The failure mechanisms of organic coatings on Zinc Aluminium Magnesium substrates under exposure to natural conditions & accelerated corrosion environ

Full Title: The failure mechanisms of organic coatings on Zinc Aluminium Magnesium substrates under exposure to natural conditions and accelerated corrosion environments
Coil coatings are used to protect aluminium and steel from natural environments, whereby adhesion and anticorrosive protection are the essential properties to maintain good corrosion resistance. Many steel products are based of hot dip galvanised steel coated with a pre-treatment, a primer, and a topcoat. In the last few years, steel producers have developed lower thicknesses of the galvanising layer-using an alloy of 10 microns of zinc aluminium magnesium (ZAM) in order to decrease the total cost of the substrate by reducing the thickness of the sacrificial layer, offering the same corrosion protection as thicker zinc layer of 20 microns.
In the last decade, the industry partner, Becker Industrial Coatings Ltd. (Beckers) has developed and commercialised chromate free primers for ZAM substrates with varying success. The same primer was found to have varying corrosion resistance when coated on different grades of ZAM substrates. In addition, polyester cross-linked with isocyanate generally has better corrosion resistance than polyester cross-linked with melamine.

The aims of the project are to investigate and monitor the corrosion failure mechanisms of coil coatings on different grades of ZAM substrates. To study the coatings behaviour when exposed in salt spray, Prohesion, and the natural site at Bohus Malmon and to correlate with electrochemical impedance spectroscopy (EIS) and scanning vibrating electrode (SVET). Raman or IR spectroscopy could be used to identify the corrosion products produced during the testing.

The CDT will produce 50 graduates with doctoral level knowledge and research skills focussed on the development and manufacture of functional industrial coatings. Key impact areas are:

Knowledge
- The development of new products and processes to address real scientific challenges existing in industry and to transfer this knowledge into partnering companies. The CDT will enable rapid knowledge transfer between academia and industry due to the co-created projects and co-supervision.
- The creation of knowledge sharing network for partner companies created by the environment of the CDT.
- On average 2-3 publications per RE. Publications in high impact factor journals. The scientific scope of the CDT comprises a mixture of interdisciplinary areas and as such a breadth of knowledge can be generated through the CDT. Examples would include Photovoltaic coatings - Journal of Materials Chemistry A (IF 8.867) and Anti-corrosion Coatings - Corrosion Science (IF 5.245), Progress in Organic Coatings (IF 2.903)
- REs will disseminate knowledge at leading conferences e.g. Materials Research Society (MRS), Meetings of the Electrochemical Society, and through trade associations and Institutes representing the coatings sector.
- A bespoke training package on the formulation, function, use, degradation and end of life that will embed the latest research and will be available to industry partners for employees to attend as CPD and for other PGRs demonstrating added value from the CDT environment.

Wealth Creation
- Value added products and processes created through the CDT will generate benefits for Industrial partners and supply chains helping to build a productive nation.
- Employment of graduates into industry will transfer their knowledge and skills into businesses enabling innovation within these companies.
- Swansea University will support potential spin out companies where appropriate through its dedicated EU funded commercialisation project, Agor IP.

Environment and society
- Functionalised surfaces can potentially improve human health through anti-microbial surfaces for health care infrastructure and treatment of water using photocatalytic coatings.
- Functionalised energy generation coatings will contribute towards national strategies regarding clean and secure energy.
- Responsible research and innovation is an overarching theme of the CDT with materials sustainability, ethics, energy and end of life considered throughout the development of new coatings and processes. Thus, REs will be trained to approach all future problems with this mind set.
- Outreach is a critical element of the training programme (for example, a module delivered by the Ri on public engagement) and our REs will have skills that enable the dissemination of their knowledge to wide audiences thus generating interest in science and engineering and the benefits that investments can bring.

People
- Highly employable doctoral gradates with a holistic knowledge of functional coatings manufacture who can make an immediate impact in industry or academia.
- The REs will have transferable skills that are pertinent across multiple sectors.
- The CDT will develop ethically aware engineers with sustainability embed throughout their training
- The promotion of equality, diversity and inclusivity within our cohorts through CDT and University wide initiatives.
- The development of alumni networks to grow new opportunities for our CDT and provide REs with mentors.