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Corrosion Protection of Metallic Surfaces

Corrosion protection and prevention is of central importance in all sectors of industry. For consequences of corrosion will always lead to consequential costs. It is a great task for the varnishing industry to stop or at least to slow down these processes especially at industrial plants. Due to the increased users consciousness concerning environmental questions and also because of legal requirements (e.g. VOC-contents) water-based varnishes are used to an increasing degree. It is, however, still a challenge for the varnishing industry to produce aqueous coatings which will at the same time offer a good protection against corrosion.

The efficiency of an antirust coating will depend to an essential part on the degree and scope of the preparation of the base. Normally a derusted, dry and fat-free base is necessary for a long-term protection against corrosion. Quite often these conditions are not given in practice. In many cases residual rust will remain on the surface and in the pores. The antirust effect of the coating seems to be satisfactory at first. However, the result after some time: rust will destroy the new coating from underneath.

The oxidation of iron in the air, the rusting process, is rather a complicated process, which can be described schematically by the following reaction equation:

2 Fe

2 Fe2 + 4ey 2 Fe3 + 2 OHy 2 Fe(OH)3

O2 + 4ey + 2 H2O 4 OHy 2 Fe


2

+ H2O + O2 2 Fe
3

+ 6 OHy

-------------------------------------------------------------2 Fe + 3 H2O + 1 O2 2 Fe(OH)3 This is a classic redox reaction. By interrupting one of the half reactions the complete process is interrupted and this way corrosion is stopped.

Bernd Schwegmann GmbH & Co. KG Wernher-von-Braun-Str. 14 53501 Grafschaft-Gelsdorf Germany www.SchwegmannNet.de

This is why you cannot do without a corrosion inhibiting pre-treatment or a respective additive especially in case of water-based corrosion protection systems. However, the commonly used methods have all got their special disadvantages: Pre-treatment with primer means an additional step in the working process Corrosion preventing pigments will need a certain minimum thickness of the coating Many corrosion inhibitors are not stable against pH-influences and humidity.

An additive would be desirable, which can be used in every common system, directly applied on a coarsely derusted surface and will warrant a lasting corrosion protection. An effective protection against corrosion should a) b) prevent the access of corrosive active substances (mechanical barrier effect) or/and intervene in the electro-chemical corrosion process in such a way that this process is prevented or at least delayed (electrochemical influence).

This can be realised very effectively by the formation of a metallo-organic complex, the so-called chelate complex. Chelate complexes have got great importance in nature and also in chemical analysis as extremely stable compounds (haemoglobin, vitamin B12, aluminium-detection with alizarin etc.)

By forming a metal chelate the further oxidation of the metal is prevented by stopping any further reaction of the Fe
3

(s. reaction scheme).

This reaction is, put in simple words, a transformation of the instable Fe-III-oxides into the Fe-II-oxide as component of a very sparingly soluble chelate complex. Iron-II-compounds are known, for instance, from iron oxide-pigments, as very stable compounds. The result is a stable, metal organic layer solidly adhesive at the metal surface which cannot be oxidised any further so that the bound Fe-ions are not available any more for the continuation of the electro-chemical corrosion. Furthermore the building of this layer will effectively prevent any further attack of oxygen on the metal underneath in the sense of a barrier layer. This way you will practically have a chemical compound between metal surface and organic coating. The result is permanent protection against corrosion.

Bernd Schwegmann GmbH & Co. KG Wernher-von-Braun-Str. 14 53501 Grafschaft-Gelsdorf Germany www.SchwegmannNet.de

The corrosion inhibitor Schwego Corrit developed by Schwegmann Company exactly follows this principle just like Korrodur, which has been established in the market for years and therefore offers corrosion protection especially for iron metals, which can be used in many systems (repair varnishes, DIY, one-layer rust protection systems): Existing residual rust will be passivated by transforming it into an extremely stable metal complex. The moistening of the base is improved. The adhesion of the varnish coating to the substrate is optimised. It can be applied on rusty surfaces only the loose rust will have to be removed.

Schwego Corrit can be used as additive for water-based systems with almost all current varnishes and can be added to abt. 2 %. This way, practically each normal varnish can be equipped with corrosioninhibiting properties without any further changes to the recipe. Korrodur is added to abt. 3 % to conventional, i.e. solvent-based systems.

Bernd Schwegmann GmbH & Co. KG Wernher-von-Braun-Str. 14 53501 Grafschaft-Gelsdorf Germany www.SchwegmannNet.de

As an example of a practical application the photo of a coating after several months of outside weathering exposure is shown.

On the photo on the left you can see the comparison, the photo on the right shows the sample with 3% Schwego Corrit. In the upper half a water-based primer (red) was applied in each case, in the lower half a white coating varnish was applied. An example of a recipe is shown in the following. It is remarkable that the metallic base of the damages remains shiningly metallic apart from some discolourations, which can be attributed to the reaction with the chelate forming agent and will not show any beginning rust. The compared sample is completely rusty.

Bernd Schwegmann GmbH & Co. KG Wernher-von-Braun-Str. 14 53501 Grafschaft-Gelsdorf Germany www.SchwegmannNet.de

********************Starting Formulation************************* Designation: aqueous metal primer, oxide red with Schwego Corrit 3% Acrylate with Stryol

Basis:

Alberdingk AS 2681

Composition: dest H2O 10,40% Dowanol DPM 3,80% Schwego Foam 8013 (Schwegmann) 0,60% Talkum AT extra (Norwegian Talc) 5,00% Microdol Extra (Omya) 8,00% Zinc phosphate ZP 10 (Heubach) 10,00% Zinc white resin seal (Heubach) 0,50% Bayferrox 130 M (Bayer) 8,50% Schwego Pur 8050 (Schwegmann) 1,20% Propylenglykol 11,00% Schwego Corrit (Schwegmann) 3,00% Dissolver and then bead mill Fineness 25- 30m Then prepare the following positions and slowly add the above-mentioned paste by stirring Alberdingk AS 2681 (Alberdingk&Boley) 30,00% Adhesive resin EP-DS 1300 (Degussa Hls) 3,00% Artificial resin EP-DS 50 (Degussa Hls) 5,00% Total of recipe: 100% Notes concerning the processing: Weigh out together pos. 1 to pos 10 and dissolve, then add pos. 11 with the dissolving unit running and disperse until the new fineness of 25-30m is reached. Prepare pos.12 to Pos.14 and slowly feed the dye paste. For adjusting the viscosity: Propylene glycol

Bernd Schwegmann GmbH & Co. KG Wernher-von-Braun-Str. 14 53501 Grafschaft-Gelsdorf Germany www.SchwegmannNet.de