battle corrosion

7/28/2019 Battle Corrosion

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2012

RUSTBULLET

Bat t l eCor r osion


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ember BATTLE CORROSION

R U S T B U L L E T w w w . r u s t b u l l e t . c o m Pa e 2

Contents

Execut ive Summary ___________________________________________________________ 3

Int roduction to Corrosion_______________________________________________________ 4

History of Corrosion________________________________________________________________ 4

Corrosion and need for its prevention _________________________________________________ 4

Corrosion ________________________________________________________________________ 7

Types of Corrosion _________________________________________________________________________ 8

Types of Prevention _______________________________________________________________________ 10

Modifying the Environment ______________________________________________________________ 10

Working the Metal______________________________________________________________________ 11

Corrosion in the United States of America ________________________________________ 13

Corrosion Costs___________________________________________________________________ 13Industry Economics _______________________________________________________________ 14

Corrosion Accidents in the U.S. ______________________________________________________ 15

Major Prevention Methods Used (Coatings)____________________________________________ 16

Rustbullet Solution________________________________________________________________ 18

Conclusion__________________________________________________________________ 20

Bibliography ________________________________________________________________ 21

Disclaimer __________________________________________________________________ 22

About Rustbullet_____________________________________________________________ 23


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R U S T B U L L E T

Corrosion has been one of the biggtrillion every year from the world ebring to attention the problem of cooccurred where corrosion has playe

explosions in the pipelines and oil s

Corrosion costs across industries hamaterials, and a lack of efficient cocorrosion problem can be addressecorrosion science and adoption of bmaterials, but an equal proportion ocosts are involved. Following is a fof industries affected by corrosion.

Figure 1 Corrosion Costs from ac

Corrosion is a natural process and

their original brittle form. A simplepresence of anodic and cathodic poioxygen. With proper prevention mecorrosion.

Corrosion methods can be classifie

1.) Controlling the external environ

2.) Controlling the internal environ

While corrosion has been a problewhere measured, that an increasedcreated. Many agencies around the

best practices for corrosion preventiNACE, Institute of Corrosion (U.K.

Of all the available methods for corcoatings and coupling of coatingsthe form of metal coatings (galvaniWhile all coatings have their advanavailable taking into account ease,

BA TTLE CORROSION

w w . r u s t b u l l e t . c o m

Executive Summaryst sources of wastage in the world causing us to losonomy, yet it has long stayed under the radar. Thisrosion and its adverse effects. Several catastrophic

d a vital role, such s the collapse of Berlin Congress

pills caused due to sinking ships weakened by corro

ve shown that they are a result of design efficiencierosion prevention mechanisms. Most factors contriif sufficient efforts are made in research and devel

etter practices. Costs of corrosion are not limited tof indirect cost such as loss of efficiency, delays, andigure of the corrosion costs in U.S.A. which gives a

ross industries representing the total cost of corr

ill invariably occur as a process where the metals w

electrochemical process of corrosion requires certaints, presence of an electrolyte to work as a catalystasures the process can be disrupted, and materials c

into two categories.

ent of corrosionent of corrosion (the electrochemical process in th

identified as early as the 1800s, it is only recentlywareness of its effects and new prevention methodsorld are now trying to create awareness about corr

on. Some of these associations are World Corrosion), Australasian Corrosion Association and many oth

osion prevention, the best available methods haveith cathodic protection. There are many types of coation), paints, powder coatings and some more innages and disadvantages, a careful analysis reveals tpplicability and cost.

Pa e 3

almost $1.3paper attempts toevents haveHall, gas

sion.

