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Coatings designed for heavy duty applications in the Marine & Protective Coatings market are exposed to aggressive environments such as strong chemical solvents, marine atmospheres, UV light, abrasion, among others. Nowadays, the major part of the commercially available products that target this industry are solvent borne.
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This presentation briefly updates a two-part article printed in Water Engineering & Management in 2001. It begins with the benefits of waterborne coatings and gives examples of where they may be used.
A formulated nanoparticle dispersion increases the cross linking of waterborne protective coatings without reducing the formula shelf life. Among the cross linking-related improvements are MEK rub resistance, humidity and immersion resistance, tensile strength and blocking resistance. The findings are in accord with a non-covalent mechanism of cross linking.
The development of environmentally-friendly corrosion resistant coatings is one area of recent focus in the coatings industry. For example, the Department of Defense owns more than 460,000 facilities around the world and reports the annual cost of corrosion of around $800 million. The coatings used on these structures frequently rely on older polymeric coating systems that do not meet the current requirements for environmental/regulatory concerns.
Coatings are utilized in a wide variety of applications (floor, wall, roof, etc.) and on many different substrates (concrete, steel, drywall, etc) in commercial architectural settings, and performance requirements will obviously vary depending on the intended use and environment.
Coatings are constantly being asked to go to greater extremes, such as lower VOC and higher performance. This paper will discuss coating technologies that are being asked to go beyond the typical protective and aesthetic aspects of coatings and offer other functions. Several types of waterborne functional coatings will be described, including technologies for combating noise, heat, and air pollutants.
Watermain failures are not often recognized as corrosion but are usually referred to merely as “watermain breaks” because watermain pipe appears sound prior to failure. Some of the causes of watermain breaks are poor design, improper installation, surge or water hammer, soil movement, manufacturing defects, impact, internal corrosion, and external corrosion. Figure 1 shows some of the possible causes of the DI pipe.
The Federal Highway Administration has a top-level technology goal targeted toward the development and deployment of the “Bridge of the Future.” This is a conceptual short span bridge that demonstrates significant improvements over the current state of the practice – particularly with regard to ease and speed of construction and long-term durability.
Erosion-corrosion plays an important role in determining the durability of the erosive/corrosive slurry handling equipment. The combined action of erosion and corrosion produces a high degradation rate. Material loss rate due to erosion-corrosion is usually significantly higher than the sum of material loss rate due to pure erosion and pure corrosion acting separately. The degradation in erosion-corrosion is primarily by matrix extrusion due to abrasive particle impact.
Implementation of classification and certification programs for durable industrial and infrastructure maintenance coating systems is hindered by a lack of test protocols to reliably accelerate the aging process and estimate service lifetime. This gap in the industry also hurts development efforts toreformulate or add new color choices to existing product lines. The first problem can be addressed by performing long-term weathering testing at outdoor exposure sites in places like south Florida and Arizona, but the need to wait 5 or 10 years or longer to confirm a classification or certify a product makes such schemes difficult to implement and ultimately reduces their value.
Boiler system is one of the most critical systems for a utility plant. A utility plant had experienced high percentages of boiler downtime owing to boiler tube sheet cracking failures. Investigations carried out revealed high stress at the tube-to-tube sheet joint in the boiler fire-side entrance. Tube-to-tube sheet joints at the boiler fire-side entrance had been fabricated by strength welding and without any expansion. The strength welded joint had created undue stress leading to cracking of the weld joint by thermal expansion. A higher quality expanded joint consisting of expanding, flaring and seal welding the fire-side entrance was implemented during the re-tube process. The utility plant has now zero downtime due to boiler tube failure. This article summarizes the description and history of failures with the boiler at the utility plant; investigations and corrective actions carried out; and the present improved condition of the boilers.
Powder metallurgy with hot isostatic pressing (PM-HIP), which enables to densify powders in a furnace at high pressure and temperature is a newly developed manufacturing process for pressure retaining part in nuclear industry. It has advantages such as weld free near-net shape products, improved material properties for castings, short process time, saving in raw material costs, etc. EPRI have conducted several tests such as tensile test, impact test, chemical composition analysis on the manufactured samples for pressure retaining applications.