Electrodeposited coatings corrosion resistance

Block copolymer latexes Electrodeposition resins Light-curable compositions Synthetic drying oils Corrosion-resistant electrodeposition coatings... 

The process of electrodeposition has been developed to provide uniform, highly adhesive, corrosion-resistant primer coats, particularly for the automotive industry. (The ultimate solution to the corrosion problem is simply to replace metal with plastic, as is done for many applications.) In the most common form of the process, polymers that contain carboxylic acid functionalities are produced. These polymers are then solubilized in an aqueous medium by partial neutralization with a base to give macroanions (P represents a polymer backbone) the macroanions are beheved to exist as micelles. 

In addition to the alloys in Table 4.21, Ni-Sn and Ni-Ti alloys also possess useful corrosion resistance. Ni-Sn alloys are extremely brittle and, because of this, are used only as electrodeposited coatings. Ni-Ti alloys over a wide range of compositions have been studied, of which perhaps the intermetallic compound NiTi (55 06Ni-44-94Ti) has attracted the most interest. 

It will be seen that the design of articles to be electroplated can have a considerable effect on the corrosion resistance of the electrodeposited coating. The chief effects are the result of variations in deposit thickness, but also important are features which can influence the adhesion, porosity and physical properties of the deposit. Good design will also avoid features of the plated article capable of trapping liquids or solid contaminants which might cause more rapid corrosion. 

Fig. 12.9 Corrosion resistance of tin-nickel electrodeposit impaired by pseudomorphic porosity originating on cold-rolled steel surface (left). Panel on right has had the shattered grain surface removed by chemical polishing (0-125 iim removed). Coating thickness 15 iim-, panels exposed 6 months to marine atmospheric corrosion (Hayling Island)...

Compared with other methods, vacuum evaporation produces coatings that have a most satisfactory corrosion resistance, e.g. 0.005 mm of evaporated Cd gives a degree of protection to steel similar to that afforded by 0.01 mm of electrodeposited Cd. Cadmium coatings on ferrous and other substrates can meet authoritative specifications concerning corrosion... 

With tin coatings on brass, the interdiffusion of coating and substrate brings zinc to the surface of the tin the action can be rapid even with electrodeposited coatings. The effect of zinc in the surface layers is to reduce the resistance of the coating to dulling in humid atmospheres, and the layer of zinc corrosion product formed makes soldering more difficult. An intermediate layer of copper or nickel between brass and tin restrains this interdiffusion . 

A major advantage of the electroless nickel process is that deposition takes place at an almost uniform rate over surfaces of complex shape. Thus, electroless nickel can readily be applied to internal plating of tubes, valves, containers and other parts having deeply undercut surfaces where nickel coating by electrodeposition would be very difficult and costly. The resistance to corrosion of the coatings and their special mechanical properties also offer advantages in many instances where electrodeposited nickel could be applied without difficulty. 

Electrodeposition This method of paint application is basically a dipping process. The paint is water-based and is either an emulsion or a stabilised dispersion. The solids of the paint are usually very low and the viscosity lower than that used in conventional dipping. The workpiece is made one electrode, usually the cathode, in a d.c. circuit and the anode can be either the tank itself or suitably sized electrodes sited to give optimum coating conditions. The current is applied for a few minutes and after withdrawal and draining the article is rinsed with de-ionised water to remove the thin layer of dipped paint. The deposited film is firmly adherent and contains a minimum of water and can be stoved without any flash-off period. This process is used for metal fabrications, notably car bodies. Complete coverage of inaccessible areas can be achieved and the corrosion resistance of the coating is excellent (Fig. 14.1). 

A matter of considerable importance in the selection of an application method is its efficiency. Spray techniques are usually inefficient, since many droplets drift past the target and are lost. Even electrostatic spraying can waste as much as 35% of the paint. There is some loss of paint in most methods, but roller coating, curtain coating and electrodeposition are very efficient. Electrodeposition is also a very useful technique where corrosion resistance is important, since it applies a uniform coating over nearly all surfaces of even the most complex-shaped article. 

Applications Electrodeposition of cationic paint resin on automobiles (connected to the cathode) provides a uniform, defect-free coating with high corrosion resistance, but carries with it about 50 percent excess paint that must be washed off. UF is used to maintain the paint concentration in the paint bath while generating a permeate that is used for washing. The spent wash is fed back into the paint path (Zeman et al., Microjiltration and UltrajUtration, Marcel Dekker, New York, 1996). 

Electroless deposition as we know it today has had many applications, e.g., in corrosion prevention [5-8], and electronics [9]. Although it yields a limited number of metals and alloys compared to electrodeposition, materials with unique properties, such as Ni-P (corrosion resistance) and Co-P (magnetic properties), are readily obtained by electroless deposition. It is in principle easier to obtain coatings of uniform thickness and composition using the electroless process, since one does not have the current density uniformity problem of electrodeposition. However, as we shall see, the practitioner of electroless deposition needs to be aware of the actions of solution additives and dissolved O2 gas on deposition kinetics, which affect deposit thickness and composition uniformity. Nevertheless, electroless deposition is experiencing increased interest in microelectronics, in part due to the need to replace expensive vacuum metallization methods with less expensive and selective deposition methods. The need to find creative deposition methods in the emerging field of nanofabrication is generating much interest in electroless deposition, at the present time more so as a useful process however, than as a subject of serious research. 

Zinc and its alloys are good materials for corrosion-resistant coatings and they are widely used in the automobile industry. The electrodeposition of zinc or its alloys is normally performed in aqueous electrolyte solutions. However, zinc and its alloys can be obtained in improved quality from ionic liquids. It was shown that Lewis acidic ZnCl2-[EMIM]Cl (l-ethyl-3-methylimidazolium chloride) liquids in which... 

Use Hardener for platinum and palladinum in jewelry, electrical contact alloys, catalyst, medical instruments, corrosion-resistant alloys, electrodeposited coatings, nitrogen-fixing agent (experimental), solar cells (experimental) the oxide is used to coat titanium anodes in electrolytic production of chloride the dioxide serves as an oxidizer in photolysis of hydrogen sulfide. 

Development of Epoxy Resin-Based Binders for Electrodeposition Coatings with High Corrosion Resistance... 

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