, use of wronguting to thepment ofdirect cost ofsimilar otheridea of the array

sion

ill try to return to

n factors such asnd presence ofn be saved from

material)

nce the costshave beension effects and

Organization,ers.

roven to betings available invative coatings.e best options


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Introduction to Corrosion

History of Corrosion

Though Plato (427-347 B.C.) mentions corrosion in Phaedo For this earth, and the stones, and the entireregion which surrounds us are spoilt and corroded, like the things in the sea which are corroded by thebrine ... the problem of corrosion was possibly identified in 1675 through the work of Robert Boyle.Similarly while the electrochemical theory was given by W.H. Wollaston in 1801, it was not until 1903 apersuasive paper was put forth by Whitney where corrosion was suggested to be an electrochemicalprocess.

Similarly, the first prevention methods can be traced back in history going as back as 1824 when SirHumphry Davy used iron anodes to protect the copper on the ships in the British Navy from corrodingeffects of the sea water. The use of impressed current was possibly first attempted by Edison, for the samepurpose of preventing the corrosion of ships.

While we see that the identification of the problem of corrosion and the efforts to find a solution havebeen on for more than 200 years, the scale of corrosion damage to the world today displays the lack ofeffort and attention that corrosion has received.

Corrosion and need for its prevention

If corrosion was a country, its annual GDP would be $1.6 to $1.8 trillion, collecting revenues from

industries across the world, taking in almost 3.1-3.5 % of a nations GDP. These are only the direct cost

of corrosion taking into account the cost of materials, equipment and services for replacement and

maintenance. There are a lot of costs involved which can be considered as indirect cost, which will

possibly double the given figure making it one of the richer countries in the world. A summarization of

these direct and indirect costs can be classified in the following categories.

Costs of lost products: Corrosion just does not generate loss of the material in pipelines, storagecontainers and tanks, but also causes loss of water, oil or any other materials being transported. It isestimated that 25% of the water is lost due to leakage.

Cost of loss due to inefficiency: In places such as power plants or similar, there will be loss of heattransfer and capacity of the storage equipment.

Cost of loss due to contamination: Corrosion products will also mix with the materials being stored ortransported through various pipelines and affect the quality of water, chemicals or pharmaceuticals.

Cost of loss due to break in operations: Corrosion decreases the life of structures and can result incomplete shutdown of machinery, plants, and other equipment.

The major industries that have to bear most of the corrosion costs are construction industry, chemical andpetrochemical, transportation industry verticals such as rails, automotive and aviation. Defense industry isalso largely affected due to corrosion.

A lot of concerns are also raised by corrosion some of which are given below.

1. Security Issues: Corrosion severely compromises on the mechanical properties of the structure, in

terms of strength, shape and others. The weakening of these factors has resulted in catastrophic events


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in the past. Several deaths are caused on the road by failure of corrosion weakened components in the

car. Some of the corrosion disasters would be collapse of the silver bridge, Bhopal gas tragedy, the

sinking of Erika and many more. The probability of explosions, fire, release of toxic chemicals and

structural damage is severely increased by corrosion, alarmingly raising the threat to safety.

Sinking of Erika in December 1999, single oil spill was equal to the total oil spill in the world till 1998.

2. Health Issues: Corrosion products get dissolved in the water pipelines, causing adverse effect on the

health of consumers. They also get dissolved into the factory drainage systems, and while a company

is complying with all the safety regulations when releasing the waste in water, the merging of

corrosion products can lay waste to all the efforts.

Copper pipes carrying the water on being corroded getting mixed into the water distributed to homes

vs. normal water

3. Wastage of resources:With price of oil rising every day, each drop spilled due to leakage is a big

weight on our already depleting resources. Loss of efficiency in plants and factories due to corrosion,

waste of water, and waste of other resources in form of repair materials, and manpower are all

examples of waste of resources.


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4. Declining product life: Something which is made for years can be rendered useless within months, if

no measures are taken to prevent corrosion. There are examples such as the DC-3 aircrafts and Eifel

tower. The aircrafts were made for 20 years have survived more than 60 years, Eifel tower was

designed for 2 years and still stands tall, all due to efficient design and proper material selection.

