ‹
JANUARY 2024 | CORROSION PROTECTION
13
© AdobeStock
ADVANCEMENTS
Flame Spray thermoplastic powders and their corrosion protection performance by Susanna Giovannini Ibix Srl Industrial Division – Lugo (Ravenna), Italy susanna.giovannini@ibixindustrial.com
T
he flame spray application of thermoplastic powder is the only technology that allows using thermoplastic powders directly on site, without the need to set up an actual coating line, thanks to a portable device designed
specifically for this operation. This consists of the deposition of
The flame spray technology for the application of thermoplastic coatings geared towards protecting both metal and concrete substrates against corrosion has many advantages over traditional systems. IBIX has developed equipment and devices suitable for the application of thermoplastic powders in one coat. 14
CORROSION PROTECTION | JANUARY 2024
semi-fused polymer particles on a heated surface whereby the process heat causes the particles themselves to flow and melt into a homogeneous, complete polymer coating. This technology brings several benefits, including long-lasting corrosion protection in terms of electrical insulation and chemical resistance, but also osmosis protection. The flame spray technology can be used in all weather conditions (hot or cold and even rainy, provided that the surface is protected from direct rain). In terms of application, it has several advantages over traditional systems, from the possibility to apply the coating in one step (on metal) to rapid commissioning (after being coated, the parts can be handled and used immediately), up to the complete absence of overspray (so that there is no need to protect nearby equipment, vehicles, etc.). It is 100% environmentally friendly, with no harmful emissions. Finally, touch-ups and repairs are easy and always possible. Let us now look in detail at these advantages and a few application cases.
ADVANCEMENTS
The benefits of thermoplastic coatings
friendly. Specific flame spray grades are used for Three-Layer
Thermoplastic coatings offer excellent protection of metal
Polyethylene (3LPE) and Three-Layer Polypropylene (3LPP)
or cement structures against corrosion and wear, as well as
systems1.
considerable chemical resistance. They provide significantly higher performance than other coatings, particularly in terms
The benefits of the flame spray technology
of increased durability, environmental impact, and the ability
This technology is more environmentally friendly, effective, and
to provide protection even at temperatures down to -70 °C.
efficient than multi-layer liquid systems in several respects:
Through the application of selected thermoplastic powders, such
it produces no overspray;
as PHC PolyHotCote, Polyfusion, FSPP, FSPE, etc., IBIX Srl’s
it has an advantageous specific weight;
flame spray systems guarantee an environmentally friendly, long-
it generates the target layer in a single application step and
lasting, extraordinarily uniform coating, certified for use in the
without curing;
food industry and suitable for use with drinking water, as well as
its climate risk is minimal;
for indoor and outdoor use even in adverse climatic conditions,
it reduces labour requirements;
thanks to excellent resistance to sunlight, salt spray, water, air,
it is characterised by fast application times that result into
and chemical pollutants in general.
reduced ancillary costs;
Thicknesses can range from 300 μm to over 3 mm for some
it ensures immediate commissioning.
selected powder grades. It is possible to achieve smooth and durable finishes, as well as non-slip textures and glow-in-the-dark finishes. Thermoplastic coatings are easy to maintain, clean (being resistant to chemical detergents), and repair, and they are completely environmentally
The Three-Layer Polyethylene (3LPE) system is applied to pipes operating at temperatures between -70 and 95 °C. The Three-Layer Polypropylene (3LPP) system is applied to pipes operating at temperatures between 0 and +110 °C.
1
JANUARY 2024 | CORROSION PROTECTION
15
ADVANCEMENTS
The one-coat application process of the flame spray technology as opposed to the multi-layer application of liquid paints significantly reduces the amount of product used, and quality and thickness control is immediately possible with any corrective measures promptly applicable.
Through the application of selected thermoplastic powders, IBIX’s flame spray systems produce coatings that are suitable for both indoor and outdoor use even in adverse climatic conditions.
Its application-related benefits are also considerable. First of all, it allows all the advantages of thermoplastic powder coatings over liquid corrosion protection systems to be transferred to the construction site, in the total absence of solvents or other nasty ingredients (food industry approvals). Secondly, its one-coat application process as opposed to the multi-layer application of liquid paints significantly reduces the amount of product used, and quality and thickness control is immediately possible, therefore, corrective measures, if necessary, can be taken on the spot. Finally, the resulting coating can be repaired at any time thanks to the small size of the flame spray gun version and guarantees excellent, longlasting performance.
Flame spray equipment The equipment is compact, portable, easy to use, and ideal for treating immovable structures and large components, even in the workshop and during on-site maintenance operations. It enables to Thicknesses can range from 300 μm to over 3 mm for some selected powder grades.
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CORROSION PROTECTION | JANUARY 2024
obtain various thicknesses thanks to the
ADVANCEMENTS
application guns coming in three different sizes and capacity levels: standard, straight flow application guns, available in three sizes (small, medium, and large) and two different versions (with a handle and a trigger for metal and with a straight handle for concrete), which are fully interchangeable; Centurion guns with IBIX wide spray pattern technology, ensuring: - faster spraying and more uniform layers; - easier overlay and better powder release; - no streaks or powder build-up; - minimised risk of unmelted powder with air trapped in the coating. new Maxi Hi-Tech guns that pack the power of two guns in one and offer: - 30 cm spray pattern (compared to 15 cm achieved with the large standard Centurion gun); - greater thickness in fewer passes and superior coating uniformity; - halved coating times; - availability of both versions for metal and non-metal substrate (concrete, fibreglass, etc.); - possibility to coat over 300 sqm (on concrete, for example) in a single working day.
Application 4.0: the evolution of the flame spray technology Atlantis, IBIX semi-automatic system, is the only “all-round portable coating system” on the market, also available in a 4.0 version. It is ideal for spraying thermoplastic powders in two modes, flame spray and flock spray, and it includes the following: flock spray equipment for electrostatic spraying in manual mode, with a fluidised bed tank and an electrostatic gun; semi-automatic flame spray equipment with an application gun featuring an automatic flame ignition device, available in two
Thermoplastic coatings offer excellent protection of metal or cement structures against corrosion and wear, as well as considerable chemical resistance.
versions (metal or non-metal) and in various sizes. 4.0 hardware equipment; 4.0 software equipment with dedicated software & app including:
pre-treatment method (profile: 40-50 microns – SA: 2.5).
- digital infrastructure
This is followed by preheating with temperatures ranging from 130
- ibixconnect.ibix.it
to 190 °C, depending on the melting point of the powder grade
- cloud data storage
used, by means of the coating equipment’s gun (flame only, no
- data integration with the user’s management system.
powder spraying), possibly equipped with optional accessories such as super-heaters (for thicker metals).
The application process
The powder is then applied by activating a switch located on the
The application process starts with the preparation of the
gun itself or by pulling the gun trigger. It is carried through the gun
substrate by removing any pre-existing coating, cleaning and/or
by dried compressed air and, once it hits the preheated substrate,
degreasing and shot blasting, which is the recommended
it immediately melts and adheres to the surface.
JANUARY 2024 | CORROSION PROTECTION
17
ADVANCEMENTS
In the final phase, the substrate is aircooled. If necessary, the process can be speeded up with a water quenching operation. The coating of the metal workpiece is thus complete. Its thickness depends on the number of passes performed; generally, the minimum thickness reached on metal is 300 microns.
A snow shovel bucket coated with PHC-A powder (orange colour) for its release properties, with the blade coated with the higher abrasion-resistant PHC-Plus (black colour).
Advantages in terms of durability and fields of application: a few examples from around the world... We would like to present a few examples of successful applications of the flame spray technology in Europe and Americas. The electrical insulation properties of IBIX flame spray coatings allowed the company Hydro Aluminium in Norway to protect their extrusion fume pipes against extreme marine and electrical corrosion (intense magnetic fields and sea water used to cool down roof structures). The work was divided into several steps from 2003 to 2008. A durability level equal to over twenty years was achieved. An example of increased chemical resistance of parts coated with this technology is the metal tank used for the Navy’s underwater training in Pisa (Italy), which is subject to strong corrosion by chlorinated water. Several layers of twocomponent paint with a thickness of > 1 mm had been applied over the years. IBIX carried out a shot blasting operation and then coated the surface of the tank with PHC AQUA product. This thermoplastic coating will provide far greater durability and resistance than the previous system, without suffering the chemical aggression of chlorine which caused downtime in the Navy base’s diving activities. In the mining industry, the chemical and electrical resistance of ore electro-winning equipment is crucial. For instance, at
The Pesaro seafront railings before and after the application of the PHC product with combined flock spray/flame spray technology.
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CORROSION PROTECTION | JANUARY 2024
the Copiapo Mine in Chile, IBIX coated large metal structures of the copper
ADVANCEMENTS
electro-winning plant. After three years of exposure to sunlight and continuous contact with acid substances, the coating showed no defects or changes and very long life can be expected. In Argentina, the PHC-PLUS coating was applied to some truck beds to increase abrasion resistance and material release properties. It was applied in two colours (black top, white bottom) with a thickness of around 1 mm for better wear control.
...and two successful cases in Italy Seafront railings coating project in Pesaro The railings of the Pesaro promenade had been coated with polyurethane paints that did not withstand the strong corrosive action exerted by the marine environment. The damage caused resulted in the need to carry out several touch-ups over time, which unfortunately did not solve the severe corrosion problem causing great dissatisfaction on the part of the local inhabitants. IBIX chose to intervene by applying PHC-A coatings with combined
Water-proofing and protective coating of condominium concrete roofs, Ferrara, Italy.
flock spray and flame spray technology. A thickness of 900-1000 µm was obtained in one coat. The devices used were the IBIX 25 portable blaster for shot blasting and Atlantis in its 4.0 version for coating. Water-proofing and protective coating
also be used for asbestos encapsulation
project of condominium concrete roofs
as certified according to the UNI
in Ferrara
10686:1998 standard.
The specially engineered thermoplastic
Polyfusion has been applied on the
powder grade for coating non-metal
concrete flat roof of 4 condominiums in
substrates, such as concrete, tiles,
Ferrara, Italy, after repairing previously
fiberglass etc. Polyfusion has been
existing cracks and other concrete
successfully applied on thousands sq.
defects. The project was carried out during
meters flat roofs and covers to provide
the month of December confirming that
long-lasting waterproofing and corrosion
flame spray thermoplastic coatings can
protection.
be applied outdoors throughout the year.
Polyfusion coating has been certified as
Polyfusion will keep the concrete roof
fully impermeable in compliance with the
waterproof with excellent weathering
UNI EN 12390-8:2019 standard and it can
resistance for many years to come. ‹
IBIX presented a solution entailing the use of thermoplastic powders and mixed technology, flame spray + flock spray. JANUARY 2024 | CORROSION PROTECTION
19
ADVANCEMENTS
Sherwin-Williams launched the new thermal insulative coating Heat-Flex® 7000 By The Sherwin-Williams Company Cleveland (OH), United States
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CORROSION PROTECTION | JANUARY 2024
ADVANCEMENTS
The new Heat-Flex 7000 thermal insulative coating system from Sherwin-Williams Protective & Marine offers personnel protection, insulating capabilities and solar heat reflectivity for an array of industrial applications.
