Coatings

 Organic Coating
 Inorganic Coating
 Metallic Coating

Page # 1
M. A. Islam
 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

Coating: The layer of organic or inorganic or metallic compounds or any combination of

materials that are applied on surfaces using any specific processes to protect from
corrosion and decorative purpose [15].

Classification of Coatings:

I. Organic Coating

II. Inorganic Coating

III. Metallic coating – Noble Coating and Sacrificial Coating

Selection of coatings:

 Required corrosion resistance

 The anticipated lifetime of the coated material

 The number of parts being produced and the production rate

 The usage environmental

 Reduce fogging
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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

 
I. Organic Coating: Coatings of Organic compounds are applied on the surfaces of
metallic materials to provide a physical barrier for corrosion protection and for
decorative purpose.

i. Paints: Paints are a mixture of insoluble particles of pigment suspended in a continuous

organic or aqueous vehicle.

Pigments: The substances that provide the coatings

a) Metallic Oxides –TiO2, Pb3O4, FeO3

b) Compounds -ZnCrO4, PbCO3, BaSO4, Clays

The vehicles: The vehicles are the substances that may dry by evaporation of the solvent
in which they are dissolved, or they may polymerize through application of heat or by
addition of catalysts (Such as lead, manganese, or cobalt soap )

c) Natural Oil - Linseed or Tung oil

d) Synthetic Resins - Phenol-formaldehyde, silicone and polymide, alkyd resins, Vinyl

resins and epoxy resins

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

ii. Varnishes: Varnishes are mixtures of drying oil, dissolved resins and a volatile
thinner.

iii. Lacquers: Lacquers are resins dissolved in a volatile thinner sometimes containing
pigments.

Points to remember

 Paints in general are not useful for protecting structures buried in soils – Coal tar
coating is useful

 Linseed Oil and Tung Oil based paint are not recommended for metallic structures
totally immersed in water

 Synthetic resins are frequently used particularly for continuous contact with water
or resistance to acids, alkalies or higher temperatures

 To reduce atmospheric pollution aqueous vehicle paints is preferred

 Apply several coats rather than one for required thickness

(Because pores are better covered by several applications and evaporation or dimensional
changes during polymerization are better accommodated by thin films)

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

Paint qualities for corrosion protection

1. Provide a Good Vapor Barrier. All paints and its vehicles are more or less
permeable to water and oxygen and effective sealing of pores and other defects can be
done by multiple – coats of the paints.
2. Inhibit against Corrosion. Corrosion-inhibiting pigments incorporated into the prime
coat should be effective corrosion inhibitors and must be water soluble enough to
supply the minimum concentration of inhibiting ions necessary to reduce the corrosion
rate and at the same time not soluble to be leached out of the paint.
3. Provide Long Life at Low Cost: The rate of deterioration of a paint depends on the
particular exposed atmosphere( Atmospheric pollution, rain and sunshine)

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

Surface preparation for paint application

1) Cleaning All Dirt, Oils, and Greases from the Surface
2) Complete Removal of Rust and Mill Scale

3) Cleaning All Dirt, Oils, and Greases from the Surface

a) Solvents: Mineral spirits, naphtha, alcohols, ethers, chlorinated solvents, and so on
(Applied by dipping, brushing, or spraying)
b) Alkaline Solutions: Na3PO4, NaOH, Na2O · n SiO2 , Na2CO3 , borax and sometimes
sodium pyro or metaphosphate and a wetting agent.
(Applied by hot bath and electrolysis)

 Alkaline solutions provide a method of removing oily surface contamination that is

cheaper and less hazardous than the use of solvents.
 Alkaline solutions are more efficient in this particular function than solvents, but
perhaps less effective for removing heavy or carbonized oils.

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

2. Complete Removal of Rust and Mill Scale

a) Pickling: The process of removing the scale of a material in acid with a suitable
inhibitor for a certain temperature and time. Example - Pickling of Iron is done by
dipped into H2SO4 acid (3 – 10% by weight) containing a pickling inhibitor (Amino S)
at a temperature of 65 – 90 ° C for an average of 5 – 20 min and Oxide next to the
metal surface is dissolved, loosening the upper Fe3O 4 scale.
b) Blasting: The process of removing scale by high - velocity particles impelled by an
air blast or by a high velocity wheel is called Blasting. (Blast materials usually consist
of sand or sometimes of steel grit, silicon carbide, alumina, refractory slag, or rock
wool byproducts)
c) Fame cleaning: The process of removing scale by spalls off the surface through
sudden heating of the surface with an oxyacetylene torch.
d) Weathering: The process of removing scale by keeping the materials naturally for
several weeks or months
Among all methods pickling or blasting are most effective

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

Table: Effect of Surface Preparation of Steel on Life of Paint Coatings

[J. Hudson, J. Iron Steel Inst. 168, 153 (1951); (with W. Johnson), ibid.168,165 (1951)]

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 Coatings

 Organic Coating
 Inorganic Coating
 Metallic Coating

Page # 9
M. A. Islam
 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

II. Inorganic Coatings

A. Glass Coating: Vitreous enamels, glass linings, and porcelain enamels with suitable
coefficient of expansion fused on metals.

