Corrosion-resistant coating and method of processing metal structures

 

(57) Abstract:

Multi-layer anti-corrosion coating comprises a primer layer formed of at least two zinc-containing layer and at least one coating layer formed from aluminium-containing material, while the zinc - and aluminium-containing layers are formed in the environment of ethyl silicate binder. The method of anticorrosive treatment of metal structures is the formation of the pre-prepared surface priming zinc-containing layer in an environment of ethyl silicate binder by sequentially applying at least two layers, and then applying at least one coating layer made of aluminium-containing material in the environment of ethyl silicate binder. Preliminary preparation of the surface lead by degreasing and subsequent blast cleaning or by two-stage phosphating. When forming an undercoat layer of fine powder of zinc and ethyl silicate binder is used at a ratio of 1:1 to 2:1, respectively, and when forming the coating layer of aluminum powder and ethyl silicate binder used in their massova,7, the butyral 5,5 - 7,7, phosphoric acid (73%) 0,15 - 0,45, ethyl 72,1 - 76,5, water - the rest. Corrosion-resistant coating has a high aesthetic properties, provides long-lasting protection, has high corrosion resistance throughout the range of aggressiveness air environment and areas of moisture. The method can reduce the raw material and labor costs, to simplify the existing technology anti-corrosion treatment. 2 C. and 7 C.p. f-crystals, 2 tab.

The invention relates to a method of anticorrosive treatment of metal structures by applying to the surface of the corrosion-resistant metal coating and can be used, for example, to process supports the air lines, open distribution devices of high-voltage substations, guardrails, load-bearing structures of industrial buildings and structures, fixtures and other products.

To provide corrosion protection products intended for prolonged use in conditions slightly aggressive, mid-aggressive and very corroded environment, known metal coating with a film thickness of 60 to 300 μm, for example zinc, which cause Metaoutline structures from corrosion. Construction norms and rules N 2.03.11-85, Ed. The USSR state Committee for construction Affairs, M., 1986].

Method of hot-dip galvanizing, which consists in lowering articles into a bath of molten zinc, unacceptable for processing large dimensions and requires high energy consumption. Method of thermal spraying though and is applicable for processing dimensional structures, however, associated with high energy costs and high losses of zinc during its deposition on the surface. The method of electrochemical anodization requires considerable effort associated with high requirements to the quality of the processed surface and high energy costs.

Closest to the present invention is corrosion-resistant coating comprising an undercoat layer containing a binder based on epoxy resin/polyisocyanate, epoxy resin/polyamine or cured under the influence of moisture macromolecular polyisocyanate, fine zinc powder and solvent, and a coating layer containing a binder based creatorial and clinoatacamite/polyisocyanate and solvent. The method of anticorrosive treatment with ispolzovat, and then applying a top coat when the temperature 12020oC. (DE 3531370, MKI 09 D 5/08, 1987).

Known coating has a fairly good corrosion resistance and elasticity, which ensures long-term operation of the product in environments with increased aggressiveness, however, when it is applied on the surface it is difficult to achieve a uniform thickness, and because of the heterogeneity and the sloppiness of the coating on the individual, the most "weak" areas have pockets of pitting corrosion. Also known composition during formation of the coating does not provide high adhesion to metal, which is necessary to prevent subsurface corrosion.

The present invention is the creation of a corrosion-resistant coating with a high aesthetic properties, providing long-term electrochemical protection, suitable for application, including overall product having high corrosion resistance throughout the range of aggressiveness air environment and areas of moisture while reducing raw material and labor costs in its application.

The problem is solved by the fact that applying corrosion-resistant multilayer metalcote is Arial, containing fine powder of zinc in the environment of ethyl silicate binder and at least one coating layer formed from a material containing aluminum powder in an environment of ethyl silicate binder.

The method of anticorrosive treatment of metal structures is applied on prepared surface of the multilayer zinc-containing coating, characterized in that the first form the primer layer by sequentially applying at least two layers, with layers made of a material containing fine powder of zinc in the environment of ethyl silicate binder, and then applying a covering layer made of a material containing aluminum powder in an environment of ethyl silicate binder.

Preliminary preparation of the surface lead by degreasing and subsequent shot blasting or by two-stage phosphating solutions of o-phosphoric acid with the formation of a thin reactive film, causing high adhesion of the coating to the steel substrate. Application of a layer on the processed surface of the lead by means of air or airless spray, brush, containing fine powder of zinc and ethyl silicate binder at a ratio of 1:1 to 2:1, respectively. Known composition available under the trade name "CVAs".