Having looked into the effects of corrosion one needs to understand why does this happen? We willquickly look at how corrosion affects the structural integrity.

1. Mechanical Strength: Corrosion undermines the mechanical strength of the material to withstandloads, and therefore creates stress points in a structure, which can cause loss of structure.

2. Water-resistance:The material should be water resistant, and corrosion takes away the impermeablenature of the material. This weakens and allows external particles to enter the storage material.

3. Physical Properties: Physical properties such as thermal and/or electrical conductivity, or thermaland/or electrical resistance is affected by corrosion.

A survey done by a large US based chemical company reveals various factors which are responsible forcorrosion. A quick breakdown of the results is as follows

Factor responsible for corrosion Share in %

Lack of proving, new design, materials,or process

36%

Lack of, or wrong, specifications 16%

Bad Inspection 10%

Human Error 12%

Poor Planning and coordination 14%

Other 4%

Unforeseeable 8%

One can easily notice that only 8% of the time, corrosion prevention was not possible because of

unforeseeable circumstances. Therefore, almost 92% of the corrosion that occurs is preventable.

Although this still is a very large figure, corrosion experts have concluded that adoption of good corrosion

prevention measures can reduce the present cost of corrosion by 20-25%, which means approximately

$416 to $461 billion can be saved in the worlds economy.


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Corrosion

Now that we know the significance of Corrosion, and understand the problems caused by it, in order to

find a solution, one first needs to completely understand the problem of corrosion. So lets start by

defining corrosion.

Corrosion is a natural electrochemical process. In order for it to occur, it needs the following components:

1. An Anode2. A Cathode

3. Oxygen Supply4. An Electrolyte5. A conductive path for the electron transfers.

We will for illustration purposes take the example of Iron (Fe) and the electrochemical reactions it goesthrough during corrosion.

Two kinds of reaction can lead to corrosion, one is anodic reaction, in which the metal, iron in this case,gives away electrons, which can be shown by the following reaction

Fe Fe2+ + 2e-

When the pH level is high, a surface film of Ferrous Oxide is created, the equation for which is givenbelow

2Fe + 3H2O Fe2O3 + 6H+ + 6e-

Now, in a cathodic reaction the electrons are provided by the reactions between water (H2O) and oxygen.

O2 + 2H2O + 4e- 4OH-

Now the decrease of oxygen will increase the pH due to creation of hydroxide ions.

It is this potential difference between the metal and the solution on the surface, which is the main factordetermining the rate of reaction and controlling the products formed due to the electrode reaction.

Pictorial representation of a typical corrosion process


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What one needs to understand here is that corrosion is a natural process, trying to bring back the metal toits original state as found in nature. For example, steel is made from iron ore and a lot of energy is addedwhen steel is formed. This energy stays with steel, and because of its high energy state, it would try toreact given an opportunity to move back to its original state. So the fight against corrosion is our fightagainst nature which has been on for a long time, with nature still holding the upper hand. However,

significant improvements have been made, which will be discussed further. For now we need tounderstand the main forms of corrosion which we are most likely to encounter.

Types of Corrosion

Galvanic Corrosion

This form of corrosion occurs when dissimilar metals are in contact. For example, a screw in a metalsheet. When two metals with different compositions get in contact in the presence of an electrolyte (whichis more often than not present in some form of water or other chemicals), the higher reactive metal willcorrode very quickly while the other metal will stay protected. Some examples of such a mix will be steel

with copper or steel with brass, where the steel starts corroding.

Wrong combination of screw and surface metal causing corrosion

Crevice Corrosion

This type of corrosion happens when in an electrolytic solution there is an increased concentration of ionsor dissolved gases. Since the solution gets trapped between the extension and the pipe slowly the oxygenlevels starts dropping and the metal begins to oxidize.

