Corrosion Protection

Corrosion protection is vital for anyone who owns metal assets. As time goes on, metal will slowly be eaten away by corrosion if it’s not properly treated. This process can be accelerated by certain environmental factors, such as chemicals, salt water, and more. But with the right corrosion protection plan in place, you can extend the life of your assets and protect your investment.

Corrosion of metals is a major problem in many industries. It leads to loss of strength and durability of metal products, and can ultimately cause them to fail.

Hayden Corporation Thermal Spray Corrosion Protection

Thermal spraying can reduce or inhibit corrosion in two primary ways: by providing a barrier to corrosive attack and by actively engaging in corrosive action to prevent attack of the substrate.

Barrier Coatings

Thermal spray coatings of materials that are naturally non-corroding can be used to protect metals from corrosive action by providing a barrier between the metal and the corrosive environment. Barrier protection prevents or reduces corrosion by shielding the susceptible material from exposure to the corrosive agent. Coatings of nickel alloys, including some stainless steels and carbide coatings with nickel binders, do not tend to corrode and can reduce the amount of exposed, unprotected surface. This method is further enhanced by the use of sealers that fill the microscopic pores that occur in most thermal spray coatings.

Since corrosion is essentially a process of surface oxidation, it can be accelerated by heat. In situations where hot corrosion is of particular concern, barrier coatings can be used in conjunction with high-temperature coatings designed to reduce heat transfer. These thermal barrier coatings then work to reduce the effect of heat on corrosive action. 

Corrosion Control Coatings

Although aluminum and zinc are often considered to be corrosion resistant in many natural environments, the mechanism by which coatings of these materials offer corrosion protection actually involves minor corrosion of the coatings themselves. Both of these materials will tend to oxidize more readily than steel, and so coatings of aluminum and zinc on steel actively inhibit corrosion of the steel by diverting corrosive action to the coating material. 

Both of these metals will form oxides as they react with the corrosive environment, and these oxides further enhance the protective function of the coating. Much as sealers work to fill microscopic pores and voids in barrier coatings to prevent the migration of corrosive fluids from the surface to the substrate, the oxides that form in zinc and aluminum form and fill in the natural microscopic pores and voids in these coatings. Zinc oxide is powdery and white and will gradually wash away over time. Aluminum oxide is harder and more solid and will tend to remain in place as the coating ages, forming an additional protective barrier.

Benefits of Thermal Spray Corrosion Protection Coatings

Thermal spray coatings offer several advantages, when compared to other conventional means of corrosion protection, such as painting or coating with epoxy. Metallic thermal spray coatings are typically thicker than paint systems and tend to be better tolerant of wear and abrasion. They can be applied quickly and easily, even in adverse conditions, and require no cure time; thermal spray coatings are fully finished as soon as they are applied, and they may be applied outdoors to surfaces that are cold and damp without adverse effects.

The chief advantage of thermal sprayed corrosion protection by cathodic coatings like aluminum and zinc is its ability to protect even exposed surfaces near the coated area. The active function of the coating material in arresting corrosive action means that scratches and gouges that can often occur in harsh environments, and even adjacent surfaces that could not be reached for coating, will likely continue to be protected by the coating that remains. This durability, combined with the low cost of aluminum and zinc, can mean significant savings in total lifetime cost for equivalent corrosion protection.

Typical Parts that Need Corrosion Protection

Most iron and steel components will readily corrode in outdoor environments, particularly in coastal areas where salt can accelerate corrosion. Since corrosion (or oxidation) typically leads to loss of material, corrosion can cause structures to weaken, even to the point of failure.

Corrosion protection coatings are commonly used on structural steel elements, such as bridge beams and bearings, that will be continuously exposed to weather. Pipelines and process piping are also frequently coated to ensure that corrosion does not reduce the wall thickness of the pipe and increase the risk of rupture. Steelwork in marine environments, such as ship hulls, bulkheads, and hatchways are also often coated prior to painting to ensure that damage to the painted surface does not create a corrosion problem that could spread beneath the paint. 

Parts that need corrosion protection are typically made of metals, such as iron or steel. These parts usually are exposed to the elements, such as water, air, and salt. Over time, the exposure causes the metal to corrode, or break down. Rust is a type of corrosion visible on the metal's surface. The corrosion causes the metal to weaken and eventually fail. Corrosion protection helps to prevent or slow down the process of corrosion. It is important to use corrosion protection on parts that are essential to the function of a machine or structure, such as support beams or pipes. Without corrosion protection, these parts would break down and need to be replaced more frequently. As a result, using corrosion protection can extend the life of a machine or structure and save money in the long run.

Protect Your parts Against Corrosion

Hayden Corporation has experience with a variety of corrosion protection solutions. We can work with you to determine the best solution for your needs, and we will provide the expert services necessary to apply the coating correctly. Contact us today to learn more about our corrosion protection thermal spray coating services.

For more information on how to protect your metal surfaces from corrosion, contact Hayden Corporation. We are a leading provider of thermal spray services, and we can help you find the right solution for your needs. We offer a variety of different thermal spray processes, and we can custom-tailor a solution to meet your specific requirements. Contact us today!

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