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Cavitation erosion of the rudder has been a serious problem in the high-speed container ship industry. It is well known that the lifetime of a conventional coating system is about 6 months against cavitation bubble collapse. Although STS 316L stainless steel has been applied to prevent such a problem, there are several drawbacks such as high repair cost and poor workability.
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Industry constantly seeks improved methods to evaluate protective coatings. In immersion service, protective coatings act to reduce electrochemical activity at the metal/coating interface. Tracking this activity via the use of segmented panel testing appears to offer additional insight into coating performance that may aid in coating design and predicting longer-term performance.
In this paper failure analysis methodology will be applied to the principal mechanisms by which paints and coatings fail during service; with specific application to case studies involving T&D pipelines and utility structures. The case studies will apply standard failure analysis techniques to determine the primary causes and modes of failures.
Adhesion performance is required for every coating system. The adhesion between coatings and substrates is one of the most critical determining factors in the overall success of any coating material. Material design and formulation are key components of high-performance coatings and rely heavily on the accurate measurement and evaluation of adhesion in the coating systems.
Global Environmental Regulations have driven many coatings developments over the last decades. Today´s regulations around worker safety and environment protection are seen as important drivers in new product development. More recently such regulations are spreading widely, as people want to live on a planet where everyone can enjoy a better quality of life, breathe clean air, where rivers and oceans are preserved, and the impact of humans on wildlife is reduced.
VOC was one of the paint emissions accused to be an environmental hazardous material and among the main causes for SBS (Sick Building Syndrome). The term SBS was coined in the late 1970's to describe situations where building occupants experienced acute health problems. “According to WHO (World Health Organization), 4.3 million people a year die from the exposure to in-house air pollution”
A new patent-pending resin technology incorporated into the epoxy/polysiloxane part A portion of a two-component coating system, using an amino-silane curing agent, has shown significant improvements in flexibility, gloss and color retention. Corrosion resistance and adhesion to non-sandblasted metal substrates have also shown improvements. The new resin technology may be considered for low-VOC and HAPs coating systems.
Besides economic considerations, ecological and regulatory factors play an increasingly decisive role nowadays in the formulation of innovative coating systems. It is therefore no surprise that the call for zinc-free anti-corrosive pigments or those that do not require labeling has steadily increased in recent years. Zinc-free technology is not new. Numerous pigments based on calcium, strontium, aluminum, and magnesium phosphate have been available on the market for a long time.
It does not take one with too much intelligence to note that our infrastructure is in dire shape. Not only does this include our water & wastewater areas, but our road and bridge systems need substantial help. Deterioration due to environmental issues, water and chemicals that are used which cause for serious corrosion and erosion concerns. Over the years, a variety of methods have been employed to help with these issues, but all have individual characteristics and problems.
Many protective coatings markets have recently seen high demand for higher performing coatings or linings. For example, with enhanced oil recovery, many more assets are now used throughout these processes from the oil / water separation tanks to the acid injectors. The temperatures are higher and corrosive environments are more severe. Formulation chemists are working hard at trying to push the extent of the performance of typical resin systems, but it seems that most of the development has been done and the extent of the performance available has been maximized.
Two component polyurethane coatings are used in a variety of applications including industrial maintenance. These coating systems were introduced in the 1970’s primarily as topcoats; characterized by their excellent weatherability, toughness, and chemical and stain resistance. When formulated as ambient cured systems, traditional two component polyurethanes typically sacrifice cure time for pot life unless plural component application equipment is employed.
Of the most severe operations in the oil and gas industry are operations under high pressure and high temperatures where pressures and temperatures exceed 1000 psi and 212°F (100°C). Such operations may contain a variety of chemical constituents such as CO2 and H2S gases, hydrocarbons, and water. To address corrosion issues, materials engineers look into either upgrading to expensive alloys or use protective coatings.