The life of metal instruments can be improved by protecting the material against corrosion. Corrosion reduces the mechanical strength of a metal, leading to rapid degradation. The equipment is exposed to a higher risk of structural damage.
An experiment-based research concluded that corrosion degrades the strength of metals. The intensities of corrosion were classified as minor, severe and moderate depending upon the level of corrosion and the minimum thickness ratio (μ).
Corroded pipes can cause contamination of water, imposing health risks. Solid corrosion can lead to blockage of pipes and valves, resulting in mechanical rupture.
There have been many conventional methods to minimize corrosion. Here are a few of these methods and their drawbacks:
Steel objects are immersed in a solution at temperature ranging from 815°F to 850°F. The solution contains 98% zinc along with minor elements (Bi, Ni, Al) that are added to enhance the coating properties.
There are numerous reasons as to why galvanization isn’t the ideal choice for material coating of equipment. As soon as the galvanized material comes in contact with brass, it stimulates dezincification, resulting in a perforated structure, with reduced mechanical strength. Therefore, the galvanized material is required to be properly isolated, which is not an ideal condition for many industrial requirements.
Another major drawback includes the fact that copper cannot be used with galvanized steel as it triggers a chemical reaction, weakening the metallic joints. This limits the industrial usage of galvanized equipment majorly.
It is an electrochemical process, which involves an oxidation reaction at anode resulting in corrosion reduction of the material at cathode. An active metal serves as anode and undergoes oxidation to provide free electrons to the corroding material.
The process is highly complex and expensive. It requires frequent maintenance and inspection. The anodes used in the process have limited current and are therefore rapidly subjected to corrosion.
The material is coated with paint or powder to provide a barrier between material and environment. The method involves several layers and different compositions of paint according to the environment in which material is exposed.
All barrier protection methods that use organic materials have a degree of permittivity. The coating is porous and once humidity or moisture penetrates the barrier, it triggers corrosion. The barrier-coated material requires frequent maintenance, increasing the cost.
These drawbacks can be avoided by using aluminized process for corrosion protection. It protects the material against sulfidation, carburization, hydrogen permeation, and oxidation.
VaporKote has been providing Boronizing service to its customers in Anaheim, CA. We provide high-quality coating service by performing metallurgical analysis to allow our customers to operate at high temperature levels.
Get in touch with us now to get a customized solution for your industry.