An example of a Crevice Corrosion


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Pitting

In this form of corrosion, small pits are formed on the surface of the metal or alloy. A minute

imperfection in the metal/alloy is enough to start pitting, which then grows bigger slowly. This is one of

the dangerous forms of corrosion as it is not noticeable at first. One of common examples of this would

be exposure of stainless steel to chlorides, especially sea water.

Pitting of stainless steel by chlorine disinfection

Erosion Corrosion

Erosion corrosion occurs by a mixed attack from chemicals such as chlorides and also mechanical graze.Type of fluid plays an important role here and materials which have a passive layer are attacked moreeasily. The physical abrasion removes the passive layer and the chemicals then work on the bare metalsurface. This is most common in pipelines and marine environment.

Marine corrosion of Steel Pipes

Stress Corrosion

This is a combination of tensile stress which causes cracks and then the corrosive environment takesadvantages of the exposed metals and further weakens the metal through corrosion which reduces itsmechanical strength. This means the weakened metal is now under the same tensile stress it was before,but due to the reduced capacity to bear the load, cracks widen and new cracks occur which further

corrode. The classic example of this would be the fall of Berlin Congress Hall in 1980.

Berlin Congress Hall before Collapse Berlin Congress Hall after Collapse


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Types of Prevention

In order to prevent corrosion, the main aim is to prevent the electrochemical reaction from happening or

at least slow down the rate of this electrochemical reaction significantly.

Broadly, there are two ways through which the above said goals can be accomplished.

Modifyi ng the Envir onment

By modifying the environment around the metal structure to be protected, one can prevent or slow downcorrosion. This can be accomplished through

(a) Removal of Oxygen

The oxygen around the metal structures can be reduced through the use of strong reducing agents such assulphite, or by use of boiling water. In this case the pH range of water should be from 6.5 to 8.5. This ishowever not practical for open systems since fresh oxygen is in regular supply from the atmosphere.

(b) Inhibitors

Inhibitors are chemical additives, used to reduce the rate of corrosion. They can be further classified into

( I ) Anodic Inhibitors

This will interfere with the anodic reaction by creating a thin film along the surface of the metal and

raising the potential of the metal, thereby slowing down the reaction. However care needs to be takenwhen using anodic inhibitors since if not present in sufficient concentration, there will be pitting due topresence of small sites which are not well protected. Some examples of anodic inhibitors are nitrite,silicates and ferricyanides.

(II) Cathodic Inhibitors

As the name suggests, these stop or inhibit the cathodic reaction from ever taking place by reducing thearea for corrosion. This is done by precipitating insoluble species such as Zinc ions. These are consideredsafer than anodic inhibitors.

(III) Adsorption type Corrosion Inhibitors:

Organic inhibitors work by either blocking the surface from corrosive environment or by slowing downthe electrochemical process. Some examples are amino (NH2), phosphate (PO3H2) and carboxyl(COOH).

.

(IV) Mixed Inhibitors


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This involves the use of both cathodic and anodic inhibitors in the same solution to utilize the propertiesof both, providing anti electrochemical layer and preventing pitting corrosion.

Working the Metal

By making certain changes either in the metal composition or by using external applications corrosionprocess can be significantly reduced.

( I )Cathodic/Anodic/Impressed Current (affecting the metal)

(A) Cathodic protection

Cathodic protection is achieved by restraining the electrochemical reaction at the anode. This can beachieved by two methods.

(i) Sacrificial Anodes:

When two dissimilar metals are in contact with each other, the metal with lowest potential will corrodeand the one with higher potential will stay safe. Therefore, a metal with lower potential than the targetmetal which is to be protected is connected with the target metal. This way the target metal stays safewhile the other metal corrodes on its behalf. An example of this would be zinc or aluminum inconjunction with mild steel. When connected together zinc or aluminum will start corroding while themild steel stays safe.

(ii) Impressed Current

Here an auxiliary anode is used and a direct current is provided, which changes the direction of flow ofions, thereby protecting the metal. The anode is this case is permanent unlike the sacrificial anodesystem.