Flex 7000 can protect personnel from skin-contact burns on process assets operating at up to 350°F. A single topcoat of this new product also provides a significant level of insulating value that can help to prevent process heat losses or, conversely, to protect against solar radiant heat gain, which can otherwise cause vaporization losses in storage tanks. Other coating products often require multiple coats to provide similar personnel protection and insulating value.” Compared to conventional insulation and cladding systems, which require time-consuming fabrication and installation, the spray-applied Heat-Flex 7000 insulative coating is far easier and less costly to apply and maintain. Although Heat-Flex 7000 does not provide as much R-value as conventional insulation in dry conditions, it forms a closed-cell film that resists moisture penetration — from rain, water sprays or humidity —far more effectively than conventional insulation. Therefore, its thermal efficiency remains consistent in even the wettest conditions. By
T
contrast, any cracks or seams in insulation/cladding systems can admit and hold water, which displaces insulating air and greatly
he new Heat-Flex 7000 thermal insulative coating
reduces the insulation system’s R-value. This moisture may
system from Sherwin-Williams Protective & Marine
become trapped at the insulation/substrate interface, significantly
offers personnel protection, insulating capabilities
raising the risk of the formation and proliferation of CUI.
and solar heat reflectivity for an array of industrial
Because there’s no way for water to penetrate down to the asset
applications. The single-component, spray-applied coating system
substrate and remain trapped there — and because no physical
meets Occupational Safety and Health Administration standards
cladding system is applied on top of the coating — Heat-Flex
for protecting personnel from skin-contact burns on assets
7000 eliminates the risk of CUI altogether. Coated assets are
operating at temperatures up to 350°F (177°C) in one coat.
also easier to inspect and repair, as insulation/cladding systems
A single coat of Heat-Flex 7000 can eliminate the costs of
require periodic removal for inspections or specialized ultrasonic/
installing, inspecting and repairing conventional insulation and
radiography testing for CUI. The Heat-Flex 7000 coating system
cladding systems for personnel skin-contact protection, thereby
requires only a brief visual inspection for damage to the coating
also eliminating the common threat of corrosion under insulation
surface. Repairs are far simpler too, involving application of the
(CUI). In addition, the coating reduces thermal losses on assets
coating over any damaged areas.
that need to stay warmer or diminishes solar heat gain on assets
Heat-Flex 7000 can protect heat-sensitive assets (tanks, fuel
that need to stay cooler.
pipelines, water cooling lines and other assets) from solar
Able to be directly applied to hot substrates, Heat-Flex 7000
heat gain. In these situations, a reflective white formulation is
is spray-applied in a single coat — typically 50-75 mils dry film
recommended to insulate the asset, enabling it to maintain a lower
thickness (DFT) — over a required corrosion-resistant primer. The
internal operating temperature. Lower operating temperatures can
coating system features new technology that yields a thick, fully
help reduce the loss of fuels or cooling water in tanks and pipes
cured coating film with a high volume that effectively resists the
due to vaporization, as well as reduce the need for expensive
transfer of heat from the underlying substrate to the surface, as
vapor-recovery or cooling equipment.
well as from the surface to the substrate.
The Heat-Flex 7000 coating system can be specified for use in
“Heat-Flex 7000 represents a step-change in our insulative
indoor or outdoor environments to protect personnel and insulate
coatings technology,” said Neil Wilds, Global Product Director,
assets and processes involved in oil and gas production and
CUI/Testing for Sherwin-Williams Protective & Marine. “Because
refining, mining, power generation, chemical processing, offshore
of its new chemistry and formulation, a single topcoat of Heat-
and marine operations. ‹
JANUARY 2024 | CORROSION PROTECTION
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© AdobeStock
RESEARCH BREAKTHROUGH
Drones Protect Wind Turbines from Ice By Monika Weiner science journalist – Munich, Germany
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CORROSION PROTECTION | JANUARY 2024
RESEARCH BREAKTHROUGH
The project “TURBO — Temporary coating by means of drones”, that was developed by the experts both from the Fraunhofer IFAM and Fraunhofer IPA, is based on the use of drones to prevent the ice formation on the rotor blades.
D
amp, cold conditions are the enemy of wind power. If a layer of ice forms on the rotor blades, this can result in rotational imbalance and, hence, increased wear. In such cases, the turbines often have to be shut down
for several days, leading to massive losses for the operators due to the pause in electricity production. Now, for the first time, a Fraunhofer team has succeeded in using drones to protect rotor blades against ice. The new technique has been developed jointly by experts from the Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM and the Fraunhofer Institute for Manufacturing Engineering and Automation IPA in the project “TURBO — Temporary coating by means of drones.”
JANUARY 2024 | CORROSION PROTECTION
23
RESEARCH BREAKTHROUGH
Up to now, operators who wanted to protect their wind turbines against ice had to dig deep into their pockets heating mats that can be integrated in the blades or systems to pump warm air into the rotors are extremely expensive — as is the use of helicopters to spray de-icing agent onto the turbines. “Drones that are only used when needed offer a cost-effective alternative,” says Andreas Stake, project manager at Fraunhofer IFAM. However, in order to use drones to prevent ice, a number of conditions have to be met: As well as being environmentally friendly, the coating materials need to demonstrate good adhesion and sufficient durability so they remain on the rotors for weeks and protect them from ice. The spraying system used needs to be highly accurate but lightweight at the same time. And finally, the drones need to have a high pay-load and allow for very precise control.
Important for wind turbines: environmentally friendly materials and precise application equipment The Fraunhofer researchers working on the TURBO project succeeded in developing a prototype which fulfills all of these requirements: the coating material designed by the scientists at Fraunhofer IFAM in Bremen is made from urea and wax, is
Coating drone during a spray test: the coating material is applied by the drone via a lance.
environmentally friendly and demonstrates good adhesion. This material can be applied quickly and easily using a spray technique and also dries quickly. The coating underwent testing in an ice chamber at the institute to confirm that it reliably protects against the formation of frost. The team at Fraunhofer IPA built the equipment used to apply the coating. It consists of a small pump which presses the fluid urea/ wax mixture at high pressure into a long, thin lance, at the tip of which is a nozzle with a diameter of just 0.3 millimetres. This airless pump system is able to produce droplets with a diameter of 100 micrometres. Even at wind speeds of 35
About Fraunhofer-Gesellschaft The Fraunhofer-Gesellschaft, based in Germany, is the world’s leading applied research organization. By prioritizing key
kilometres per hour, these droplets can still be sprayed precisely
technologies for the future and commercializing its
onto the edges of the rotor blades where they then solidify. The
findings in business and industry, it plays a major
edges are particularly important as this is where the icing process
role in the innovation process. A trailblazer and
starts when wet, cold air hits the turbine.
Ensuring success with simulations Dr. Oliver Tiedje, project manager at Fraunhofer IPA, and his team determined the technical parameters — for example, the required pressure, an efficient atomization method and the optimum
trendsetter in innovative developments and research excellence, it is helping shape our society and our future. Founded in 1949, the Fraunhofer-Gesellschaft currently operates 76 institutes and research units
droplet size — using fluid dynamic simulations. “Our decades
throughout Germany. Around 30,800 employees,
of experience in modelling coating processes really helped us
predominantly scientists and engineers, work with an
out. We were able to draw on this expertise,” says the physicist. “However, we did have to adapt the process parameters to the complex geometry of the wind turbines.”
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CORROSION PROTECTION | JANUARY 2024
annual research budget of roughly €3.0 billion, €2.6 billion of which is designated as contract research.
RESEARCH BREAKTHROUGH
The researchers now intend to work with industry partners to develop the technique further and get it ready for series production. There are numerous applications in which drones can be used to apply coatings, ranging from ice protection for wind turbines and overhead lines in rail transport to building refurbishment — for example, repairing defects in render on parts of buildings that are difficult to reach. The “TURBO: Temporary coating by means of drones — Icing protection of wind tur-bines as a case study” project was supported by 19 companies including coating and raw material manufacturers, manufacturers of coating equipment and drones, and operators of wind turbines. The project was submitted to the German Federation of Industrial Research Associations (AiF) via the Research Society for Pigments and Coatings (FPL) as part of the programme for promoting industrial cooperative
Simulation of coating by means of drone under the influence of wind.
research (IGF), and is funded by the Federal Ministry for Economic Affairs and Climate Action (BMWK). ‹
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SCIENCE
OUTLOOK
Fatigue corrosion and its prevention by Pier Luigi Bonora AITIVA Association and University of Trento, Italy
Fatigue corrosion is one of the least understood and controlled problems, since it is caused by factors and interactions of different kinds and origins. Here, you can read an in-depth analysis of this phenomenon and how it can be prevented.
F
atigue corrosion can be classified among the mechano-chemical corrosion phenomena (Table 1), which all have one aspect in common: the synergism
of increased action. In other words, the simultaneous action of the mechanical and chemical and/or electrochemical contribution reduces the service life of the material or structure much more than the sum of the damages caused by corrosion and mechanical stress acting separately, in any order.
MECHANO-CHEMICAL CORROSION Fretting corrosion
Corrosion due tofluid dynamic action: - Under deposit corrosion - Erosion-corrosion - Cavitation - Impingement attack Stress corrosion Static efforts Fatigue corrosion Periodically variable efforts
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CORROSION PROTECTION | JANUARY 2024
SCIENCE OUTLOOK
JANUARY 2024 | CORROSION PROTECTION
27
SCIENCE OUTLOOK
A metallic material subjected to variable mechanical stresses
For example, the use of s - N curves, initially used to represent the
periodically undergoes structural, physical, and chemical changes
characteristics of the various materials subject to fatigue only, has
that depend on the following parameters:
proven to be extremely useful also with CF.
the nature, structure, shape, and surface finish of the metal;
In fact, the comparison between the two diagrams makes it
the amplitude and frequency of the cyclic effort applied;
possible to assess the suitability and possible limits of the use
the environment.
of specific materials. The s - N curves or Wolher curves are
Especially in relation to the latter parameter, these modifications
constructed by placing the maximum cyclic load value on the
can take the names of “fatigue”, “fatigue assisted by corrosion”,
ordinates and the number of cycles leading to fracture on the
or “corrosion due to fatigue”. In the absence of any contributions
abscissas. The abscissa in particular is logarithmic. There is thus
from the environment, the failure of a material is only due to
an actual contraction in correspondence with long durations,
stresses with intensity values varying over time. This occurs under
since in this area the curve’s slopes are generally very small. Using
considerably lower loads than those corresponding to the static
this diagram, the resistance and fatigue limits can be calculated.
resistance of the part and failure is eminently fragile; that is due
In Figure 1, the line a shows the fatigue resistance of a ferrous
to the effect of cyclic loads and only in a smaller part to time, as
material without a corrosive environment1. The dotted LA line
instead happens in deformation processes under constant loads.
represents the fatigue limit (definable only for ferrous metals)
The definitive fracture of an object can be considered the final act
as the maximum force below which a material can presumably
of a progressive damage process. Indeed, we can interpret fatigue
withstand an indefinite number of cycles. As in case A, line B
life as a succession of three distinct phases:
represents the fatigue resistance value of the same sample but
Nucleation and grouping of cracks during the incubation phase;
with a superficial notch. Finally, line C represents the fatigue
Slow propagation of cracks, which progressively increase their
resistance value of the sample previously considered in a
speed up to a critical value in the growth phase;
particularly aggressive environment (corrosion fatigue).
Finally, a third phase, called fracture, in which macroscopic
The crack nucleation mechanism has been the subject of
damage occurs to the structure.
numerous studies; among the most reliable theories, all involving
Although the phenomena of fatigue and corrosion fatigue (CF)
lattice defects, we would like to mention the following ones:
are fundamentally different, it is common practice to compare the results obtained in the two fatigue situations in homogeneous conditions to analyse the different behaviours of the same material.
Figure 1 - Diagram for the assessment of resistance and fatigue limits.
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CORROSION PROTECTION | JANUARY 2024
Fatigue resistance is the maximum force applicable to a metal for a certain number of cycles without causing fractures.
1
Figure 2 - Formation of surface micro cracks through the pendular movement of dislocations on preferential planes where dislocation sources are located.
SCIENCE OUTLOOK
Oding’s theory: fatigue stresses tend to localise point defects, in
All these theories are linked to the experimental evidence of
particular vacancies, which preferably agglomerate in a lenticular
persistent slip bands that lead to the formation of extrusion-
or spherical shape in areas subject to shear stresses, where there
intrusion point couples. However, this is not the place to discuss
is a certain concentration of stresses: the concomitant presence
fracture mechanics in depth: therefore, please refer to the specific
of defects and stresses leads to crack nucleation.
literature.
Shanley’s theory: it explains the formation of surface micro cracks through the pendular movement of dislocations on preferential planes where dislocation sources are located. Reaching the edge of the crystal, the dislocations cause some rows of atoms to emerge, which can undergo alterations such as weakened metallic bonds along those rows, when the crystal tends to regain its primitive structure following the reversal of the sliding’s direction. Such weakening of bonds also extends to adjacent atomic strands; this forms an area in which the cohesive forces between the atomic planes are greatly weakened. A kind of chain reaction is therefore possible that can lead to the formation of a micro crack (Fig. 2). Hott’s theory: it is linked to the almost elliptical motion of the dislocations which, when moving along closed trajectories, generate for each revolution a raising or lowering of the area inside the path corresponding to a reticular plane. Cottrell and Hull’s theory: it introduces a mechanism based on the action of two sources of dislocations acting on planes with opposite angles. At each load cycle, these two sources originate an extrusion and an intrusion (Fig. 2). The crack originating from the surface discontinuities created by the extrusions and intrusions begins to propagate following the direction of flow of the latter (Fig. 3a and 3b).
