{"id":744,"date":"2014-07-03T08:00:46","date_gmt":"2014-07-03T13:00:46","guid":{"rendered":"https:\/\/www.ulprospector.com\/knowledge\/?p=744"},"modified":"2016-04-12T08:57:55","modified_gmt":"2016-04-12T14:57:55","slug":"pc-corrosion-inhibitive-pigments","status":"publish","type":"post","link":"https:\/\/ulprospector.ul.com\/744\/pc-corrosion-inhibitive-pigments\/","title":{"rendered":"Understanding Corrosion Inhibitive Pigments"},"content":{"rendered":"

The annual cost of steel corrosion\u00a0is estimated to be over $400 billion in the United States and $2 trillion globally. Corrosion\u00a0is a process where the metal can be degraded by electrochemical and\/or chemical processes. This article will discuss the use of lead- and chrome-free corrosion inhibitive pigments in coatings where corrosion is primarily from electrochemical processes. Accordingly, the correct use of corrosion inhibitive pigments can be of enormous economic value.<\/p>\n

Metals desire to be in their most thermodynamically stable state, which, in simplified terms, is the naturally occurring state of matter in its lowest energy state. Metals ordinarily exist naturally as oxides (e.g. iron oxide, aluminum oxide, zinc oxide, because oxides represent their lowest energy state. Corrosion is an electrochemical deterioration of a metal due to the reaction with its environment to transform the metal into its lowest energy state. Oxidation occurs at the anode (positive electrode) and reduction occurs at the cathode (negative electrode). Corrosion is normally accelerated by the presence of water, oxygen and salts (particularly of strong acids).<\/p>\n

For example in the case of steel:<\/p>\n

\"Corrosion1\"<\/p>\n

\"Corrosion2\"<\/p>\n

 <\/p>\n

 <\/p>\n

 <\/p>\n

 <\/p>\n

 <\/p>\n

Corrosion inhibitive pigments can deter corrosion by multiple mechanisms. However, all of these mechanisms have the ability to disrupt the electrochemical corrosion reaction in common.<\/p>\n

Cathodic inhibition<\/em> inhibits corrosion by impeding the flow of electrons at the cathode, whereas anodic inhibition inhibits corrosion by impeding the flow of electrons at the anode. The following is the standard EMF series of metals with the more inert or cathodic metals toward the top and the more anodic or active metals toward the bottom:<\/p>\n

\"Corrosion3\"<\/p>\n

Accordingly, in the above EMF series, Zn is more active than Fe. When a zinc rich primer is applied over steel, zinc\u00a0will oxidize preferentially to steel and thus prevent the underlying steel from oxidizing. In this scenario, Zn is anodic (more readily oxidized) to steel and therefore protects steel from oxidation. Thus, steel is protected from corrosion by cathodic inhibition, as well as by the barrier that the zinc-rich primer provides. When choosing a corrosion inhibitive pigment, several factors must be considered.<\/p>\n

Environmental factors that influence the rate of corrosion include moisture, pH of the moisture, wet and dry cycles, soluble salts, temperature and time.<\/p>\n

For example, moisture, soluble salts, higher temperatures and longer exposure times all normally exacerbate corrosion in coated metal films. With these issues in mind, the evaluation criteria and test methods must be carefully contemplated before selecting corrosion inhibitive pigments.<\/p>\n

The comparative corrosion resistance of coatings will vary dramatically depending on the test environment: Natural exposure and exposure conditions, salt spray (95% humidity\/5% salt and always moist), acidic salt spray, prohesion cyclic corrosion (wet and dry cycle with 0.04% ammonium sulfate and 0.05% salt, electrochemical impedance spectroscopy, salt soak or other. Most experts agree that accelerated tests are not always a good indication of how the coated metal will perform in the real world.<\/p>\n

Additional considerations are the metal type (e.g. steel, aluminum, galvanized), pretreatment and cleanliness of the surface. If the metal surface is not properly cleaned and prepared, the coating will lack adequate adhesion and premature failure will result.<\/p>\n

Furthermore, the type of coating in which the pigments will be used affects the selection of appropriate corrosion inhibitive pigments. Considerations include whether the coating is solventborne, waterborne, powder, air dry\u00a0or baked,\u00a0and if the film will be cross-linked\u00a0or thermoplastic. You should also consider the coating’s resin type and pigment volume concentration.<\/p>\n

Corrosion inhibitive or passivating pigments promote the formation of a barrier layer over anodic areas, thus passivating the surface. To be effective, these pigments have a minimum solubility. If the solubility is too high, the pigment will leach out of the coating too rapidly- reducing the time that the pigment is available to inhibit corrosion. If the coating film is more open (e.g. air dry latex), water permeation is higher and thus the corrosion inhibitive pigment will be depleted more rapidly. To function properly, the coating must permit the diffusion of some water to dissolve the pigment. Accordingly, blister formation may result under humid conditions as the pigment dissolves. Higher Tg (glass transition temperature) and higher crosslink density binders are known to improve blister resistance.<\/p>\n

