Investigating the long term effects of creep with chromate free primers
Lead Research Organisation:
Swansea University
Department Name: College of Engineering
Abstract
Creep has negative conations in many walks of life. It is no different in the field of Coil Coated metal. Creep describes what happens when corrosive materials insidiously force their way between the two halves of the paint metal interface. The process starts from the cut edge of a piece of painted metal advancing inwards at a rate determined by the strength of adhesion, the anticorrosive weaponry lined up against it and of course the strength of the conditions pushing the chemicals forward.
Chromate Free Primers for Galvalume suffer badly from edge corrosion. Some people believe that this slows down after a period of time and coatings on substrates such as Galfan and HDG 'catch up' on the extent of creep from the cut edge after a period of time (5 years) but at Beckers we have not seen this. We would like to understand the differences between edge corrosion on galvalume and the other 2 substrates. To this end we would like to apply the electrochemical methodology; Scanning Vibrating Electrode Technique (SVET) to a small selection of primers plus topcoats applied to the above mentioned substrates.
Project aims:
The aim of the project is to characterise the cut edge corrosion that takes place on Galvalume, Galfan and Hot Dip Galvanised Steel using electro-chemical techniques. The panels will be coated with chromate containing and chromate free primers plus topcoats. A maximum of 2 different anti-corrosive pigments will be tried. Any differences will be investigated and the parameters that impact on the speed of cut edge corrosion will be addressed in an effort to slow down the rate of edge corrosion. Correlations between electrochemical testing, Salt Spray and Exterior exposures will be attempted.
Chromate Free Primers for Galvalume suffer badly from edge corrosion. Some people believe that this slows down after a period of time and coatings on substrates such as Galfan and HDG 'catch up' on the extent of creep from the cut edge after a period of time (5 years) but at Beckers we have not seen this. We would like to understand the differences between edge corrosion on galvalume and the other 2 substrates. To this end we would like to apply the electrochemical methodology; Scanning Vibrating Electrode Technique (SVET) to a small selection of primers plus topcoats applied to the above mentioned substrates.
Project aims:
The aim of the project is to characterise the cut edge corrosion that takes place on Galvalume, Galfan and Hot Dip Galvanised Steel using electro-chemical techniques. The panels will be coated with chromate containing and chromate free primers plus topcoats. A maximum of 2 different anti-corrosive pigments will be tried. Any differences will be investigated and the parameters that impact on the speed of cut edge corrosion will be addressed in an effort to slow down the rate of edge corrosion. Correlations between electrochemical testing, Salt Spray and Exterior exposures will be attempted.
Planned Impact
The COATED2 CDT will support the aims of the EPSRC/TSB SPECIFIC IKC and the EPSRC CIM in Large Area Electronics at Swansea University through the provision of 40 research engineers (REs). The SPECIFIC IKC has ambitious targets to create buildings that are power-stations through the use of functional coatings. The targets include:
- A £1billion UK manufacturing sector creating business opportunities with export potential
- Creation of around 7,000 manufacturing/construction sector jobs
- Generation of up to 1/3 of the UK's renewable energy target
- Reduction in CO2 emissions of up to 6 million tons
The CIM in Large Area Electronics has key aims that are synergistic with the IKC, in particular to address the challenges of low-cost manufacturing of multi-functional LAE systems and to support the scale-up of technologies for functional materials. Both projects have shared technologies and processes and RE support through COATED2 will have significant impact on achieving their aims through:
- The supply of highly trained and enthusiastic REs for a growing new industry base
- Encouraging radical thinking for REs in terms of optimisation and up-scaling of laboratory concepts to an industrial scale
- Achieving greater engagement with new and existing industry and academic partners.
The COATED2 RE cohorts will provide impact in a number of key areas -
Knowledge
- Research projects defined by industry with a real scientific or engineering need at their core ensuring relevant research is embedded within the industrial partner/University.
- Engagement of multiple partners through the CDT/IKC's open innovation arrangements permits sharing of knowledge between otherwise discrete industries
- Each RE will produce 3 publications and attend 1 international conference disseminating knowledge into the academic community.
- RE research will be evidenced in taught modules ensuring that quality of training is enhanced year on year.
- Development of new technologies will create a lead for the UK in up-scaling of complex functional coated products.