(B) Anodic protection

This type of protection is possible only in the case where the metals/alloys display passivity when incontact with an electrolyte. Here the speed of corrosion is decreased by controlled anodic polarizationwhich stimulates passivity.

(II) Alloying

Metals can also be saved from corrosion by alloying. The most used example of this would be addition of

chromium to iron in certain amounts (12% and/or more), which will result in a passive film of chromium

oxide on the surface. This is how stainless steel works. When alloying the potential of the resultant alloy

changes which increases its corrosion resistance. In some cases as above, a thin film is formed which

protects the metal. Aluminum in its pure form, also creates a thin film of aluminum oxide which protects

it from corrosion.


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(III) Coatings

In the recent years, coatings have proven to be most successful form of protection from corrosion. Theyare sometimes used in conjunction with the cathodic/anodic protection systems, but they on their ownhave also been proven good enough to offer strong protection from corrosion. There are natural coatings ametal forms and then there are many manmade coatings.

These can be broadly classified as

(a) Natural Protective Coating, such as the one formed on aluminum in the form of aluminum oxide.(b) Another metal used as coating such as zinc or tin (Zinc coating is also known as galvanization)(c) Organic Coatings, such as paints, powder/resin, plastics, and oil & greases.

These coatings can either provide a protective layer or prohibit the electrochemical reaction by formingminiscule barriers between the cathodic and anodic points present on the surface of the metal.


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R U S T B U L L E T

Corrosio

Corrosion Costs

U.S. with its size in terms of area aof corrosion. Large area implies difUS implies that the total wastage dcorrosion through a comparison

In the past 20 years, the cost of natdroughts and freezes comes to be mof corrosion every year for U.S. cocorrosion costs hit U.S. every yearcombined together. This is 3.1% ofindustry has played in corrosion cos

Figure 1 Split of total cost of corro$137billion).

The cost just mentioned is only theof delays, failures, taxes and overhedouble the figure to $552 billion, re

Pulp and Pap

$6.0

Agricultural,

$1.1

Food Processing,

$2.1

Hom

Appliance

Cost of Corrosion in US

BA TTLE CORROSION


n in the United States of America

d in terms of industry has possibly suffered the moserent weather conditions across U.S. while the huge to corrosion is also colossal. Lets understand the

ral disasters such as hurricanes, tornadoes, floods, fore than $380 billion in total, averaging $17 billiones to be approximately $276 billion every year. Soith approximately the combined effect of all the na

U.S. GDP annually. Figure 1 gives an overview ofts

sion into various industries contributing to it (Tota

direct cost of the U.S. GDP, if indirect costs which iads of goods and services, is taken into account, thi

presenting 6% of the GDP.

Oil and Gas, $1.4

Mining, $0.1

Petroleum

Refining, $3.7

Chemical,

Petrochemical,

Pharmaceutical,

$1.7r,

s, $1.5

D billion

Pa e 13

t from the handsindustry size of

loss caused by

res, storms,per year. The costbasicallytural disastersthe part each

l Cost

ncur in the formwould essentially


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ember

R U S T B U L L E T

Industry Economics

Utilities and Transportation togethe

look into both categories also displfor 75% of the total wastage causedfor more than 70% of the total corrcosts in the U.S. Figure 2 and 3 shrespectively.

Figure 2 Split of Corrosion Costs i

Figure 3 Split of Corrosion Costs i

Even during the cost estimation ofcould not be estimated and an accurlimitations. It is believed that the cobetter designs and corrosion prevenboth the erosion corrosion and the p

Drinking water

and Sewer

Systems, $36.0

Cost of Corrosion in USD billion

Ra

Motor Vehicles,

$23.4

Cost of Corrosion in USD billion

BA TTLE CORROSION


r account for more than 50% of the total corrosion c

ys that in utilities drinking water and sewer systemsby corrosion, while in transportation, motor vehiclesion cost. These two together account for almost haw the cost distribution of corrosion in Utility and T

n Utility Industry

n Transport Industry

orrosion, certain sectors such as telecommunicationate cost in terms of railroads could not be taken duest on bridges can be cut to almost one third of the ption methods. Same goes for the pipelines, a majoritting problems is imperative.