Although the phenomena of fatigue and corrosion fatigue (CF) are fundamentally different, it is common practice to compare the results obtained in the two fatigue situations in homogeneous conditions to analyse the different behaviours of the same material.
Figures 3a and 3b - The crack originating from the surface discontinuities created by the extrusions and intrusions begins to propagate following the direction of flow of the latter.
JANUARY 2024 | CORROSION PROTECTION
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SCIENCE OUTLOOK
The role of the environment Figures 4 and 5 summarise the interaction models between oxygen and the slip band and between the oxide layer and the dislocation during crack nucleation. In the first case, the vacancies generated by the applied stress attract a high concentration of oxygen, which prevents the micro crack from healing and accelerates the breakage rate; in the second case, cavities and voids are created by the presence of the oxide and the crack formation is anticipated. The gaseous environment affects crack propagation to a greater extent than crack nucleation. Aqueous environments, on the other hand, play an important part in the nucleation mechanism of fatigue cracking. Four theories explain, at least in part, the possible mechanisms of fatigue corrosion: 1 - Concentration of stresses at the base of the hemispherical pits created by a corrosive environment: this hypothesis has been discussed and refuted several times. It seems clear that, although the presence of pits leads to a reduction in service life, it is to be considered more a consequence than a cause of CF. 2 - Electrochemical attack on a plastically deformed metal area, while the undeformed part acts as a cathode. The action of short-circuited galvanic elements in the presence of structural deformations is undoubtedly the origin of accelerated, localised corrosion. Many electrochemical investigations have brought contributions in support of this theory. 3 - Electrochemical attack on the tears in an otherwise protective oxide surface film. The resulting electrochemical cell could promote rapid dissolution of the metal near the emerging slip band, resulting in accelerated failure (Fig. 6). 4 - Lowered surface energy of the metal due to absorption from the environment with increased speed of propagation of micro cracks. This theory, based on the reduction of surface tension, has received much credit among Russian researchers. Karpenko was the first to suggest that the CF mechanism consisted of two phases: the appearance of fatigue cracks due to environmental adsorption and subsequently a corrosion reaction occurring within the cracks.
From top: Figure 4 - The interaction model between oxygen and the slip band. Figure 5 - The interaction model between the oxide layer and the dislocation during crack nucleation. Figure 6 - Electrochemical attack on the tears in an otherwise protective oxide surface film.
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CORROSION PROTECTION | JANUARY 2024
SCIENCE OUTLOOK
Duquette and Uhilig, studying the effects of dissolved oxygen and of anodic and cathodic currents and potentials in solutions with different pH values, hypothesised a crack initiation mechanism based on the preferential dissolution of the metal on the steps of the slip bands emerging on the surface. Dissolution unlocks several blocked flow processes, accelerates the extrusionintrusion phenomenon, and consequently results in premature crack nucleation and causes its initial growth. Crack propagation is further accelerated by the propagation of the pit created by corrosion at the sample’s surface and preferential dissolution at the top of the cracks. The initial fracture has undoubtedly a mechanical nature resulting from the concentration of stresses at the top of the cracks. Ultimately, it can be concluded that none of these theories alone can clarify all the phenomena related to CF. The complex and varied nature of the interactions involved in CF (chemical, physical, mechanical, structural interactions) actually entails the contribution of one or another of these mechanisms from time to
The complex and varied nature of the interactions involved in CF (chemical, physical, mechanical, structural interactions) entails the contribution of one or another of mentioned mechanisms from time to time.
time.
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SCIENCE OUTLOOK
Prevention As already pointed out, in the absence of environmental influences, the effects of the application of loads to a structure can
b) on the metal itself (structure, dimensions, surface state); c) on the environment and the corrosion protection system as a whole (cathodic protection, inhibition…).
be studied through the fracture mechanics method, which enables to predict the time at which a defect or crack is grown to such an
We summarise below the main interventions required in the
extent as to overcome the resistance of the material. This means
design phase.
that stress and fatigue are to some extent dependent on time. The
Preventive measures:
introduction of corrosion in the system quite completely nullifies
- Choosing suitable materials;
such calculations, since the phenomenon becomes catastrophic
- Minimising or eliminating cyclical efforts;
and, therefore, unpredictable.
- Increasing the size, mass, or strength at the critical sections;
The only way to withstand corrosion fatigue is to prevent the
- Reducing effort concentration or redistributing the efforts;
effects of the presence of corrosion.
- Opting for aerodynamic lines to favour the distribution of forces
A typical example of this is that of railway axles: they are subjected
and balance the forces and stresses along the component;
to a very large number of bending stress reversals during their
- Giving the correct shape to the critical sections;
service life and are therefore designed for infinite life by keeping
- Achieving enough flexibility to reduce overvoltages due to
the expected service stress ranges below the fatigue limit of the
thermal expansion, vibrations, impacts, and works on the
material (Fig. 7a and 7b).
structure and system;
Corrosion nullifies such efforts unless effective protective
- Avoiding rapid variations in load, temperature, and pressure
coatings and frequent inspections are designed and carefully
values;
implemented.
- Avoiding structural or internal stresses;
The fracture shown in Figure 7b refers to the train derailment that
- Avoiding structures subject to tremors or vibrations and
occurred in 2009 in Viareggio (Italy).
eliminating their causes;
The means for preventing fatigue corrosion can be classified as
- Increasing natural frequency to avoid resonance fatigue
follows:
corrosion;
Stress control
- Increasing ductility and impact resistance.
Corrosion control
Specifications:
Control of synergism (CF) through interventions:
- Elimination of stresses or tensions due to heat treatments,
a) during the design and material choice phase;
hammering, moulding, rolling, etc. to generate compressive
The only way to withstand corrosion fatigue is to prevent the effects of the presence of corrosion. A typical example of this is that of railway axles: they are subjected to a very large number of bending stress reversals during their service life and are therefore designed for infinite life by keeping the expected service stress ranges below the fatigue limit of the material. Figure 7a - Railway axle.
32
CORROSION PROTECTION | JANUARY 2024
SCIENCE OUTLOOK
stresses, which are less dangerous for fatigue;
in the presence of CF. Moreover, the inhibitors’ action, be it
- Suitable surface finishes
absorption, oxidation, or complexation, must be particularly rapid,
- Protective coatings (zinc plating, chrome plating, copper
much more than in the presence of other phenomena such as
plating, nitriding etc.) so as not to cause monthly stresses.
corrosion-erosion or stress corrosion cracking.
Changing or inhibiting the corrosive environment
In conclusion, fatigue corrosion and its prevention are far from
Analysing efforts through PC software.
being an understood and controlled problem. It is necessary to study the micro mechanisms of this phenomenon, surface-
Protection
environment interactions especially in relation to mechanical
The electrochemical protection methods are based on the
properties, the effects of the oscillations’ frequency and
imposition to the structure, through an external power source,
amplitude, the interaction with other concomitant phenomena
a potential value suitable to prevent or minimize the corrosion
such as static stresses and friction corrosion, and the effect of
onset. Cathodic protection involves the imposition of a potential
the fluid dynamic conditions created by the same source of the
in the range where only reduction reactions are possible.
fatiguing stress. ‹
Its implementation to prevent fatigue corrosion is a controversial topic and, although it often brings some benefits, it is not the solution to the issue; in particular, it has recently been ascertained that the most difficult-to-reach areas of the stressed metal (for example, the bottom of a crack) can escape
Bibliography
electrochemical control and be corroded at any point.
For an in-depth approach to corrosion engineering and
Anodic protection, suitable for stainless steels, consists in
the mechano-chemical corrosion of metallic materials, we
imposing and keeping, by means of a potentiostatic power
recommend the following books:
source, a potential value inside the passive state (see static plot
- Robert D. Biederman, Corrosion Fatigue, Hassell Street Press,
in Figure 8). It is extremely dangerous in the presence of CF, as
September 9, 2021
is clearly highlighted in Figure 8, showing that in the presence
- Pietro Pedeferri, Corrosion Science and Engineering
of CF no passive state is available. The use of inhibitors has
(Engineering Materials), Springer Ed., September 21, 2018
been studied by several authors, but the debate is still open. It
- Pietro Paolo Milella, Fatigue and Corrosion in Metals, Springer
is known that inhibitors must be added in higher concentrations
Ed., October 5, 2012
Figure 7b - Fatigue corrosion fracture in a railways axle.
Figure 8 - Anodic protection, suitable for stainless steels, is extremely dangerous in the presence of CF.
JANUARY 2024 | CORROSION PROTECTION
33
ADVANCEMENTS
Oil & Gas Goods Receipt:
The Hidden Killer of Preservation Planning? by Cortec® Corporation St. Paul (MN), United States - productinfo@cortecvci.com
34
CORROSION PROTECTION | JANUARY 2024
ADVANCEMENTS
P
icture this. An oil and gas facility has gone great lengths to make sure its warehoused goods and spares are preserved and protected against corrosion and therefore ready to install at a moment’s notice.
However, when workers go to install a new piece of equipment that is sealed in foil and was never opened, they suddenly find the vessel covered with rust and no longer viable. What went wrong with their preservation planning? Why did they receive this surprising discovery on a unit that should have been in pristine condition? Cortec® answers these inquiries with another question
In the Oil & Gas industry it is essential TO PUT A PLAN IN PLACE for handling the material that needs to be protected against corrosion. Cortec® has the right preservation solution for this issue.
that demands every facility’s attention: Is your inbound supply chain and material handling the hidden killer of your preservation planning?
Point of failure: goods receipt and material handling While oil and gas facilities should have a sound preservation plan in place during both construction and operation, the point of goods receipt is a critical time that can easily be overlooked due to competing interests of speed, cost, and skill. Although receiving shipments is typically a job for material handlers, it may require the skillset of an engineer or maintenance worker to detect any problems with the quality of the good received— whether in terms of corrosion or mechanical damage. To make matters worse, sometimes incoming goods are so thoroughly packed and crated that it does not seem worth the time and effort to inspect and repackage them. Other times, they are inspected, and an airtight packaging system is breached so equipment that may have been received in good condition is no longer protected during subsequent storage. In each case, corrosion may enter the picture without detection until it is too late to remedy the situation. surfaces, leaving components ready for immediate use without
The importance of a plan
the need to remove greasy rust preventatives.
Oil and gas facilities can save time and money in the long run by
Better yet, if oil and gas facilities request their suppliers to use
knowing the corrosion concerns of goods receipt and having a
specific preservation materials and processes at the time of
plan in place to preempt problems. This can start by creating a
shipment, the likelihood of goods rusting on a long ocean journey
standard operating procedure for handling and inspecting goods
drops significantly. Basic actions such as hydrotesting vessels
received and training material handlers in what to look out for. By
with VpCI®-649, fogging piping modules with CorroLogic® Fogging
catching corrosion on incoming goods, the facility can place the
Fluid VpCI®-339, and shrouding skids in MilCorr® VpCI® Shrink
responsibility to correct the problem back on the supplier and
Film with custom access doors for inspection can go a long way
avoid unwanted corrosion surprises at the last minute when there
toward ensuring goods arrive corrosion free and, in some cases,
is no time left to fix them.
equipped for ongoing protection into months of storage.
If material handlers are expected to open and inspect the
Worth the investment
packages, they should also be trained in proper repackaging with
While an onsite preservation plan is critical for oil and gas
preservation materials. This may include heat shrinking with
facilities, personnel must not overlook what happens or does not
VpCI®-126 HP UV Shrink Film and proper placement of VpCI®
happen at the key moment of goods receipt. Putting a corrosion
Emitters. Both of these offer dry protection in enclosed spaces
plan in place for material handling may take time and effort, but it
through the diffusion of Vapor phase Corrosion Inhibitors, which
will be well worth the investment made to avoid the more serious
are attracted to and form a protective molecular layer on metal
corrosion problems that could otherwise happen. ‹
JANUARY 2024 | CORROSION PROTECTION
35
VOICES
People I met By Pier Luigi Bonora, AITIVA Association and University of Trento, Italy
© AdobeStock
"In more than fifty years of career, I could assist and contribute a little to the evolution of corrosion science and corrosion control. I had a chance to meet many of the protagonists of this adventure. Many of them have become friends and I will talk of both their achievements and their personalities."
