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The corrosion of aircraft costs the U.S. Department of Defense more than $20 billion annually and accounts for approximately 20% of all maintenance. Coatings are the most effective way to protect aircraft, but they have a finite lifetime and must be maintained or replaced before the underlying substrate is damaged by corrosion. Current aircraft maintenance practices call for coating inspections and repairs based on elapsed time and not on measurements of coating health.
A compact and autonomous corrosion sensor using the principle of electrical resistance variations of its metallic sensitive tracks has been used for different applications under atmospheric corrosion conditions. The measurement of the corrosion rate is performed in-situ both under laboratory and field exposure. From the results it is possible to better understand the atmospheric corrosion of steel and hot-dip galvanised steel under various exposure conditions. The technique should also allow the design of realistic and reliable corrosion tests for different indiustrial applications.
The corrosion is a spontaneous chemical reaction connected to heat exchangers and pipelines that degrades the strength and quality of utilized steel. The aggressive environment, which is ongoing, intense, and frequently difficult to totally prevent, is the key factor contributing to the metal's deterioration. Additionally, it demonstrates a serious economic problem that causes industrial operational assets to require expensive repairs, ruining the public space.
Stress corrosion cracking (SCC) is a failure mechanism that occurs in susceptible materials exposed to a corrosive environment and submitted to tensile stress above a certain threshold. In the presence of these combined factors, SCC can occur and potentially lead to the failure of an asset. This failure mechanism has been widely reported in several susceptible alloys of carbon steel, making SCC a considerable threat for pipelines in contact with corrosive soil.
With the objective of reducing the number of welding passes in thick plate welding, hybrid laser-arc welding technique was utilized to one-pass weld 25mm thick steel plates. Butt joints were designed with a square groove and 2.5mm air gap. Either ceramic strip or submerged arc welding flux was used for joint backing. The joint gap was filled up with cut-wire particles of the same chemical compositions as those of the arc welding filler wire. Cut-wire particles were inserted to protect the backing material from direct interaction with the laser irradiation. Welding parameters were optimized to obtain full penetration joints without damaging the backing material. Square groove butt joints of 25mm thickness were successfully welded in one welding pass. Similarly, 50 mm thick square groove butt joints could be double-side welded
Industrial usage of Plasma Electrolytic Oxidation (PEO) has grown consistently in recent years, thanks to the improved characteristics imparted to the oxide film in terms of surface adhesion, hardness, crystallinity, uniformity, and corrosion resistance. The metallic substrate is not subjected to elevated temperature and the overall equipment complexity is relatively simple, making the technique a good candidate for surface functionalization. In PEO treatments, high voltages are employed (~ 150-750 V 1) allowing for the formation of an insulating, or at least semiconductive, oxide layer that’s limits ion transport responsible for the initial coating growth. Beyond the spark voltage (prerequisite the enter the PEO regime) oxidation does not occur only as the result of a continuous flow of ions but rather it takes place after the cooling of a plasma discharge.
Traditional coating systems for steel have often used a sacrificial primer, barrier coat and topcoat, to provide good UV resistance and appearance. One fundamental problem with all organic coating systems is that there will always be some permeation through the coating. These systems are therefore sacrificial in nature and have a finite life. The use of multi-coat systems also dramatically increases application time, presenting problems both for new construction and maintenance projects.
The measurement of climatic conditions prior to applying a coating is vital to the success of the process, as it is well known that a surface at the dewpoint temperature will have a thin film of moisture over which the paint will be applied.