Electrical

Utilities, $6.9

Gas

Distribution,

$5.0

Utility Industry

$47.9 bn

ilroad Cars,

$0.5 Aircraft, $2.2

Ships, $2.7

HAZMAT

Transport, $0.9

Transportation$47.9

bn

Pa e 14

osts. A deeper

alone accountss alone accountlf the corrosionansport categories

s, electronicsto certainesent by utilizingeed to address


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Corrosion Accidents in the U.S.

Some of the catastrophic events faced on account of failure to address corrosion in time are given asfollows.

Corrosion of Natural Gas Pipeline: This event claimed the lives of twelve people and resulted in a totalloss of $998,296. There was an explosion in the gas pipeline running through Texas and New Mexico toArizona and California. The released gas caused extensive property damage in 55 minutes of its lifetime.On post inspection it was discovered that while on the outer the pipes looked corrosion free, they wassignificant corrosion on the inside, causing thinning of the pipelines and pitting at many places. Propercorrosion measures could have prevented this accident from happening.

Collapse of the bridges: Two bridges have gone down on account of corrosion. One was the Highway

35-W Mississippi Bridge in 2007 and the other was the silver bridge in 1967. The collapse caused the lossof life 46 individuals with many more sustaining serious injuries. Similar was the fate for the people onthe Mississippi Bridge.

Figure 26: Highway 35W-Mississippi Bridge collapse in Minneapolis on August 1, 2007

Similarly a lot of cases including airplanes and ships have been reported which failed due to delay inaddressing the corrosion problems.

Many industries face these problems every day, and while there are many options available now, coatingshave been most popular. The most popular coating types have been described in the next section.


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Major Prevention Methods Used (Coatings)

The three more popular coating systems are Galvanization, Spray Coating and Powder Coating. They arefurther discussed as follows,

1. Galvanization: Galvanization is the process in which a coating of zinc is applied over the metal suchas steel or iron, in order to prevent corrosion. Zinc is a very corrosion resistant metal, which can surviveunder most conditions. It also acts as a sacrificial anode, so even when the coat is scratched, the exposedmetal will not corrode, as zinc would corrode first. It is applied through hot dip process mostly althoughthere are other methods used such as electrochemical and electrodeposition process.

Galvanization however has its limitations. It does not do very well against marine environment, and if theenvironment increases the rate of corrosion, then the galvanized layer will give way and the metal willcorrode. Therefore the lifetime of galvanized coatings will vary wildly as per the environmental

conditions.

Loss of galvanized layer causing corrosion of the roof metal

2. Powder Coating: Powder coatings are possibly the most popular solution for protection againstcorrosion. It comprises of fine particles of resins and pigments, which are then electrostatically chargedand applied to the surface of metals. Once they are applied, they are heated so as to melt and form asmooth coating on the surface.

There are several methods for applying powder coatings but most often the two that are used are

A. Electrostatic spray: In this process a spray gun charges the particles which are then sprayed onto the surface of the intended metal.

B. Fluidized bed powder coating: In fluidizing bed process, the powder particles are melted by thepart on which it is to be applied. The part is pre heated to a temperature significantly higher thanthe melting point of the powder.

The two main classifications of powder coatings are Thermosetting coating, and thermoplasticpowdercoatings. The major difference is while the thermoplastic powder coating melts it maintains its chemicalcomposition, whereas in a thermosetting powder once the melted portions settles into a film, it chemically


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crosslink with each other and the resultant compound is of a higher molecular weight than the originalparticles which were melted.