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CORROSION PROTECTION | JANUARY 2024
VOICES
C
orrosion arose as an issue alongside the Industrial
microscope. Epelboin was among the first to use the techniques
Revolution, but it became a socioeconomic problem
of potentiostatic and potentiodynamic recording of polarization
with the extensive use of both stationary and energized
curves. He was also one of the most enthusiastic advocates of
metal objects, i.e. at the end of the 19 century. As a
the use of impedance methods for the study of electrochemical
th
Science, Corrosion is the daughter of Electrochemistry and the
kinetics. Thanks to the implementation of experimental
granddaughter of Thermodynamics, Kinetics, and Fluid dynamics.
advancements and to the construction in his laboratory of
Time of hard pioneering
potentiostats adapted to transfer function analyzers, impedance could be measured over a very wide range of frequencies. While
Corrosion control by coatings has a different story: the
I was there, the paints of both Concorde and Airbus aircraft
development of metallic coatings started with Brugnatelli’s
were under test in his laboratory. I was the only chemist among
first experiments in 1805, whereas organic protecting coatings
physicists and I enjoyed my fifteen minutes of glory. In the end, the
suffered a stagnant situation up to the 1970s. In those days
first impedance plot of a painted aluminum surface was published,
when I started studying organic coatings (opening afterwards to
signed by Takenouti and me.
metallic, composite, inorganic, ceramic…), durability problems
I came back from France with two passions: EIS and paints,
were easily solved by means of lead and chromium. Corrosion
specifically protective organic coatings. I was soon totally
people knew little (and cared less) about paints. Paint companies
immersed in these two topics thanks to the establishment of a
often covered rust with durable zinc chromate pigmented alkyd
long-term planned collaboration with the Italian branch of PPG
paint, and that was all. This well-established situation was totally
(previously IVI, Industria Vernici Italiane, a FIAT subsidiary). It
unacceptable in the automotive. A revolution in coatings started
should be noted that in the 1970s, FIAT owned a Research Centre
in the transportation industry, and it was characterized by both
with more than 4000 members in Orbassano, near Turin (Italy),
phosphatizing and electrophoretic deposition (EPD). EPD is
whereas FIAT Railways was the first (and the only one for several
a term for a broad range of industrial processes that include
decades) to produce active tilting trains with the trademark
electro-coating, e-coating, cathodic electrodeposition, anodic
Pendolino1. The FIAT Office in Brussels was the base of almost
electrodeposition, and electrophoretic coating, or electrophoretic
all European Projects involving Italy. In this framework, I worked
painting. Before entering into details, I must mention the year 1971,
with all these institutions and also with Ferrari, where it was
the moment when I started to move from dealing with a subject to
my privilege to introduce the implementation of both EPD and
managing it: my first approach to organic coatings happened when
phosphatizing, as well as the concept of a Ferrari as a durable
I spent some months at Sorbonne, in the Laboratory of Israel
object and not only a speedy racing one or a costly toy. During
Epelboin.
this period, I started a collaboration and a warm friendship with
Epelboin used to state: “Every experiment should be carried
Giovanni Bianchini, a creative chemist at IVI and after at PPG.
with the aim to put the results in a handbook”. No statistics. Only rigid control of all parameters. He knew what a dangerous
https://en.wikipedia.org/wiki/Pendolino
1
and impervious path is the one of pioneers. But his career was built exclusively out of innovations, even with the risk of taking a wrong turn. Actually, the well-known logo of impedance, the snail (escargot) is in many instances an artifact, which escaped for years the recognition of an experimental mistake, voiding many “selves” of physical meaning. Nonetheless, the “handbook method” is the achievement everybody should tend to. If I tried to compare Epelboin’s laboratory with something understandable, I would choose a cruise ship, with a powerful and efficient engine, elegant fluid dynamics, a skillful crew, a wise and brave captain, exploring unknown horizons. Epelboin, a Romanian Jew living in France, survived and even published under the false name of Bernard during the war. The originality and the added strength of his research lay in the joint use of the methods of electrochemical kinetics and those
Corrosion control by coatings has a different story: the development of metallic coatings started with Brugnatelli’s first experiments in 1805, whereas organic protecting coatings suffered a stagnant situation up to the 1970s.
of material characterization such as X-rays and the electron
JANUARY 2024 | CORROSION PROTECTION
37
VOICES
With Giovanni, I spent many years focusing on innovative research
all advancements were discussed in an open, cultural, deeply
on EPD, until his premature death in 1992.
involving atmosphere from 1974 to the late 1990s).
The coatings business was gradually moving from craftsmanship
That is the past, of course. However, I cannot forget the explosion
to modern science and technology, pushed and enhanced by the
of new ideas, patents, methods, and technologies that hit the
growing need and demand for both high durability and aesthetics,
coating sector in that period. A time of pioneering discovery. I
giving rise to the flourishing of test methods, quality standards,
attended the Conference three times and Angelos and his wife
new improved resins, additives, and adhesion promoters.
Angelika invited me to the homologous event in the US, on Hilton
Electrochemistry started to be involved, mainly in the academic
Head, an artificial island offshore Charlotte, with 18 greens, 18
environment, while the industry began to trust accelerated
hotels, and the “castle” of Pizza Hut’s owner. Unfortunately, it was
weathering tests, with field exposure in Arizona, Florida, Alaska,
raining all the time and it looked just like Ferrara in November.
and so on. Every car manufacturer patented its own protocol for
The heritage of the Athens Conference was taken on by a great
quality assessment. International Conferences were attended
scientist working in Fargo, North Dakota (USA). There, in the
everywhere by hundreds (in the USA, thousands) of specialists,
middle of nowhere, he was able to build an outstanding Institute
sponsored by extremely generous companies in bloody (but
for Polymers and Coatings research. He honored me with his
constructive) competition with each other.
friendship: his name was Gordon Bierwagen. His achievements
During the last twenty years of the past century, I met the whole
were widespread and recognized all over the US and beyond,
set of people involved in coating science and technology, let
which would require several pages to report about. He was a great
alone industrialists. I organized two workshops in 1981 and 1983
scientist, but for me mainly a lovely person, with spontaneous
in Genoa, Italy, (ETM 1 and ETM 2, the ancestors of AETOC),
empathy (only slightly hindered by his strict, often rather cryptic
where the trend towards innovation but also the reciprocal
Midwest American pronunciation), who had made family patriarchy
blindness of corrosionists towards polymers and of paint
an authentic art. The people I met? A crowd – many of whom I
manufacturers towards corrosion science were fully evident.
had the chance to gather within the Working Party “Coatings” of
Happily enough, this gap was tentatively closed by FATIPEC (which
the European Federation of Corrosion which I founded in 1993
was more application and sales-oriented), the biannual Gordon
and which is nowadays the most attended and prolific Session of
conference on coatings and films (which was more focused on
EUROCORR, even though when I conceived it, some commented
basic science and saw a traditionally strong US participation),
that it was a wishy-washy topic.
the FSCT Conferences (mainly exhibitions, but with lively
For a few years now, the WP has been attended mainly by people
scientific contributions), and last but not least, the International
from the Academy dealing with advanced research, including
Conference in Organic Coatings Science and Technology, the
nanotechnology, self-healing pre-treatment processes, composite
Athens Conference, the Angelos Patsis Symposium (where
electro-coating, and smart coatings. At present, industrial coatings
Israel Epelboin
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CORROSION PROTECTION | JANUARY 2024
Angelos Patsis
Gordon Bierwagen
VOICES
look like a mature technology where durability and reliability play
David acted as a link between Cambridge and Manchester,
a role in competitiveness, whereas advancements are seldom
where he devoted thirty-eight years to research at the UMIST
the object of promotion. Globalization and the concentration
Corrosion Centre founded by Graham Wood in 1972. I met
of brands are contributing to the relative disappearance of
David in 1983, at my second Symposium on electrochemical
companies from international conferences. Over time, the
test methods for coatings, in Genoa. He was deeply involved in
myriad of SMEs that formulated and manufactured most of the
all debates and offered revealing contributions. Unfortunately,
milestones of polymeric coatings have disappeared, like Jonas in
at the official dinner, he was not happy with the menu, which
the mouth of a few whales.
included “tagliatelle chocolate”. While he was leaving the table in
It was not like this in the 1970s and 1980s. That was a time of
discomfort, Professor Llewellin Leach from Reading was anxiously
pioneering in the field of advanced polymeric coatings. The
questioning the cook for the recipe…
contribution of the research centers of many paint companies was
John Edwin Oakley (Jack) Mayne was half academic and half
outstanding and widespread. The most important achievements
industrialist, but mainly a humanist. He crossed my professional
shown at international conferences were brought by scientists
life many times, always leaving a sign of warm human relation, of
such as Harry Post of AMERON, Mike Mitchel of International
peculiar ability to listen and understand, a vivid will to help and
Paints, Clifford Schoff, Peter Kamarchik, and Giovanni Bianchini
contribute. I can only borrow the words of eminent Rumanian
of PPG, as well as Gordon Bierwagen, who was a major scientist at
electrochemist Edeleanu: Jack “has provided both moral and
Sherwin-Williams from 1970 to 1989. I cannot forget Otto Vogt of
in many cases material support to individuals who are now well
SIKA, the mentor of Joerg Vogelsang, and Joerg himself, of course,
known in the field of corrosion. There are any number of us who
our past EFC President, the multifaceted and indefatigable
regard Jack as the most generous man we have ever met and
student of materials science, investigator, and leader, a rock
even people like U.R. Evans and Sam Hoar would not have been
climber in the Alps, a successful applied researcher and, not last
as productive as they were, had it not been for the help Jack had
nor least, a loyal and cheerful friend.
given them.”
Some prominent examples of interest in protective coatings
In the framework of non-academic research, I became familiar,
inside the University world were to be found, obviously, in the UK,
and I would say friend, of Carlo Lavezzari. An industrialist, senator,
following the leadership of Evans and of J.E.O. Mayne: Douglas
patron. Outside his field, he became worldwide famous in 1978 for
Mills, Stuart Lion, Tim Burnstain, and David Scantlebury.
having been kidnapped by the famous criminal band of Francis Turatello. He was freed after twenty days mainly thanks to an intelligence network built up by his own staff. His staff adored him. His life spanned over the story of the new Italy built after Fascism. The son of a poor country family, at the age of 18 he fought as a
At present, industrial coatings look like a mature technology where durability and reliability play a role in competitiveness, whereas advancements are seldom the object of promotion. Globalization and the concentration of brands are contributing to the relative disappearance of companies from international conferences.
Partisan in the Catholic bands. Just before the end of the war, all his family was murdered by a criminal band of Red partisans (I will not comment on this: those were the hardest times). He survived pretending to be dead with a bullet in the head (which he kept all life). He graduated in Engineering while driving an old Dodge truck and selling recovered iron from war wreckage. He understood the importance of steel sheets and, above all, of both galvanized and pre-painted steel (coil coating). In brief, he was able to build the “shaped steel” industry, including pipes and even cars. Together, we went to the USSR, in Togliattigrad, intending to introduce innovative pre-treated iron sheets in the manufacturing of their Lada-Vaz Žiguli cars. Gigi once told me: “Everything one does in life must be linked to beauty to some extent.” His office and his house had their walls covered by skillfully selected paints. He also built an art gallery and, among others, sponsored an exhibition of Chagall paints and drawings. In the end, he made an offer to the Maestro and bought the whole set.
