Corrosion prevention chromates

Safety No year goes by without some widely used chemical being declared suspect on toxicity grounds. The paint industry has responded rapidly to eliminate toxic chemicals from coatings or to show how they can be used safely in an industrial environment. Examples are the elimination of specific ether-alcohol solvents and the introduction of air-fed hoods for spraying isocyanates. Of particular interest in corrosion prevention is the current pressure to eliminate chromate pigments. Currently there are no equally effective alternatives and the emphasis has had to be on safe usage. The search for replacements continues. 

The general sequence of surface preparation for ferrous surfaces such as iron, steel, and stainless steel consists of the following methods degreasing, acid etch or alkaline clean, rinse, dry, chemical surface treatment, and priming. The chemical surface treatment step is not considered a standard procedure, but it is sometimes used when optimum quality joints are required. It consists of the formation of a corrosion-preventing film of controlled chemical composition and thickness. These films are a complex mixture of phosphates, fluorides, chromates, sulfates, nitrates, etc. The composition of the film may be the important factor that controls the strength of the bonded joint. 

Conversion coatings. Some metals can be treated by oxidizing agents, preferentially chromate solutions, to prepare an oxide film saturated by chromate ions. This is one of the most effective corrosion preventing treatments of metal surfaces and is applied to aluminum, copper, and zinc. Chromate ions are known for toxic properties. Pohtical decisions have banned this surface treatment for the future. So far no alternative corrosion protecting treatment of similar effectiveness has been developed. 

B. R. W. Hinton, Corrosion prevention and chromates the end of an era Proceedings Asia Interfinish 90 (paper 30), Singapore, 1990. 

They are effective inhibitors for iron and a number of metals in a wide variety of waters. Like chromates, nitrites are anodic inhibitors and they inhibit the system by forming a passive film with ferric oxide. These are environmentally-ffiendly inhibitors. Besides steel, nitrites also inhibit the corrosion of copper, tin and nickel alloys at pH levels 9-10. Chromate is an extremely effective inhibitor for corrosion prevention of aluminum alloys. Nitrites should not be used in open systems as they would oxidize to nitrates in the presence of oxygen. 

Corrosion Inhibitors. Steel-reinforcing wire and rods embedded in concrete containing quinoline or quinoline chromate are less susceptible to corrosion (72) (see Corrosion and corrosion control). Treating the surface of metals with 8-hydroxyquinoline [148-24-3] makes them resistant to tarnishing and corrosion (73). Ethylene glycol-type antifreeze may contain quinoline, 2-chloro-, 4-amino-, 8-nitro-, or 8-hydroxyquinoline to prevent corrosion (74). 

The most effective way to prevent SCC in both stainless steel and brass systems is to keep the system clean and free of deposits. An effective deposit control treatment is imperative. A good corrosion inhibitor is also beneficial. Chromate and phosphate have each been used successfully to prevent the SCC of stainless steel in chloride solutions. 

The most favorable conditions for equation 9 are temperature from 60—75°C and pH 5.8—7.0. The optimum pH depends on temperature. This reaction is quite slow and takes place in the bulk electrolyte rather than at or near the anode surface (44—46). Usually 2—5 g/L of sodium dichromate is added to the electrolysis solution. The dichromate forms a protective Cr202 film or diaphragm on the cathode surface, creating an adverse potential gradient that prevents the reduction of OCU to CU ion (44). Dichromate also serves as a buffering agent, which tends to stabilize the pH of the solution (45,46). Chromate also suppresses corrosion of steel cathodes and inhibits O2 evolution at the anode (47—51). 

Corrosion inhibitors are substances which slow down or prevent corrosion when added to an environment in which a metal usually corrodes. Corrosion inhibitors are usually added to a system in small amounts either continuously or intermittently. The effectiveness of corrosion inhibitors is partiy dependent on the metals or alloys to be protected as well as the severity of the environment. For example, the main factors which must be considered before apphcation of a corrosion inhibitor to an aqueous system are the compatibility of the inhibitor and the metal(s), the salt concentration, the pH, the dissolved oxygen concentration, and the concentration of interfering species such as chlorides or metal cations. In addition, many inhibitors, most notably chromates, are toxic and environmental regulations limit use. Attention is now being given to the development of more environmentally compatible inhibitors (37). 

This type of corrosion can take place on any new surface of zinc and is best prevented by storing the metal in a dry, airy place until a protective layer has been formed. Zinc which has been properly aged in this way is safe against white-rust formation. Various methods are employed to prevent white rust. A chromate treatment is widely used for zinc-plated articles and for galvanised sheet, and occasionally for zinc die castings. Fatty substances, such as oils or lanolin, are sometimes used to protect larger items. 

Inhibitive Pigment a pigment which retards or prevents the corrosion of metals by chemical and/or electrochemical means, as opposed to a purely barrier action. Red lead and zinc chromate are examples of inhibitive pigments as opposed to red iron oxide which has little or no inhibitive action. 

Atmospheric corrosion can be prevented by using volatile inhibitors which need not be applied directly to the surfaces to be protected. Most such inhibitors are amine nitrites, benzoates, chromates, etc. They are mainly used with ferrous metals. There is still some disagreement as to the mechanism of action. Clearly, any moisture that condenses must be converted to an inhibitive solution. There is no doubt that the widely used volatile inhibitors are effective in aqueous solutions containing moderate... 

Note in making up the chromic acid solution it is advisable to dissolve the silver nitrate separately and add it to the boiling chromic acid to prevent excessive crystallisation of the silver chromate. The chromic acid must be free from sulphate to avoid attack on the zinc. Immerse each specimen for 15 s in a 6% solution of hydriodic acid at room temperature to remove the remaining corrosion products. Immediately after immersion in the acid bath, wash the samples first in tap water and then in absolute methanol, and dry in air. This procedure removes a little of the zinc and a correction may be necessary. 

After this primer is applied vinyl chloride-vinyl acetate copolymer is added in a series of thin films. The total thickness is usually 5 mils. Pigments like iron oxide, lead, or zinc chromate prevent corrosion of the metal substrate in acid environments and may also be included in the coating. The final coated metal has good resistance to water and many chemicals with about a ten-year lifetime. 

Barium chromate is used as a pigment in paints, ceramics, coloring glasses, fuses, and porcelains as a corrosion inhibitor to prevent elecrochemical corrosion at the joints of dissimilar metals in safety matches in metal primers in ignition control devices in pyrotechnic compositions and as an initiator for explosives. 

Dipping. A process applied to treatment of ammunition and its component metal parts in an effort to protect prevent corrosion of the surfaces. Various chromate dippings (such as Cronak, Irridite, Yellow Black Anodize have been used especially when plating is first applied. The usual requirement of a dipping process is that the 24-hour salt spray test must be met Ref Ohart (1946), 14... 

The use of various substances as additives to process streams to inhibit corrosion has found widespread use and is generally most economically attractive in recirculation systems, however, it has also been found to be attractive in some once-through systems such as those encountered in the petroleum industry. Typical inhibitors used to prevent corrosion of iron or steel in aqueous solutions are chromates, phosphates, and silicates. In acid solutions, organic sulphides and amides are effective. 

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