As the material forming the coating layer using a composition containing aluminum powder and ethyl silicate binder at a mass ratio of from 0.05:0.95 to 0.1:0.9 respectively. Composition available under the trade name "PAES".

Used ethyl silicate binder contains, wt%:

Ethyl silicate - 11,5 - 12,7

The butyral - 5,5 - 7,7

Orthophosphoric acid (73%) - 0,15 - 0,45

Ethyl alcohol is 72.1-76,5

Water - the Rest

The mechanism of formation of protective corrosion layer on the surface of the steel when applying cinnabarinus composition on ethyl silicate basis lies in the interaction at the interface of iron particles of zinc, prisoners of ethyl silicate in the shell, resulting in a durable zinc-iron-silicate layer that is resistant to water and solvents by providing mainly electrochemical mechanism for the protection of the surface. Application of aluminium-containing layer on the pre-coated with a primer the men, processed by the claimed method, the corrosion resistance of steel structures when operating in conditions of high aggressiveness increases by 5-7 years. The proposed coating provides protection of steel structures against corrosion, equivalent gorjacheotsinkovannom coating with a minimum thickness of 60 microns.

The method of processing metal structures according to the invention leads to an improvement in the corrosion resistance of zinc-containing layer and the coating as a whole. This may be due to the fact that in the proposed coverage is not only preserved electrochemical (cathodic) protection mechanism against corrosion, but, in addition, the presence of the inventive coating layer provides adequate protection from solar radiation, leading to destruction of the structure of the coating, ensures the creation of a dense porous film due to the dense aluminum, having a scaly form of particles, which leads to the exclusion of the emergence of "pitting corrosion" due to overlap then loose zinc-containing layer and eliminates the possibility of formation of white spots, spoiling the appearance of the product.

In addition, the applied layers have high adhesion to both the treated surface and to each other, hi subsurface corrosion, but also high mechanical strength of the coating as a whole. Furthermore, the method of anticorrosive treatment according to the invention simplifies the existing technology, reduces its cost by reducing raw material and labor costs. So, in a phased application of highly zinc-containing material, there are technological difficulties associated with the fact that each of the successively applied layers have the same color with matte finish, which makes visual inspection of the required rating. The lack of production facilities and technical control of the thickness of the coating may result in waste of material during formation of the coating or poor its application. Replacement of at least one zinc-containing layer on the aluminium-containing solves these challenges and significantly reduces the consumption vysokoorientirovannogo material, reducing the overall consumption of primer material and reducing the cost of coverage.

Corrosion-resistant coating and method of processing metal structures with its use is illustrated by the following examples.

Example 1 (control)

Anticorrosive processing standard steel sample size of 150 x 100 x 2 mm Provo is Nowotny layer formed from a material "cves", sequentially deposited on the surface in three stages. Each applied layer of material cves" dried in natural conditions within 20-30 minutes

Processed samples with a total coating thickness of 100-120 μm were subjected to standard tests. The data are given in table. 1 and 2.

Example 2 (control)

Anticorrosive processing standard steel sample size of 150 x 100 x 2 mm was performed by pneumatic spray primer layer on prepared surface. A primer layer formed from a material "CVAs, sequentially deposited on the surface in two stages. Each applied layer of material cves" dried in natural conditions within 20-30 min, after which the formed primer layer was applied coating layer made of once applied epoxy mark "EP 0010" by pneumatic spraying. The drying is conducted under natural conditions within 20-30 minutes

Processed samples with a total coating thickness of 150 to 180 μm were subjected to standard tests. The data are given in table. 1 and 2.

Example 3 (control)

Anticorrosive processing standarddeviation prepared surface. A primer layer formed from a material "CVAs" printed on the surface in a single step with subsequent drying in natural conditions for 20-30 minutes On the formed primer layer was applied coating layer made of aluminum powder in the environment of ethyl silicate binder ("PAES") in their mass ratio of 0.05: 0.95 to respectively by consecutive application of two stage pneumatic spraying. Each of the deposited layers was dried in natural conditions within 20-30 minutes

Processed samples with a total coating thickness of 50-60 μm were subjected to standard tests. The data are given in table. 1 and 2.