JANUARY 2024 | CORROSION PROTECTION
39
VOICES
Jack O Mayne
Carlo Lavezzari
Giordano Trabanelli
Leo Cavallaro
On my first steps
with empirical means, with the will of daring – whereas today
It is dangerous to allow an old man to talk. You know when he
such a myriad of papers are presented by Chinese and Korean
starts, but not when he will stop. I was asked to talk about the
researchers.
people I met, I knew, I heard of in the world of corrosion. I have
In 1963, the Director of our Institute of Chemistry in Ferrara, Leo
started this account from 1971, my own Damascus conversion to
Cavallaro, died at the age of 58. We used to refer to him as “the old
the religion of coatings. However, I had been involved in corrosion
champ”… He crossed my life very briefly, but his work left a mark in
science and technology, as well as in corrosion control since
the European network of corrosion scientists. At this point, I must
about 1961 – although in 1958, I already knew that this had to
name another great man, both a metallurgist and a patron: Aldo
be my career. When I started to study Chemistry, my tutor was
Daccò, a rich, enlightened, generous metallurgical industrialist
Professor Giordano Trabanelli, nicknamed “the Titan”. He was
and a designer of boat engines. During his term as the Chairman
a man of deep Catholic faith, an austere, upright Catholic. At a
of the Italian Association of Metallurgy, together with Cavallaro,
time of fights between Communism and the Church in Italy, he
he founded and sponsored the Aldo Daccò Corrosion Research
was an example of great charisma. I had known him since my
Center, the first successful example of a public-private enterprise
childhood, but when he became my tutor, he insisted we address
and the first School of Corrosion Technology in Europe (I believe).
each other extremely formally. His deep sense of justice, his intellectual honesty excluded any form of privilege or personalism. Not an easy man, but a perfect teacher and an inspiring Master. His work on inhibitors was outstanding. His Symposia in Ferrara (Italy) attracted many Texans, Russians, and Arabians in search of the magic way to spare their steel oil wells. Cars began to have their water cooling systems protected during my graduation thesis. Beyond his field of expertise, inhibitors, Trabanelli was an innovator, a pioneer, a curious person. He was mastering the first potentiostats, the first oscillographs to study transients (speaking of which, I cannot avoid mentioning Luigi Grifone, the President of the AMEL factory, a brave entrepreneur with the “virus” of research, as well as a cultural humanist: for years, he built the best instruments for electrochemistry and corrosion), the semiconducting properties of corrosion products at the time of Gerisher, Myamlin, Pleskov, the photopotentials studied
40
CORROSION PROTECTION | JANUARY 2024
"It is dangerous to allow an old man to talk. You know when he starts, but not when he will stop. I was asked to talk about the people I met, I knew, I heard of in the world of corrosion. I have started this account from 1971, my own Damascus conversion to the religion of coatings."
VOICES
Thomas Percy Hoar
Front to back, left to right: (first row) H.H. Uhlig, M.G. Fontana, F.L. LaQue, M.C. Bloom, (second row) Z.A. Foroulis, M. Cohen, T.P. Hoar, R.C. Carlston, (third row) J.D. Sudbury, M. Pourbaix, D. Robertson, H.L. Logan, J.J. Harwood, (fourth row) T.P. May, H. Leidheiser Jr., E.H. Phelps, (fifth row) R.M. Hurd, F.W. Fink, R.T. Foley, H.T. Yolken
Pourbaix’s Christmas greetings postcard
Trabanelli led the Centro up to his retirement, and I am proud to
In 1949, knowledge was not so advanced, when Herbert Hulig
consider it my springboard and the nest where I got the “virus”
asked the United Nations for funds for more extended studies on
that enables me to treat heavily rusted wrecks as fascinating. The
corrosion science. Yet, he had already published his Corrosion
Symposia on inhibitors (SEIC, held every five years since 1960)
handbook, which is still like a Bible for us, while all over the world
were attended by all world gurus in the field and I was involved as
corrosion studies were already being conducted by people I have
a “valet” to take care of many of them, who became familiar faces
never had the chance to meet: Whitman, Tafel, Evans, Langelier,
and respected colleagues in the following years.
Frumkin, Kirkov. Their achievements actually concerned corrosion
It was not so with Thomas Percy Hoar (Tippy), who died in 1978.
science, but corrosion technology and especially corrosion
In 1965, I took him to lunch as a “valet” and it was clear that he
protection were still far away. Metal industrialists shouted to
was also an expert in both food and beverages: his culture in
Evans: “You guys stop fighting corrosion: we need to sell!”.
terms of cheese and single malts was universally renowned.
Two of those people of the “thirties” I had the chance to meet
He often looked like he was sleeping during talks but after the
were George Chaudron and Marcel Pourbaix. With the latter in
applause, you could be sure that his questions would have
particular, I had a warm, friendly relationship. Marcel Pourbaix was
been sharp and focused. After being awarded a PhD by the
my idol in the 1960s because of his creation: the CEBELCOR, an
University of Cambridge, Dr. Hoar conducted detailed research
outstanding laboratory where not only science advancements,
into the corrosion mechanisms of tin and tinplate in neutral and
but testing methods, rules, and standards were developed. It was
acid solutions, which among other things led to the process
so renowned that, although private, it was one of the founding
of chromate inhibition for tinplate and the recognition of the
institutions of CITCE, later named ISE, International Society of
importance of steel-base compositions, as demonstrated in one of
Electrochemistry. Pourbaix was a man of culture, a musician, a fan
the early applications of statistical analysis to corrosion research.
of Ravel. “Gaspar de la Nuit” was played when he passed away at
However, I would like to remember him mainly for the (still?)
the age of 94. He was a strong little man full of feelings: I saw him
famous Hoar report. The original survey on the cost of corrosion,
crying when I told him that, contrary to his knowledge, his (and
the “Hoar Report”, was commissioned in 1966 by the British
my) friend Patrizio Gallone was still alive. I would also like to spend
Parliament and estimated that the cost for the UK economy was
some words for Patrizio, the father of the Chlor-soda industry, a
between 3-4% of GNP per year. Similar surveys undertaken in the
European gentleman: Italian father, Irish mother, both French and
USA and Japan shortly afterwards also calculated similar annual
German education. It was a privilege to work with him in one of my
costs. Nowadays, the fact that the social cost of corrosion is still
exciting adventures in the field of electrochemistry. He was the
so high shows that the awareness of its danger is still far from
President of ISE and organized the ISE Meeting in Venice, where
being widespread and effective. Knowledge of corrosion is almost
I first met Koloturkin, the Director of Karpov Institute Moscow.
total, but it is a privilege of a few.
Going back to Pourbaix, he was a Belgian born in Russia by
JANUARY 2024 | CORROSION PROTECTION
41
VOICES
chance in 1904. In 1938, he introduced his famous theory of E/pH diagrams in his PhD thesis. It was not easy to get it understood and appreciated in the academic environment. Only after the war did it actually achieve universal consensus. Since then, he was so happy about his discovery and so proud to show and explain it in detail on any occasion that academic Georges Chaudron, his tutor for his PhD thesis, used to nickname him “bolero” like the obsessive music of Marcel’s beloved Ravel. His “Atlas of E/pH diagrams” is the best link between thermodynamics and kinetics – between possible and feasible. His theory of pitting breakdown potential enhanced the use of passivable alloys. My path crossed again with Georges Chaudron (nicknamed “le chaton”) as his effigy was placed on the medal I got from CEFRACOR in 2001. The events that have led me to get some of the awards I have received are strictly linked to some of the people whom I have met and who have pushed me with both example and help. One of the most important was Jos Weber, a great technologist, a leader, the
Marcel Pourbaix with Evans in Cambridge
Materials Manager at company Sulzer. We met in Budapest, at Corrosion Week, in 1974, and from then on Jos was always a shade behind my shoulders at every step, including my nomination as the President of EFC. He was an innovator and a promoter of so many activities in the field of corrosion, of testing, of education, of innovation. I consider him the best example of the synergistic fusion of science and development, of culture and technology, of joy of living and hard work. When I met him at the Corrosion Week in Budapest, the plenary lecture had to be delivered by Yakov Koloturkin, the Director of Karpov Institute. However, he did not come and he was replaced by Pourbaix. I would have been curious to meet him, the only Russian corrosion specialist who had never attended the SEIC in
The CEFRACOR golden medal
Ferrara. Russians were the welcome guests of Cavallaro, who used to take the few, old, precious instruments the Institute owned out of the closets on those occasions… I actually met Koloturkin later on, in 1980, at ISE Meeting in Venice. From my close friends Lajos Meszaros and Tibor Garai (I will talk about them in a while), I learned that he was not only the Director of Karpov Institute and a “Red Star” Deputy in Moscow but also the Director of a hidden Institute where research was much more secret. He died of a heart attack. He used to take a long cold bath every morning. Was there any link? In Venice, I also met Raphael Agladze. He himself later told me the following story. In the late 1930s, as a young research fellow of the Karpov Research Institute of Moscow, he published a paper about the electrochemical production of pure manganese in the laboratory. One night, at the beginning of WW2, a loud
Jos Weber receiving the 1991 European Corrosion Award
knocking at his door announced a visit by the KGB. As it is easily understandable, his frightened thoughts went to Gulags (and he hid all his rubles in an internal pocket of his overcoat...) but
42
CORROSION PROTECTION | JANUARY 2024
VOICES
actually, after a long Daedalic detour on a big black car, at 3 a.m.,
It is now time for me to introduce the memory of Lajos Meszaros.
he found himself in front of Stalin, surrounded by the whole
His life was practically the opposite of the ones I have just
Politburo. “Are you Raphaelin, the son of Elia Agladze, my Georgian
mentioned. A great mathematician, an experimentalist, a humanist
childhood friend?” “I am.” “Are you able to produce manganese?”
of wide, deep culture, a leader in a sense. He never accepted
“I got some grams.” “I need some tons in two months.” “But...”
the political situation in Hungary, he never spoke a word of
“With this paper and my signature, you can get all the means you
Russian, and he was never allowed to get a higher role than that
need.” Raphael went to Georgia (where there are rich manganese
of “technician”. Yet, he succeeded in managing the research plans
ore mines, besides several wineries), took all the huge grape
of his laboratory from behind the scenes. Science, art, music,
stomping barrels he could find to build electrochemical cells, got
literature, his cigarettes, the paleolithic Moskvich car with which
the required power sources through flights from trans-Uralian
he used to reach his dream country: I remember his childish joy
factories, and produced the first tons of pure Mn, with which
during his visits to Ferrara, to Genoa, to Trento. “Tutto è buono a
the ballistic steel needed for USSR’s tanks and hence the tanks
Italia”, was his awkward-Italian motto.
themselves were made available. Stalin had not followed the
Following Patrizio Gallone during his term of Presidency at ISE
advice of his own intelligence about the need for such metal
in 1976-1983, I practically lived inside the International Society of
before. Raphael Agladze (1911-1989) then got the Stalin Prize and
Electrochemistry, studying a flow-bipolar cell for purifying water.
became a scholar, first in the USSR and then in Georgia. A great
Professor Gallone developed his activity in the field of applied
scientist and a great technologist, he was the founder and the
research.
director (1956-1960) of the Institute of Applied Chemistry and Electrochemistry (now the Raphael Agladze Institute of Inorganic Chemistry and Electrochemistry). This is one of the least known of the very many adventures that have occurred in the world of electrochemical engineering. In Venice, he asked me to welcome his younger son George in my Laboratory in Genoa, which I did and, I suppose consequently, in 1983 I was invited as the only foreign researcher and a personal guest of Koloturkin at the USSR Conference of Electrochemistry, and then in Tbilisi as the personal guest of the Agladze family. Tamaz Agladze, his elder son, was a prominent scientist and a wise politician. His charming wife Marina was the daughter of the
"The events that have led me to get some of the awards I have received are strictly linked to some of the people whom I have met and who have pushed me with both example and help."
pianist Neuhaus and the adopted daughter of Boris Pasternak.
Portrait of Yakov Koloturkin
Rafael, George (Gogy), and Tamaz Agladze
Left to right: T. Garai, L. Meszaros, Academician A. Devaj, a student, P.L. Bonora, B. Lengjel
JANUARY 2024 | CORROSION PROTECTION
43
VOICES
Digby MacDonald
Roger Staehle
Susan Smialowska
His work was documented by various publications not only in
as flint. He joined SEIC in Ferrara while I was carrying out my
electrochemistry but also in electrotechnics and radiology. For more
graduation research and gave me remarkable advice. I remember
than twenty years, he worked for electrochemistry company Oronzio
Roger’s three worlds, i.e. A) a world with corrosion costs as they
De Nora. He was not only its Director of Research, but he also led
are, B) a world with minimized corrosion-related costs, and C) an
important industrial projects, including the realization of some of the
imaginary world without corrosion, resulting in as follows:
biggest electrochemical plants in the world. Besides the industrial
A – C = costs of corrosion, our fault
applications of electrochemistry, Professor Gallone also dealt with
A – B = realm of awareness, education, standards
metal corrosion and cathodic protection issues. He wrote two books
B – C = realm of research
that were appreciated not only in Italy but abroad as well: Principles
I met him for the first time in Ferrara, when he visited the
of Electrochemical Processes (1970) and Treatise of Electrochemical
laboratory where I was learning how to use the first Italian (AMEL)
Engineering (1973).
potentiostat in 1960.