- Training modules are accessible to Industrial partners providing knowledge beyond the scope of the core CDT.
Economy
- Future industry leaders will be created from the CDT. 96% of previous REs at Swansea have moved onto industry related careers.
- Innovative new products and processes will catalyse new industries and technology advances in established manufacturers generating wealth.
- 8 Patents have been filed by the IKC since 2011 and REs are critical for the on-going development of IP exploitation.
- SPECIFIC Innovations has been established to develop business models and spin-out companies for the exploitation of IP created through the CDT and IKC attracting inward investment.
- The facilities within SPECIFIC and the CIM coupled with extensive industrial partners bridges the gap between research and wealth creation ensuring that outputs from the CDT are maximised.
Society
- REs will engage in active outreach to promote their research and attract more people into STEM activities.
- There have been over 1000 separate visits to the IKC/CDT raising awareness of the product potential to a range of end users.
- Research activity at the CDT supporting the IKC and the CIM will contribute towards alleviating fuel poverty, reducing CO2 output and providing energy security
- Water purification, bio-inspired coatings and durability research benefits developed and developing nations.
People
- The CDT will produce 40 highly skilled individuals trained to support industry and academia
- Graduates of the scheme moving into employment will grow networks between academia and industrial partners creating new opportunities for the CDT.
- Shared seminars with other institutions will enable REs to gain insights into complementary research and raise awareness of available facilities and resources
- A £1billion UK manufacturing sector creating business opportunities with export potential
- Creation of around 7,000 manufacturing/construction sector jobs
- Generation of up to 1/3 of the UK's renewable energy target
- Reduction in CO2 emissions of up to 6 million tons
The CIM in Large Area Electronics has key aims that are synergistic with the IKC, in particular to address the challenges of low-cost manufacturing of multi-functional LAE systems and to support the scale-up of technologies for functional materials. Both projects have shared technologies and processes and RE support through COATED2 will have significant impact on achieving their aims through:
- The supply of highly trained and enthusiastic REs for a growing new industry base
- Encouraging radical thinking for REs in terms of optimisation and up-scaling of laboratory concepts to an industrial scale
- Achieving greater engagement with new and existing industry and academic partners.
The COATED2 RE cohorts will provide impact in a number of key areas -
Knowledge
- Research projects defined by industry with a real scientific or engineering need at their core ensuring relevant research is embedded within the industrial partner/University.
- Engagement of multiple partners through the CDT/IKC's open innovation arrangements permits sharing of knowledge between otherwise discrete industries
- Each RE will produce 3 publications and attend 1 international conference disseminating knowledge into the academic community.
- RE research will be evidenced in taught modules ensuring that quality of training is enhanced year on year.
- Development of new technologies will create a lead for the UK in up-scaling of complex functional coated products.
- Training modules are accessible to Industrial partners providing knowledge beyond the scope of the core CDT.
Economy
- Future industry leaders will be created from the CDT. 96% of previous REs at Swansea have moved onto industry related careers.
- Innovative new products and processes will catalyse new industries and technology advances in established manufacturers generating wealth.
- 8 Patents have been filed by the IKC since 2011 and REs are critical for the on-going development of IP exploitation.
- SPECIFIC Innovations has been established to develop business models and spin-out companies for the exploitation of IP created through the CDT and IKC attracting inward investment.
- The facilities within SPECIFIC and the CIM coupled with extensive industrial partners bridges the gap between research and wealth creation ensuring that outputs from the CDT are maximised.
Society
- REs will engage in active outreach to promote their research and attract more people into STEM activities.
- There have been over 1000 separate visits to the IKC/CDT raising awareness of the product potential to a range of end users.
- Research activity at the CDT supporting the IKC and the CIM will contribute towards alleviating fuel poverty, reducing CO2 output and providing energy security
- Water purification, bio-inspired coatings and durability research benefits developed and developing nations.
People
- The CDT will produce 40 highly skilled individuals trained to support industry and academia
- Graduates of the scheme moving into employment will grow networks between academia and industrial partners creating new opportunities for the CDT.
- Shared seminars with other institutions will enable REs to gain insights into complementary research and raise awareness of available facilities and resources
People |
ORCID iD |
| Hamilton McMurray (Primary Supervisor) | |
| Peter Morgan (Student) |