Example 4 (inventive)

Anticorrosive processing standard steel sample size of 150 x 100 x 2 mm was performed by pneumatic spray primer layer on prepared surface. Surface preparation led by degreasing and subsequent blast cleaning. A primer layer formed from a material "CVAs, sequentially deposited on the surface in two stages. Each applied layer of material cves" dried in natural conditions for 20-30 minutes On sformirovavshuyusya ("PAES") in their mass ratio of 0.05: 0.95 to respectively by consecutive application of two stage pneumatic spraying. Each of the deposited layers "PAES" dried in natural conditions within 20-30 minutes

Processed samples with a total coating thickness of 80-100 μm were subjected to standard tests. The data are given in table. 1 and 2.

Example 5 (inventive)

Anticorrosive processing standard steel sample size of 150 x 100 x 2 mm was performed by pneumatic spray primer layer on prepared surface. Surface preparation led by the two-stage phosphating solutions of o-phosphoric acid. A primer layer formed from a material "CVAs, sequentially deposited on the surface in two stages. Each applied layer of material cves" dried in natural conditions for 20-30 minutes On the formed primer layer was applied coating layer made of aluminum powder in the environment of ethyl silicate binder ("PAES") in their mass ratio of 0.1: 0.9 respectively by applying one phase pneumatic spraying. The applied coating layer was dried in natural conditions within 20-30 minutes

Processed samples with a total coating thickness of 80-100 μm were subjected to standard tests. Data Pref is I resistance is determined according to the established procedure in conditions of salt mist chamber (up to defeat corrosion 50% of the surface of the sample) and in conditions of tropical climate (without corrosive lesions). Adhesion is determined by the method of lattice cuts (GOST 15140-78). Impact strength according to GOST 6806-73. The electrical conductivity (standard capacity) TU K-AO-04-93.

As can be seen from the above data, the inventive coatings are characterized by high corrosion resistance, high adhesion, maintaining the required level of electrical conductivity, providing a protective mechanism for the protection of metal surfaces from destruction.

The inventive coating system can successfully replace the coatings produced by hot dip galvanizing, have a wide range of applications, and is useful when applied to the overall and other products.

1. Corrosion-resistant multilayer coating of the metal-containing material comprising a primer layer containing fine powder of zinc and a binder, and a coating layer containing a binder, characterized in that the put at least two coats of primer as a binder contains ethyl silicate binder, and applied at least one layer of coating layer further comprises aluminum powder, and the binder is ethyl silicate binder.

2. Corrosion-resistant multilayer coating on the ethyl silicate binder at a ratio of 1 : 1 to 2 : 1, respectively.

3. Corrosion-resistant multilayer coating on p. 1, characterized in that the material forming the coating layer contains aluminum powder and ethyl silicate binder at a mass ratio of from 0.05 : 0.95 to 0.1 : 0.9 respectively.

4. Corrosion-resistant multilayer coating on PP.1 to 3, characterized in that ethyl silicate binder contains, wt%:

Ethyl silicate - 11,5 - 12,7

The butyral - 5,5 - 7,7

Orthophosphoric acid (73%) - 0,15 - 0,45

Ethyl alcohol is 72.1 - 76,5

Water - the Rest

5. The method of anticorrosive treatment of metal structures, including preliminary surface preparation, application of primer, containing a fine powder of zinc and a binder, and a coating layer containing a binder, characterized in that first put at least two coats of primer layer containing as a binder of ethyl silicate binder, and then put a top coat layer, optionally containing aluminum powder, and the binder is ethyl silicate binder.

6. The method according to p. 5, characterized in that the preliminary preparation of the surface lead by degreasing and subsequent shot blasting or by duego primer, use a fine powder of zinc in the environment of ethyl silicate binder at a ratio of 1 : 1 to 2 : 1, respectively.

8. The method according to p. 5, characterized in that the material forming the surface layer, use aluminum powder in an environment of ethyl silicate binder at a mass ratio of from 0.05 : 0.95 to 0.1 : 0.9 respectively.

9. The method according to PP.5 to 8, characterized in that as the use of ethyl silicate binder composition comprising, in wt.%:

Ethyl silicate - 11,5 - 12,7

The butyral - 5,5 - 7,7

Orthophosphoric acid (73%) - 0,15 - 0,45

Ethyl alcohol is 72.1 - 76,5

Water - The Rest

 

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