Following Patrizio as his Assistant during this period, I met the
Let me now talk about a few women. It is not a bad topic, at
whole electrochemistry and corrosion Gotha. I recall Gosta
the end of the day... There are not many renowned women in
Wranglen and his fight to convince the USSR to allow Veniamin
corrosion, but this is mostly due to overwhelming machismo
Levich to leave the country, although it was Gallone, with his soft
since, if one looks at the technical literature or the audiences at
Italian diplomacy, who succeeded in this (officially, it was thanks
conferences, many outstanding women are there to be found.
to Edward Kennedy’s recommendation, but that was publicized for a matter of image. For the whole official story, please refer to “Electrochemistry in a divided world”, F. Scholz, Ed., Springer, 2015). I also remember Digby MacDonald, who used to give consults on corrosion in the US travelling on his own plane: undoubtedly the most authoritative mathematician in our field, but also a nice companion at the table, as I experienced during a meeting on the Mediterranean coasts of Apulia during which we “fought” together against a grilled monster sea bass. Digby’s work involved electrochemistry, thermodynamics, and corrosion science, with an emphasis on the growth and breakdown of passive films, the chemistry of high-temperature aqueous solutions, electro-catalysis, advanced batteries and fuel cells, stress corrosion cracking and corrosion fatigue, materials for nuclear power reactors, and the deterministic prediction of localized corrosion damage. On many occasions, I encountered Roger Staehle, the Editor of Corrosion (Nace) magazine, whose editorials were hard and sharp
44
CORROSION PROTECTION | JANUARY 2024
From the metaphysic approach to corrosion (ferrum corrumpitur) of Pliny the Elder to our present time, an unbelievable amount of materials and structures marks the difference. What has remained from his times are merely marble, stones, bricks, some bronze, some gold. What will remain of our times are the objectives of those people in corrosion control, many of which I am proud to have met.
VOICES
About the author: Pier Luigi Bonora
Erika Kalman
Pliny the Elder
Chemist, Master in Corrosion Science and Technology, Full Professor of Materials Corrosion and Corrosion Control, Past President and Honorary Fellow of the European Federation of Corrosion, European Corrosion Award of EFC and Gold Medalist of the French Corrosion Society, founder of the Working Party “Coatings” of EFC. His main interests include coatings, electrochemical methods in corrosion research, design and corrosion control, failure analysis, and cathodic protection of on/off-shore structures.
I am going to mention three of them: Susan, Erika, and Dora.
years as Editor many contributors came to know Dora Brasher
Susan Smialowska attended SEIC in Ferrara and I met her there,
as a friend, and very many more – especially those for whom
although I only got to listen to her talks. In 1977, however, at ISE
English is a foreign tongue – have had cause to be grateful for the
Meeting in Varna Bulgaria, we had some long, interesting talks,
evenings and weekends that she spent editing, even to the point
and I was admired by her curiosity, her enthusiasm for her next
of rewriting, papers that she felt were of scientific or practical
visit (she hoped to stay, and she did!) to the Mars Fontana Center
value but were not in clearly understandable English”. I was one
of Columbus, Ohio (USA). She became an outstanding person
of them. Dora spent one full day with me – while sharing some
there and I was often in touch with her, attracted by her work on
sandwiches – to analyze and correct my two papers. Dora Brasher
localized corrosion, on inhibitors, on hydrogen embrittlement…
spent her career at the National Physical Laboratory of Teddington
and by her smile, her brightness, her elegant Slavic charm. She
(UK), the same NPL where Hoar’s idea for sparing money through
passed away a few years ago. I am proud to have met her and I
widespread anti-corrosion procedures was practically developed.
regret we had not enough time to be friends.
NPL was the school for a lot of smart corrosionists, including Tony
Incidentally, a few years before, in the 1960s, Francesco Mazza
Mercer, Paul McIntyre, and Alan Turnbull.
had also worked in Ohio, a good friend of mine (after having been a teacher and an admired Master): he was a young researcher at
I would like to conclude my excursus by mentioning the whole
that time, but he became famous for having grasped the reason
crowd of people who, over the last sixty years, have been fighting
for the explosion of fuel tanks in the Apollo project. The fuel used
the battle of corrosion control and protective paint aimed
was pure methanol and the tanks were made of titanium. Methanol
at durability and reliability, environmental compliance, and
was wholly dehydrated, so that the least amount of water
sustainable costs and battling to provide coatings with innovative
indispensable for titanium passivation was absent – an excess of
functions (touch your smartphone display!) and spend time,
zeal, and so much for common sense.
knowledge, and dedication to widespread corrosion knowledge.
Erika Kalman was a person it was impossible to ignore.
From the metaphysic approach to corrosion (ferrum corrumpitur)
Hyperactive, curious, committed, with that touch of narcissism
of Pliny the Elder (whom I did not meet) to our present time,
that can help a lot, aggressive in science and friendly possessive in
an unbelievable amount of materials and structures marks the
human relationships. An organizer, a builder, a leader, a strategist,
difference. What has remained from his times are merely marble,
a cultured person, with a cult of family and friends. I would like to
stones, bricks, some bronze, some gold. What will remain of our
spend no words on her outstanding scientific and professional
times are the objectives of those people in corrosion control,
achievements, but to warmly honor the memory of her naturally
many of which I am proud to have met.
friendly openness to share both feelings and interests. The papers I wrote in France in 1974 were submitted to the British Corrosion Journal and Miss Dora Brasher, the forerunner of all studies on organic coatings, was its Editor. When she retired
Acknowledgments: Agnese, Vincenzo, Giacomo, Lucio, Lorenzo,
in 1980, a praising editorial mentioned: “…during her thirteen
Flavio, Stefano, Luca, Maria, Vesna, Ilario, Ula, and others. ‹
JANUARY 2024 | CORROSION PROTECTION
45
© Tiqets
RESEARCH BREAKTHROUGH
Development of novel and cost-effective corrosion resistant coatings for high temperature geothermal applications by Dagur Ingi Ólafsson and Baldur Geir Gunnarsson - Tæknisetur (IceTec), Reykjavík, Iceland Helen Ósk Haraldsdóttir, Kolbrún Ragna Ragnarsdóttir, and Sæmundur Guðlaugsson - Orka Náttúrunnar (ON Power), Reykjavík, Iceland Francesco Fanicchia, and Namrata Kale – TWI Ltd, Cambridge, United Kingdom
46
CORROSION PROTECTION | JANUARY 2024
RESEARCH BREAKTHROUGH
G
eo-Coat (www.geo-coat.eu) is an EU-funded collaborative project that has investigated newly developed coatings and Metal Matrix Composite bulk materials for use in high erosion and corrosion
environments. Specifically, the project has focused on improving the lifetime of materials used in plants for geothermal energy production by the use of specialized coatings. In 2021, at the end of this project, it was decided to coat a turbine component with one of the most promising coatings developed, the LMDHEA2 coating, and to have it tested in-situ at Hellisheiði power plant, the eighth-largest geothermal power station in the world and largest in Iceland. A diaphragm, made from A470 steel, was sectioned and a part of the section laser cladded with LMDHEA2. The part was then exposed in geothermal environment for a 8-week period and afterwards analysed for corrosion.
Materials and methods Materials A turbine diaphragm section made of A470 steel was laser cladded with the LMD-HEA2 high-entropy-alloy coating solution developed in Geo-Coat. To prevent cracks from forming in the coating, the substrate was preheated prior to deposition and the cooling of the part after deposition was controlled. Three sections of the turbine part were coated as can be seen in Figure 1. Patch C was subsequently chosen for testing in-situ at ON Power, the company which owns and runs the Hellisheiði power plant.
The Geo-Coat project1 began in 2018
© ON Power
with the goal of developing cost-effective, novel corrosion-resistant coatings for high temperature geothermal applications. We report the results of the in-situ test of an LMD-HEA2 coated turbine component section in geothermal environment. This project has received funding from the European Union's Horizon 2020 research and innovation programme. Grant agreement 764086.
1
Figure 1 - Turbine component for testing at ON Power with three coating areas.
JANUARY 2024 | CORROSION PROTECTION
47
RESEARCH BREAKTHROUGH
Test conditions The sample was tested in an aerated pressure vessel at
not represent the conditions turbine diaphragms are generally
Hellisheiði power plant. The aerated test equipment was
exposed to as the fluid composition is different and erosive
designed, manufactured, and used to test the coatings in a highly
effects were not generated in the pressure vessel. This
corrosive aerated environment (Fig. 2). The aerated equipment
environment is however quite aggressive due to the presence of
simulates the conditions materials experience in the axial seal
oxygen which sped up the corrosion process. This was considered
system suction path in geothermal powerplants. This is a pathway
a good starting point to provide the first observations on how
where steam coming from the turbine in sub-atmospheric
this combination of coating and substrate on an actual turbine
pressure conditions is sucked away from the last stage of the
component behave in corrosive geothermal environment.
geothermal turbine. In this location, steam and ambient air
The sample was situated in the equipment for 8 weeks,
mixes and creates a very corrosive oxygenated environment.
experiencing significant oxygen-induced corrosion during the
Additionally, the aerated pressure vessel simulates to a certain
exposure period. The experimental conditions can be seen in
extent the corrosive environment found in hot production
Table 1. Chemical sampling data of the fluid inside the equipment
water piping prior to de-oxygenation. This environment does
is presented in Table 2.
Figure 2 - The aerated pressure vessel equipment in operation.
Parameter
Value
Unit
Liquid analysis (w/electrodes and titration)*
Value
Exposure time
2
Months
Cl [mg/kg]
0.35
Temperature
90
[°C]
F [mg/kg]
0.072
Pressure
1
[barg]
SO4 [mg/kg]
3.7
pH
4.9
Air
492,3
[l/kg]
Table 1 - Experimental conditions of the aerated pressure vessel test.
48
Figure 3 - The sample after transferral to IceTec.
CORROSION PROTECTION | JANUARY 2024
* Sampled 31st of January 2021
Table 2 - Chemical sampling of the fluid within the aerated pressure vessel.
RESEARCH BREAKTHROUGH
Geo-Coat is an EU-funded collaborative project that has investigated newly developed coatings and Metal Matrix Composite bulk materials for use in high erosion and corrosion environments. Results Overview After testing, the sample was transferred to IceTec, where it was inspected and subsequently analysed for corrosion in an optical and scanning electron microscope. The sample was heavily corroded around the coated patch, and the A470 base material showed strong discolouring, rust patches and flaking of the material. Meanwhile, the coated patch seemed to have resisted the conditions significantly better. The edges of the coated patch were discoloured while the central parts seemed much less affected, with some small, yellow-brownish dots here and there. This indicates corrosion of the base material underneath the edges of the coated patch. It is also possible that the discolouring of the coated part of the sample is rust that has migrated from the base material surface onto the coating (Fig. 3). Surface analysis The surface of the sample was analysed using a scanning electron microscope (SEM) with energy dispersive X-ray spectroscopy (EDX). The bare A470 substrate was found to have iron-oxides covering the surface, as could be seen from optical inspection.
From the top: Figure 4 - Scanning electron microscopy image of the bare substrate surface. Figure 5 - SEM image of the coated surface of the sample, showing spherical sputter on the coating. Three areas and one point were chosen for elemental analysis. Table 3 - Elemental analysis of sites shown in Figure 5.
