Coatings continued failure

Eor steel and other ferromagnetic materials, property deterrnination is more difficult. Other tests are made to measure the continuity of protective metallic coatings. Residual stresses induced in welded stmctures and in components in service owing to chemical attack may contribute to early failure. 

General corrosion damage was the cause of failure of an A1 alloy welded pipe assembly in an aircraft bowser which was attacked by a deicing-fluid — water mixture at small weld defects . Selective attack has been reported in welded cupro-nickel subjected to estuarine and seawater environments . It was the consequence of the combination of alloy element segregation in the weld metal and the action of sulphate reducing bacteria (SRB). Sulphide-coated Cu-enriched areas were cathodic relative to the adjacent Ni-rich areas where, in the latter, the sulphides were being continuously removed by the turbulence. Sulphite ions seemed to act as a mild inhibitor. 

The standard of cleanliness which must be achieved has been stated to be that which will allow the subsequent process to be carried out satisfactorily . As an example, the degree of cleanliness required to satisfactorily zinc plate from an acid solution is somewhat higher than that required prior to zinc plate from a high-cyanide alkali zinc solution. This should never be taken as a licence to skimp on surface preparation. However, the arguments over surface-tolerant paint coatings abound and will probably continue. It is to a very large extent true that problems of early failure in metal finishing are traceable to incorrect or insufficient surface preparation. 

A continuous intact film of water-resistant paint forms an effective electrical resistance to the flow of a corrosion current (a resistance of over lO flcm through the film is easily achieved). Underfilm corrosion can then only occur if a channel of electrolyte connecting anode and cathode can be established by local adhesion failure between the coating and the metal substrate. 

Flexibility The normal anodic film begins to crack if subjected to an extension exceeding about 0 - 5%. Thinner films up to 5 nm in thickness appear to withstand a greater degree of deformation without obvious failure, and are often used for dyed coatings on continuously anodised strip from which... 

The above tests for characterising coating properties necessarily continue to involve a certain amount of empiricism. The intelligent use of these tests, however, has shown that wide variations of physical and electrochemical characteristics of coatings as a function of composition may be obtained, and further, that significant changes in these characteristics, that can be measured before the usual evidence of failure appears, occur upon natural and accelerated ageing. 

Plastics. Part of the trend to substitute plastic and composite substrates for metals can be attributed to a desire to avoid the process of metallic corrosion and subsequent failure. Relatively little attention has been called to the possible failure modes of plastics under environments considered corrosive to metals. More extensive work should be conducted on the durability and life expectancy of plastic and composite materials under end-use environments. A further consideration is the potential for polymer degradation by the products of metal corrosion in hybrid structures comprising metal and polymer components. Since it is expected that coatings will continue to be used to protect plastic and composite substrates, ancillary programs need to be conducted on the mechanisms by which coatings can protect such substrates. 

Penetrating finishes such as stains and water-repellent preservatives ( 7,8) leave little or no continuous coating on wood surface. Because there is no coating, there is no failure by blistering or peeling. These finishes are ideally suited for rough-textured surfaces difficult to paint effectively. 

Suitable for Continuous Production The equipment enables a robust production system which has been shown to operate without failure around the clock for several days. Substrates that have been coated include fiber tows, pins, industrial rollers, wire, radiators, and roll sheet material. 

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