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This paper is a narrative of the improvements in corrosion resistance, with a strong automotive bent, made during the author’s tenure. Included are anecdotes, observations, and insights gained from interaction with many technical personnel over the years. It defines the confluence of multiple factors including steel manufacturing, new facilities being built, interesting new technologies, and the influence of competition.
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In this study a coupled multielectrode array sensor (CMAS) is used for coating and pretreatment evaluation on carbon steels. The preliminary testing results are summarized and discussed for further application.
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.
Solventborne 2-pack (2K) epoxy-amine coating systems have for many years been commonly used to formulate high performance protective coatings such as metal anti-corrosion primers and concrete floor coatings. However, due to the concerns linked to their high volatile organic compounds (VOC) contents, waterborne alternatives with comparable performance are needed.
Duplex systems, also known as painting over hot dip galvanized steel, are extremely effective corrosion protection systems. However, careful surface preparation techniques need to be used to alleviate potential coating failures. The age and characteristics of the galvanized coating should be used to determine what type of surface preparation is needed. Surface preparation should develop an anchor profile for the paint without removing the zinc coating.
Corrosion is a major concern for all materials during their service lives. In particular, salts such as sodium chloride (NaCl) are known to promote corrosion and detrimentally affect coating performance. Understanding how NaCl affects water uptake into a film and its interactions with corrosion-inhibiting pigments is important for developing the next generation of anticorrosive coatings.