LOCATION ELEMENT (WT. %)
1
2
3
4
C
9.1
7.85
6.88
5.9
O
29.14
28.98
19.52
30.62
Si
1.21
0.62
-
0.68
S
0.75
0.66
-
-
Ti
0.17
0.22
0.16
0.29
Cr
13.79
23.17
19.7
32.35
Mn
0.54
-
-
2.69
Fe
23.96
15.43
14.43
15.79
Co
6.43
6.92
11.83
3.35
Ni
6.49
7.45
11.64
3.09
Mo
8.41
8.69
15.84
5.25
JANUARY 2024 | CORROSION PROTECTION
49
RESEARCH BREAKTHROUGH
The rust layer was cracked and, in some places, grainy (Fig. 4).
surface of the coating. Meanwhile, the bare base material had
EDX analysis of the coated surfaces showed most of the coating
thick patches of iron oxides on its surface due to the interaction
having reacted to the oxygen-heavy test conditions by forming
with oxygen. Corrosion was found to have started to penetrate
a thick chromium-oxide layer on top of the coating. Some iron
slightly underneath the coating at the coating-substrate interface.
oxides are also seen on the surface. The coating surface was
The substrate under the coating away from the interfaces was
grainy in places, littered by spheres of coating material from the
found to be unaffected by exposure while the bare substrate
cladding process. Some of these spheres seemed to have formed
was heavily affected (Fig. 6). At the coating-substrate interface,
iron oxides on their surfaces (Fig. 5 and Table 3).
corrosion was seen to have occurred underneath the coating itself, emphasizing the importance of good coating coverage
Cross-sectional analysis
and prevention of cracks in the coating during manufacturing.
A cross-sectional sample was cut from the larger piece and
In addition to corrosion of the underlying substrate, the coating
analysed with an SEM and EDX. The cross-sectional analyses
composition at the intersection was found to have much larger
confirmed the formation of thick chromium oxide layers on the
portion of iron in comparison to the other four elements that
Figure 6 – i) Cross-section of the coated sample, showing the coating and the underlying substrate, ii) surface of the exposed substrate, showing a rust layer on top of the A470 steel up to 75 μm thick as well as pits.
Figure 7 - EDX analysis of the coating-substrate interface, showing locations marked for chemical analysis.
50
CORROSION PROTECTION | JANUARY 2024
Figure 8 - SEM image of the surface of the coating, showing spherical artifacts from the cladding process along with chromium oxide layer.
RESEARCH BREAKTHROUGH
LOCATION
LOCATION ELEMENT (WT. %)
1
2
3
4
C
6.52
9.91
3.26
6.89
O
-
30.45
31.10
-
Si
0.18
0.21
2.28
0.22
0.26
S
-
0.15
-
-
0.49
-
Ti
-
0.22
0.81
-
3.15
-
-
Cr
12.81
50.26
57.28
17.16
Mn
0.33
4.67
2.62
-
64.87
63.85
67.28
94.59
Fe
31.88
3.55
2.32
17.25
3.71
9.11
-
0.73
-
Co
14.49
-
-
17.63
Ni
1.26
9.95
-
0.78
-
Ni
14.27
-
-
17.52
Mo
1.85
9.78
1.39
1.42
-
Mo
19.52
-
-
23.34
Ca
-
0.22
-
-
Mn
-
-
0.08
0.62
0.78
Al
-
-
0.32
-
ELEMENT (WT. %)
1
2
3
4
5
C
5.34
6.29
3.64
4.41
4.37
O
26.46
-
26.95
22.84
-
Si
0.21
-
0.29
1.42
S
1.30
-
0.13
Cr
0.29
-
Fe
59.59
Co
Table 4 - Elemental analysis of locations marked in Figure 7.
Table 5: Elemental analysis of locations marked in Figure 8.
make up the LMD-HEA2 coating. This could be due to diffusion of the elements out of the coating or simply an artifact of the cladding process. An SEM image, showing EDX analysed locations can be seen in Figures 7 and 8 along with the elemental analysis itself in Tables 4 and 5.
Conclusions Based on the corrosion analysis results performed on the LMD-HEA2 sample described in this report, the following conclusions can be summarized for the coating: The coating showed good resistance to the corrosive effect of the oxygenated test environment which it was subjected to for 8 weeks. The substrate underneath the coating was not affected by the hostile environment, apart from areas underneath the coating at the coatingsubstrate interface, as the coating did not cover the whole part. The bare and exposed A470 substrate suffered heavy corrosion, with rust layers up to 75 μm in thickness on top of the substrate. The top, exposed, surface of the coating was mostly covered in a chromium-oxide layer, protecting the coating from the oxygen heavy environment. The coating shows good corrosion resistance to this environment indicating its usefulness for service in this and similar oxygen-heavy environments. ‹
After a 8-week period of the part being exposed to geothermal environment, the coating showed good corrosion resistance for high temperature geothermal applications, and in similar oxygenheavy environments. JANUARY 2024 | CORROSION PROTECTION
51
ADVANCEMENTS
HEMPEL LAUNCHES LEADING INTUMESCENT COATING ESTIMATION SOFTWARE By Joanna Ashmead, Hempel A/S – Lyngby, Denmark
Hempel has announced the launch of HEET Dynamic, an innovative new coating software specially designed to make intumescent coating estimations on steel sections quicker, easier and accurate for structural engineers and estimators.
H
Easy to download and simple to use, HEET Dynamic is up to date with latest industry standards, providing an innovative software that makes light work of complex situations. Using in-built calculators for automated thickness and volume calculations, HEET Dynamic features a simple copy and paste functionality to give the user full control.
Key features of HEET Dynamic HEET Dynamic includes section factor calculations, default limiting temperatures, cellular beam calculations, a customisable user interface and project dashboard with libraries feature. These
empel Engineering and Estimation Technology ‘HEET’
combined features deliver efficient calculation accuracy, without
Dynamic empowers users to make efficient and
the need for overly complex technologies.
effective fire protection decisions quickly and easily,
For advanced users, the HEET Dynamic licence can be upgraded
offering up to 10 times faster calculations, without
using a feature called Structural Fire Design. The SFD upgrade
consulting third party engineering services or PFP (passive fire
allows suitably qualified engineers to flexibly calculate project
protection) coating providers.
specific design temperatures, leading to overall cost savings and
Built with the user in mind, Hempel’s HEET Dynamic software
increased productivity. In addition, the optimised PFP volume
automatically performs volume calculations with 100% estimation
and thickness calculations require less materials and utilise best
accuracy to detail the intumescent coating required for a project.
engineering practices.
In accordance with location and design codes, calculations are
Another addition available with HEET Dynamic is its BIM
based on steel profiles, fire ratings and fire testing standards.
plug-in tool. This intelligent, modifiable tool allows users to
J&D Pierce (Contracts) Ltd, said: “It is a very good piece of software for our engineers and designers. It allows us a lot of flexibility when designing structures without the need to keep contacting Hempel”.
52
CORROSION PROTECTION | JANUARY 2024
ADVANCEMENTS
About Hempel As a world-leading supplier of trusted coating solutions, Hempel is a global company with strong values, working with customers in the decorative, marine, infrastructure and energy industries. Hempel factories, R&D centres and stock points are established in every region. Across the globe, Hempel’s paints and coatings can be found in almost every country of the world. They protect and beautify buildings, infrastructure and other assets, and play an essential role in our customers’ businesses. They help minimise maintenance costs, improve aesthetics and increase energy efficiency. At Hempel, our purpose is to shape a brighter future with sustainable coating solutions. We firmly believe that we will succeed as a business only if we place sustainability at our heart. Not only is it the right thing to do, it will strengthen our competitive position, make ourselves more resilient and reduce our risk. Hempel was founded in Copenhagen, Denmark in 1915. It is proudly owned by the Hempel Foundation, which ensures a solid economic base for the Hempel Group and supports cultural, social, humanitarian and scientific purposes around the world.
work seamlessly alongside BIM software, creating automated calculations for 3D models and construction details. This intelligent tool also facilitates information flow both ways for realtime design and estimation. A representative from Billington Structures Ltd, stated: “The new HEET Dynamic software is simple and intuitive to use and the SFD and BIM integration is very beneficial for our technical staff when designing various elements of our projects.”
HEET Dynamic at a glance Developed to accurately estimate intumescent volume calculations on steel sections Designed with estimators and structural engineers in mind 100% estimation accuracy Up to 10 times faster calculations Minimises the risk of coating failure with maximum accuracy BIM plug-in tool for 3D models and construction details Structural Fire Design upgrade available for advanced users Easy to download, simple to use. ‹
JANUARY 2024 | CORROSION PROTECTION
53
MEETING
THE INDUSTRY The countdown to IVS – Industrial Valve Summit 2024 has started VALVEcampus, the association that gathers Italian industrial valve manufacturers. The event analysed corporate innovation and sustainability issues, delving into the strategic perspectives of the energy sector, which is currently experiencing a phase of transformation. During the conference, the results of the Market Perspectives report on the Oil & Gas Industrial Valve Industry, carried out by Roland Berger, were presented. The report showed that in the Oil&Gas sector, the industrial valve industry enjoys a very positive outlook in the short to medium term, supported by solid demand. New projects that further extend the geographical reach of local companies, starting in the Americas, then in the Middle East and Asia,
I
will lead the development. In the two-year period 2023-2024, VS – Industrial Valve Summit, the most important
investment in new plants is expected to grow by an average of
international event dedicated to reference technologies and
16% over 2022 (USD 183 billion per year versus USD 158 billion),
flow control solutions, is only a few months away. The fifth
the year in which the global situation stabilised after the rebound
edition of the event, organised by Confindustria Bergamo and
in 2021 from the great contraction recorded in 2020. Despite the
Promoberg, will take place at the Bergamo Exhibition Centre, in
positive projections, investments in 2023 will stay below those of
Italy, on May 15th and 16th, 2024.
the pre-pandemic period (in 2019, USD 200 billion).
In view of 2024, the organisers are enriching the offer of events
As for alternative energy sectors, growth in hydrogen and CCUS
and opportunities for networking by creating a true valve
(carbon capture use and storage) is largely expected after 2030,
week, continuing along the event’s growth path. Starting on
with the largest share of investments in the Americas, Europe,
14 May with the opening ceremony, followed by the opening
and Asia. Demand in nuclear power is also solid, both in the
of the pavilions reserved to exhibitors, IVS will offer a valuable
short and long term.
opportunity for the players in the supply chain to meet and
In the long term, Oil & Gas is expected to experience an
discuss. The event will get into full swing on 15th and 16th May
increasing overcapacity of components compared to the market
with the halls opening the doors to the international public. In
demand. The price pressure is also expected to increase at the
2022, the Summit welcomed 12,000 visitors (+12% compared
same time. The growth sectors (in particular, those related to
to 2019) representing over 60 countries, marking a record
renewables) will only partly compensate for the contraction of
number of visitors, in addition to 300 exhibiting companies (+17%
the more traditional segments. For companies in the sector, it
compared to 2019) representing 12 countries.
will be essential to introduce a series of strategies focusing on
At the same time, the extensive calendar of conferences,
three pillars: more specialisation, product, and market; more
round tables, workshops, and laboratories of the IVS scientific
added value, moving from the production of components alone
programme will continue, proving to be a space where change
to entire solutions and systems; and more presence worldwide
can be interpreted and the latest technological innovations can
with offices and labs (local content). Objectives to be achieved
be explored, identifying and analysing the new challenges. And
through company size growth and aggregation, opening the
after the two-day exhibition, there will be a further opportunity for
market to new segments, products and services. A recipe that
foreign delegations attending the fair to meet the players in the
would enable European operators to withstand the growing
extended Oil & Gas supply chain on Friday 17 May.
pressure of global and, especially, Asian players.
th
th
Recently, important players in the industrial valve supply chain featured “IVS Valve Industry Think Tank”, the event promoted by IVS - Industrial Valve Summit in cooperation with
54
CORROSION PROTECTION | JANUARY 2024
https://industrialvalvesummit.com
MEETING THE INDUSTRY
MECOC 2024: Shaping the Future of the Oil and Gas Industry of sessions, and panel discussions led by recognized experts. MECOC 2024 is designed to equip attendees with valuable insights and strategic networking prospects, ranging from innovations in corrosion prevention to the latest metallurgy advancements and their direct applications in the oil and gas sector. In addition, MECOC 2024 introduces an exhibition alongside
T
the conference, serving as a vital bridge connecting technology he stage is set for the much-anticipated 3rd edition of the
providers and end-user companies. It showcases the latest
Middle East Metallurgy Corrosion and Coatings Expo
breakthroughs and innovative products. The exhibition’s primary
2024 (MECOC 2024), a transformative event that will
goal is to foster collaboration, accelerating technology adoption
unite industry leaders, experts, and enthusiasts from across the
for industry growth. This collaborative spirit defines MECOC
globe. MECOC 2024, scheduled to take place from 06 to 08
2024, shaping a more innovative, sustainable, and prosperous
th
th
February 2024 in Rixos Marina, Abu Dhabi, UAE, underscores
future for metallurgy, corrosion, and coatings.
our unwavering commitment to the critical role of Metallurgy,
“Our objective is to foster a comprehensive approach to industry
Corrosion & Coatings in shaping the future of the oil and gas
challenges,” said Romin Mathew, Director of MECOC 2024.
industry and beyond.