Advantages

1) Enameled steels exposed to the atmosphere and soil last many years

2) Protect against high - temperature gases

Disadvantages

3) Susceptibility to mechanical damage and cracking by thermal shock

4) Crazing - Failure occurs eventually by formation of a network of cracks in the coating

through which rust appears

Applications

Airplane, exhaust tubes, gasoline pump casings, advertising signs, decorative building
panels, plumbing fixtures, appliances, and so on

Vitreous enamel coatings are used mostly on steel

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

II. Inorganic Coatings

B. Portland cement coatings: Cement is the most used materials in the world

Advantages

1) Low cost

2) A coefficient of expansion approximating that of steel (1.2×10-5/°C)

3) Ease of application or repair

Disadvantages

4) Susceptibility to mechanical damage and cracking by thermal shock

5) In sulfate - rich waters, Portland cement may be attacked, but cement compositions
are now available with improved resistance to such water

Applications

Cast iron and steel water pipe, the interior of hot and cold - water tanks, oil tanks, and
chemical storage tanks on soil or water or seawater or mine waters or all.

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

II. Inorganic Coatings

C. Chemical conversion coatings : Chemical conversion coatings are protective coatings
formed in situ by chemical reaction with the metal surface.

1) Parkerizing / Bonderizing / Phosphate coatings: Parkerizing / Bonderizing are the

commercial name of phosphate coating which are produced by brushing or spraying a
cold or hot dilute manganese or zinc acid orthophosphate solution (ZnH2PO4 plus H3

PO4 ) onto a clean surface of steel.

Phosphate coatings do not provide appreciable corrosion protection when applied alone.
They are useful mainly as a base for paints, ensuring good adherence of paint to steel and
decreasing the tendency for corrosion to undercut the paint

2) Chromate Coating: Chromate coating on steel are produced by exposure to chromic

acid and dichromate

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

3. Oxide coatings:
a) Oxide coatings on steel can be prepared by controlled high - temperature oxidation in
air or, for example, by immersion in hot concentrated alkali solutions containing
persulfates, nitrates, or chlorates. Such coatings, blue, brown, or black in color,
consist mostly of Fe3O4 and, like phosphate coatings, are not protective against
corrosion. When rubbed with inhibiting oils or waxes, as is often done with oxidized
gun barrels, some protection is obtained.
b) Oxide coatings on aluminum are produced at room temperature by anodic oxidation
of aluminum (called anodizing ) in a suitable electrolyte (e.g., dilute sulfuric acid) at
current densities of 100 or more A/m2 . The resultant coating of Al2O 3 may be 0.0025
– 0.025 mm (0.1 – 1 mil) thick. The oxide so formed must be hydrated to improve its
protective qualities by exposing anodized articles to steam or hot water for several
minutes, a process called sealing

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 Coatings

 Organic Coating
 Inorganic Coating
 Metallic Coating

Page # 14
M. A. Islam
 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

Classification of Metallic coatings from Corrosion View:

1) Noble coatings - Provide only barrier protection
2) Sacrificial coatings - Provide barrier protection, and cathodic protection

Methods of applying Metallic coatings :

 Dipping

 Electroplating

 Spraying

 Cementation

 Diffusion

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

 Dipping : Hot dipping is carried out by immersing the metal on which the coating is to
be applied, usually steel, in a bath of the molten metal that is to constitute the coating,
most commonly zinc, but also aluminum and aluminum – zinc alloy

 Electroplating: In electroplating , the substrate, or base, metal is made the cathode in

an aqueous electrolyte from which the coating is deposited.

 Electrogalvanizing is the electroplating of zinc on either iron or steel

 Eelectroless plating — that is, by chemical reduction of metal – salt solutions,

with the precipitated metal forming an adherent overlay on the base metal. Nickel
coatings of this kind are called electroless nickel-plate.

 Spraying: thermal spraying of metal coatings, a gun is used that simultaneously melts
and propels small droplets of metal onto the surface to be coated. There are several
types of thermal spraying, with the three main variables in each type being the
temperature of the fl ame, the velocity of the particles that are sprayed onto

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

 Cementation: Cementation consists of tumbling the work in a mixture of metal powder

and a flux at elevated temperatures, allowing the metal to diffuse into the base metal.
Aluminum and zinc coatings can be prepared in this way.

 Diffusion coatings: of chromium, nickel, titanium, aluminum, and so on, can also be
prepared by immers-ing metal parts, under an inert atmosphere, in a bath of molten
calcium containing some of the coating metal in solution [6] .

 Gas - phase reaction : For example, CrCl2 , when volatilized and passed over steel at
about 1000 ° C (1800 ° F), results in formation of a chromium – iron alloy surface
containing up to 30% Cr in accord with the reaction

 Ion implantation is a process of producing thin surface alloy coatings by bombarding

the metal with ions in vacuum. Such coatings of, for example, Ti, B, Cr, or Y have
specialized applications for wear and high - temperature oxidation resistance

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 Department of Mechanical Engineering
Chittagong University of Engineering and Technology

Nickel Coatings :
Nickel coatings are usually prepared by electroplating and the metal is plated either
directly on steel or sometimes over an intermediate coating of copper. The copper under
layer is used to facilitate buffing of the surface on which nickel is plated, because copper is
softer than steel, and also to reduce the required thickness of nickel (which costs more than
copper) for obtaining a coating of minimum porosity.

Metals on which the coating does not deposit include lead, tin solder, cadmium,
bismuth, and antimony.

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