Another prime consideration in the selection of a corrosion inhibitive pigment is the pH<\/a>\u00a0(EU<\/a>). For example, a pigment with a high pH may have a deleterious effect on the cure of acid catalyzed systems. Conversely, a pigment with a low pH may adversely affect the stability of waterborne systems.<\/p>\n

The vast majority of corrosion inhibitive pigments are comprised of the combination of metal ions (cations) derived from: zinc, strontium, chromium, lead, molybdenum, aluminum, calcium\u00a0or barium\u00a0and anions, such as those derived from phosphorous\u00a0(orthophosphoric and polyphosphoric acids), chromic acid and boric acid. Although chromate and lead, containing passivating pigments, are very effective in inhibiting corrosion, their use is very limited due to a variety of environmental and toxicological regulations.<\/p>\n

Suppliers of Corrosion Inhibitive Pigments Include:<\/p>\n

Buckman<\/a>
\nGrace<\/a>
\nHalox\u00a0(EU<\/a>)
\nHeubach<\/a>\u00a0(EU<\/a>)
\nNichent<\/a>
\nNubiola<\/a>\u00a0(EU<\/a>)
\nSNCZ<\/a>\u00a0(EU<\/a>)<\/p>\n","protected":false},"excerpt":{"rendered":"

The annual cost of steel corrosion\u00a0is estimated to be over $400 billion in the United States and $2 trillion globally. Corrosion\u00a0is a process where the metal can be degraded by electrochemical and\/or chemical processes. This article will discuss the use … Continued<\/a><\/p>\n","protected":false},"author":12,"featured_media":878,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"episode_type":"","audio_file":"","podmotor_file_id":"","podmotor_episode_id":"","cover_image":"","cover_image_id":"","duration":"","filesize":"","filesize_raw":"","date_recorded":"","explicit":"","block":"","itunes_episode_number":"","itunes_title":"","itunes_season_number":"","itunes_episode_type":"","footnotes":""},"categories":[16],"tags":[],"ppma_author":[1249],"class_list":{"0":"post-744","1":"post","2":"type-post","3":"status-publish","4":"format-standard","5":"has-post-thumbnail","7":"category-paint-coatings","8":"entry"},"yoast_head":"\nUnderstanding Corrosion Inhibitive Pigments<\/title>\n<meta name=\"description\" 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Lewarchik, President and CEO of Chemical Dynamics, LLC, brings 40 years of paint and coatings industry expertise to his role as a contributing author with the Prospector Knowledge Center. As a contributing writer, Ron pens articles on topics relevant to formulators in the coatings industry. He also serves as a consultant for the Prospector materials search engine, advising on issues related to optimization and organization materials within the database. Ron's company, Chemical Dynamics, LLC (www.chemicaldynamics.net), is a full-service paint and coatings firm specializing in consulting and product development based in Plymouth, Michigan. Since 2004, he has provided consulting, product development, contract research, feasibility studies, failure mode analysis and more for a wide range of clients, as well as their suppliers, customers and coaters. He has also served as an Adjunct Research Professor at the Coatings Research Institute of Eastern Michigan University. 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Lewarchik, President and CEO of Chemical Dynamics, LLC, brings 40 years of paint and coatings industry expertise to his role as a contributing author with the Prospector Knowledge Center. As a contributing writer, Ron pens articles on topics relevant to formulators in the coatings industry. He also serves as a consultant for the Prospector materials search engine, advising on issues related to optimization and organization materials within the database. Ron's company, Chemical Dynamics, LLC (www.chemicaldynamics.net), is a full-service paint and coatings firm specializing in consulting and product development based in Plymouth, Michigan. Since 2004, he has provided consulting, product development, contract research, feasibility studies, failure mode analysis and more for a wide range of clients, as well as their suppliers, customers and coaters. He has also served as an Adjunct Research Professor at the Coatings Research Institute of Eastern Michigan University. As such, Ron was awarded a sub-grant from the Department of Energy to develop energy-saving coating technology for architectural applications, as well as grants from private industry to develop low energy cure, low VOC compliant coatings. He taught courses on color and application of automotive top coats, cathodic electro-coat and surface treatment. His experience includes coatings for automotive, coil, architectural, industrial and product finishing. Previously, Ron was the Vice President of Industrial Research and Technology, as well as the Global Director of Coil Coating Technology for BASF (Morton International). During his fourteen-year tenure with the company, he developed innovative coil coating commercial products primarily for roofing, residential, commercial and industrial building, as well as industrial and automotive applications. He was awarded fifteen patents for new resin and coating formulas. From 1974 to 1990, Ron held positions with Desoto, Inc. and PPG Industries. He was the winner of two R&D awards for coatings utilizing PVDF resins, developed the first commercial high solids automotive topcoat and was awarded 39 U.S. patents for a variety of novel technologies he developed. He holds a Masters in Physical Organic Chemistry from the University of Pittsburgh and subsequently studied Polymer Science at Carnegie Mellon University. Ron lives in Brighton, Michigan with his family. 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