“We firmly believe that MECOC 2024 will serve as the ultimate
The central theme of MECOC 2024, “Shaping the Future of the
platform for the exchange of ideas, the formation of partnerships,
Oil and Gas Industry through Metallurgy, Corrosion & Coatings,”
and the exploration of solutions that will define the future of the
highlights the indispensable nature of these fields in ensuring the
oil and gas industry.”
integrity, safety, and efficiency of the oil and gas sector. These
MECOC 2024 is set to redefine the industry’s future, with
critical disciplines play a pivotal role in optimizing operations,
an anticipated audience of over 1000 attendees and 100+
enhancing asset longevity, and mitigating environmental impact.
Participating leading organizations, 60+ enlightening
MECOC 2024 features two significant conferences:
presentations, and a cutting-edge expo with 60+ exhibiting
STEEL & NON-METALLIC CONFERENCE: This conference
Companies showcasing the latest technological breakthroughs.
focuses on advancements and best practices in steel and non-
Registration for MECOC 2024 is now open. Join us in shaping the
metallic materials. Industry experts share insights into cutting-
future of the oil and gas industry through Metallurgy, Corrosion,
edge technologies and innovations.
and Coatings. Visit MECOC 2024 Website or contact us at
CORROSION & COATINGS CONFERENCE: This segment
+971 4 2790 800 for further information.
explores crucial aspects of corrosion prevention and the latest developments in coatings. Attendees gain valuable knowledge
About MECOC 2024
and strategies to protect critical assets in the oil and gas sector.
MECOC 2024 is the foremost Middle East Metallurgy Corrosion
MECOC 2024, guided by an esteemed committee comprising
and Coatings Expo 2024, dedicated to promoting innovation,
industry luminaries and experts from renowned organizations
fostering collaboration, and driving revolutionary change within
such as ADNOC, Sadara, Petronas, SABIC, Saudi Aramco, Saudi
the industry. Focusing on Metallurgy, Corrosion, and Coatings,
Electricity Company, OQ, Conocophillips, Sipchem, Borouge,
the event serves as a platform for industry leaders, experts, and
Qatar Environment and Energy Research Institute, RISE Kimab,
enthusiasts to explore the latest trends, technologies, and best
and MAADEN. This assembly of visionaries and decision-makers,
practices.
each with a wealth of experience, stands at the forefront of safeguarding the industry’s infrastructure and championing sustainable growth. Participants will have the privilege to engage in a diverse array
www.mecocmiddleeast.com
JANUARY 2024 | CORROSION PROTECTION
55
MEETING THE INDUSTRY
PaintExpo: exhibitors optimise the coating processes of the future
to products that are harmless and odourless. Unlike conventional solutions for treating exhaust air, this purely biochemical process needs very little external thermal energy, making it a costeffective method of treating solvent-charged exhaust air streams without needing to concentrate the pollutants first. In the case of hot exhaust air flows, waste heat recovery systems can be positioned upstream from the air treatment system to make use
T
of the excess heat and channel it into other processes. he industrial coating technology industry is increasingly focussing on sustainable and energy-efficient processes.
Optimising energy consumption in existing systems
This is reflected in the numerous technological
Among its customers in Europe, the company Eisenmann has
developments that exhibitors will be showcasing at PaintExpo
observed a shift from greenfield to brownfield projects. The
2024. These include energy-saving system concepts, applications
latter refers to efforts to save materials and reduce emissions
that use fewer resources and modern software that all help
by investing in modernisation and energy optimisation for
companies consume less energy, thus saving valuable resources
plants that, in some cases, are 25 to 30 years old. This is an
in their painting and coating processes.
understandable shift, given increasing prices in the energy-
At the upcoming edition of PaintExpo from 9 to 12 April 2024 in
intensive paints and coatings industry and the desire for cost-
Karlsruhe, for example, application and plant manufacturers will
effective value retention. Eisenmann addresses this by developing
be showcasing innovative solutions and products for greater
customised solutions that allow clients to conserve valuable
sustainability and energy efficiency. While exhibitors at the world’s
resources through the use of innovative products in a variety of
leading trade fair for industrial coating technology will be taking
fields. One example here is the company`s ongoing development
a variety of approaches, they will all be pursuing the same goal of
of conveyor technology in an important step towards painting and
optimising coating processes to use as little energy as possible,
coating processes that are skidless and therefore more energy
thereby protecting the environment.
efficient. Building on this success, the company then went on to develop VarioMover, a driverless transport system covering the
Energy-efficient, biological exhaust air treatment system
full automotive paint shop process.
AFOTEK, a coating systems manufacturer from Bad Hersfeld
paint-separation processes, offering an answer to the growing
in Germany, will be presenting its “AFOTEK Clean” biological
demand for alternatives to the wet paint-separation processes
exhaust air treatment system at PaintExpo 2024. “The systems
widely used in the past. The potential energy savings here are
dominating the market right now are thermal afterburners, which
huge, in part through the conversion of paint booth ventilation
generally need to be heated with gas. Our patented product offers
systems from fresh/exhaust to recirculated air modes of
an alternative by taking very little energy to break down pollutants
operation.
in air contaminated with substances such as solvents. This is
The SmartOven from Eisenmann delivers an outstanding energy
possible because the AFOTEK Clean breaks down materials
balance in the drying process while maintaining excellent paint
exclusively through biological oxidation,” says Kai Sinning, a
quality. The oven can be heated with electricity, gas, thermal oil or
member of AFOTEK’s Executive Board.
hydrogen, thus offering a great deal of economic latitude thanks
The key component of the biological exhaust air treatment system
to the wide selection of possible energy sources.
Eisenmann’s E-Cube is the ideal technology for efficient, dry
consists of two cylindrical reactor towers filled with a unique substrate. This substrate is then moistened using an agent that
Sustainable heat sources and modern software
has been enriched with nutrients. The mode of action is based on
The Swiss coating systems manufacturer e. Luterbach will be
aerobic microorganisms that oxidise carbon dioxide and water via
at PaintExpo 2024 presenting various ideas for making coating
a biochemical process that converts gaseous, organic pollutants
technologies and systems more sustainable. For drying and
56
CORROSION PROTECTION | JANUARY 2024
MEETING THE INDUSTRY
firing ovens, CEO and co-owner Fabian Luccarini envisions a
solutions for energy management, quality, efficacy and economic
renaissance of old heating media: “There’s a lot of talk about
efficiency in paint shops.
using hydrogen as a heating source but the physical parameters of existing ovens and systems make them impossible to retrofit.
Less material usage and process optimisation
Thermal oil, on the other hand, can be transported at a high level
WAGNER will be exhibiting its wide array of wet coating and
from a central district heating source to the places where it is
powder coating solutions at PaintExpo 2024. For wet coating
used. Currently, such projects are being driven forward.”
applications, the company’s focus is on sustainability as well as
Other developments promising greater sustainability and
reducing the amount of solvents, materials and energy used.
predictive maintenance can be found in the e. Luterbach software
Furthermore, the easy operability and optimised process control
and IT portfolio. The company has expanded its IoT portal,
of their products and systems make the coating process more
for example, providing predefined telephone calls and voice
productive. Exceptionally effective application and conservative
messages to alert responsible parties of any irregularities. The on-
use of materials are the hallmarks of the company’s many
site PLC makes real-time networking easier. Data are stored for
different manual and automatic airless, AirCoat and air spray
up to two weeks as an MQTT protocol and remain intact even in
guns. The new generation of high-speed rotation atomisers for
the event of internet or electricity outages.
solvent- and water-based coatings plays a major role in making
Development work on the PinCH software has also continued.
highly automated wet coating systems and robotic solutions a
“We can use pinch analyses to find the optimum pinch points
reality while at the same time focusing on using fewer resources.
between various energy flows with the aim of minimising the
The company supports this development with regular updates to
overall scope of investment and energy costs. The analysis is then
its control technology.
used in strategic planning to develop heat recovery measures
WAGNER has also made its pumps for wet coating significantly
aimed at improving the supply of energy. The potential reduction
easier to flush. The Cobra high-press double diaphragm pump,
in primary energy use can be as much as 40 per cent with a
for instance, has been optimised to dramatically reduce the
pinch analysis,” says Luccarini, explaining the advantages of this
amount of flushing agent, therefore also significantly cutting the
system-oriented method.
amount of time needed for changing colours. The highly efficient processes employed in WAGNER 2K systems help to reduce the
Efficient, environmentally friendly painting processes
environmental footprint of the coating process.
SEHON Innovative Paint Systems offers an extensive product
planning projects, taking a holistic approach to finding the ideal
and service portfolio for sustainable, environmentally friendly
system for each coating job, thus optimising surface quality on
and efficient painting processes. Customers building new
the one hand and resource usage on the other.
WAGNER assists its customers in designing systems and
systems or modernising existing ones regularly contract SEHON to future-proof overall operations in terms of energy use and
About PaintExpo
sustainability. As a result, paint shops will need only a fraction of
At PaintExpo 2022, around 430 exhibitors from 27 countries
the energy consumed in the past and may even achieve energy
presented their products and services and more than 9,000
self-sufficiency. As CEO Tiemo Sehon notes, “Environmental
trade visitors from 57 countries attended. The next edition of
protection, energy savings and sustainability have been part of
PaintExpo will take place from 9 to 12 April 2024 in Karlsruhe. The
our product and corporate philosophy for over 40 years. Even
world’s leading trade fair for industrial coating technology serves
before we receive a contract, we give our customers precise
as a showcase for innovations, applications, future technologies
written facts, figures and data showing the positive impact of
and trends in all areas of the coating industry. PaintExpo will
sustainability measures. This goes well beyond just the theoretical
cover the entire range of international products and services
targets. It allows our customers to budget precisely for every
in the industrial coating technology supply chain. This global
planned sustainability investment and maximise the amount
get-together of companies from the industry is unparalleled
of state grants they receive. When it comes to paint system
worldwide, making it highly attractive for coating service providers
technologies, painting processes or entire facilities, it’s always
and in-house coating companies from around the world.
worth talking to us when you are building from scratch, retrofitting equipment or modernising.” SEHON will also be at PaintExpo 2024 showcasing its innovative
www.paintexpo.de/en/
JANUARY 2024 | CORROSION PROTECTION
57
EDITOR IN CHIEF ALESSIA VENTURI venturi@ipcm.it
an ipcm® magazine
EDITORIAL OFFICE PAOLA GIRALDO giraldo@ipcm.it
EDITED BY
MONICA FUMAGALLI fumagalli@ipcm.it MATTEO SOTTI sotti@ipcm.it ILARIA PAOLOMELO paolomelo@ipcm.it GABRIELE LAZZARI redazione@ipcm.it
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MEDIA SALES FRANCESCO STUCCHI stucchi@ipcm.it
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GRAPHICS ELISABETTA VENTURI grafico@ipcm.it
EDITORIAL BOARD Annalisa Acquesta, University of Naples
Jérôme Crouzillac, BAC Corrosion Control
Francesco Andreatta, University of Udine
Marina Delucchi, University of Genoa
Mehdi Attarchi, Senior Materials & Corrosion Specialist
Sergio Lorenzi, University of Bergamo
Andrea Balbo, University of Ferrara
Tullio Monetta, University of Naples
Hadi Beirami, Cathodic Protection Certified Specialist
Tomáš Prošek, University of Prague
Maria Bignozzi, University of Bologna
Edoardo Proverbio, University of Messina
Stefano Caporali, University of Florence
Stefano Rossi, University of Trento
Marco Cattalini, AMPP Italy Chapter Chairman
Monica Santamaria, University of Palermo
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