metallic adhesive film

metallic adhesive film

Metal Corrosion Prevention at Extreme Conditions

Today's economy has proven that lean manufacturing is not a choice but necessity for companies planning on staying in business.  Companies are forced to be increasingly efficient in the utilization of resources.  This means effective use of materials, time, and people, which renders corrosion prevention ever more important.

Consider the failing of a critical equipment from corrosion.  Such events result in damaging of equipment, loss of production time, and additional maintenance.  Altogether these are wastes of valuable resources and thus preventing corrosion in the first place makes big difference.  While corrosion has been prevented under many conditions, there are many cases where conventional protection methods do not work.  Examples to these are the operations in cement plants.  For instance, not only do cement kilns operate under temperatures up to 1200˚C with wall temperatures around 600˚C, but they are also exposed to highly corrosive gases such as SO3, SO2, HCl, CO2, and NOx.  These conditions can cause an excess of 1 mm of corrosion per year on the support structure and cost millions of dollars to the plant.  Many solutions have been tried up to date, but until 10 years ago no solution was permanent.

In the year 1999, a group of scientists in Silicon Valley, California came together to establish 3L&T Inc. and developed a totally new kind of coating for metals.  This product was nominated FlueGard225, referring to the flue gases from which it was designed to protect equipment and the 225˚C it could withstand.  It showed unprecedented binding to steel, adhesion strength at minimum a whopping 3000 psi.  After expansion, 3L&T develop different versions of this novel coating.  Today KilnGard600SCW is able to withstand up to 600˚C, or 1157˚F.

There are four factors that affect the severity of corrosion in an environment: low pH, high temperature, high moisture, and abrasion.  Acidic conditions are commonly encountered in the presence of sulfur oxides, a by-product of burning fuels such as coal.  In the presence of an acid metals will oxidize.  High temperature generally affects the integrity of polymeric coatings on the metals to the point of failure, after which incessant corrosion ensues.  Moisture content increases the amount of condensation, thus promoting faster corrosion, and abrasion happens when flyash or small particles remove the coating, exposing the active metal to the oxidizing chemicals.

The major strengths 3L&T products bring in confronting these conditions are first the ability to withstand the high temperature, severe abrasion, and chemical attacks, and maintain their integrity after many years of exposure.  Second, 3L&T products are designed to bind to the substrate in such a way that no undercut corrosion is permitted.  That is, the corrosion stops where the coating begins, even if part of the metal is exposed to the environment.  This is a major advantage, as most coatings fail when corrosion at the triple interface of metal, coating, and condensate causes blistering of the coating.  It is caused by galvanic coupling of the metallic coating or the oxide layer with the exposed substrate, causing a crevice under the paint film.  (G. W. Walter) Once the crevice has formed, undercutting can continue by repetition.  The blisters can be hiding much corrosion under them.  3L&T products are such formulated that no undercut corrosion is permitted.  This unusual property is due to the nature of the interface between the coating and the metal.  The chemistry of the coating produces a passivation of the metal surface, which prevents the formation of cathodic and anodic regions that drive the undercutting process.

Preventing corrosion up front can save major capital investment in the future while reducing waste.  However, choosing the right protective material is important, as utilizing underperforming materials could lead to even more waste.  Metals working in operating conditions with high temperature, high chemical levels, high moisture content, and abrasion are difficult to protect.  To overcome this challenge 3L&T has developed a range of products that are applicable in such severe conditions.  These products, each of which has been tailored to specific operating environments, have unusual binding strengths to steel, owing to their special chemistry.  3L&T research team is continuously working to develop new ultra-durable coatings for different applications.  A list of the latest versions of these coatings and pictures from the field could be found at http://www.3l-t.com/.

About the Author

Isik Kuntay is the Technical Service Manager of 3L&T Inc. in Mountain View, California.

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Replacement Metallic Ring for PSP with Adhesive $3 Replacement Metallic Ring for PSP with Adhesive

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