There are many types of powder coatings available such as Epoxy Coatings, Urethane Coatings, Polyestercoatings and Acrylic coatings. These all are used for varied applications across industry.

a) There are however some limitations for powder coatings as well.

b) They are not very UV resistant and can fade in case of strong sunlight.

c) They also need a lot of infrastructure for the process to take place, which makes it unsuitable forsmall jobs, since it loses its cost effectiveness.

d) The success of the coat highly depends on the surface preparation. The surface needs to be free ofother particles, dust, oil and grease. This makes it very difficult for jobs where corrosion hastaken place and a coat is required.

e) Since high temperatures are required for powder coating, some parts such as an automotiveexhaust may show adverse effects on heating. This is also the case when there is a lead solderpresent in the parts to be powder coated. Therefore, powder coating is not recommended.

3. Painting: Painting over the surface of the metal has been done from a long time now. It not onlyincreases the aesthetic value, it also works as a barrier between the metal and the atmosphere. New agepaint solutions also have inhibitors in them which prevent the electrochemical reactions. The presence ofa metals particles means paint also acts as a sacrificial anode to prevent metal from corroding.

While paints seem like an excellent idea, there are certain limitations

a) They lack durability. You need to recoat very frequently in order for the paint to hold, thisbecomes a very cumbersome and expensive process in case of large parts such as a marine vesselor large storage tanks.

b) They are not very resistant to abrasion or mechanical damage which limits their application in alot of industries where mechanical damage has a high probability.


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Rustbullet Solution

Originally invented in Los Angeles to protect the jet wings from abrasion during flight, the product ofRustbullet has been refined for years, finally to come up with a product that is superior in almost everyway compared to spray paints and powder coatings. The product has been awarded an unprecedented two

patents.

While powder coatings are considered to be the best coating available against corrosion, rust bullet topsthat in every aspect possible. Below is a table comparing Rustbullet with powder coatings in the market.

Attributes Rust Bullet Powder Coatings

Ease of Application Yes No

Who can Apply Amateur to Professional Skilled Applicators only

Application Methods Brush, Roll, or Spray Electrostatically Applied and Heatcure Oven only

Application

Equipment

HVLP, Conventional, Airless orCommercial Spray Equipment

Specialty Electrostatic SprayEquipment

andConvection or Infrared Ovens Only

Application Location Apply at Project Location Application Facility Only

Project Restrictions No Size Limitations to OnSite ProjectApplications

Limitations on projects of any greatsize. Piece by Piece Applicationsrequiring transport to Project Site

Surface Preparation Little to No Prep Required Chemical or Mechanical SurfacePrep

Orange Peel Proper Application prevents Orange Peel Powder Coatings require moreproduct to achieve an acceptable

finish with no orange peel

Curing Process Moisture Cured in AmbientAtmosphere

High Heat Oven Cure

Finish Smooth, hard finish & impermeablesurface, Tougher than Conventional

paints

Hard finish, Tougher thanConventional Paints

Repair Scuffing & Reapplication of originalproduct by Amateur or Professional

Multiple Component Repair KitsProfessional Repair Only

Cost ModerateEven on Large Commercial projects

HighEven on Small Projects

The above table clearly displays that Rust Bullet is a superior products. Its performance has beenunmatched not only in the laboratory tests, but also in real life applications. This is further supported bythe fact that Rust Bullet has an open challenge in the market for its competitors, claiming the superiorityof its product over all existing products. Only one taker so far has come forward, which was POR-15 andthey lost the challenge.

Rustbullet when applied penetrates to the metal surface, and once it has it combines the rust and coatingto form a tough layer. Some of the examples of the work of rust bullet are displayed through the imagesbelow.


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The Imperial Dam

Rust bullet was chosen to cover the rust and corrosion that had been building up for 65 years.

Before After


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Conclusion

Corrosion has been one cost that has gone unnoticed for many years, even when identified as early as the1800s. However there are increasing no. of institutes across countries, such as NACE (U.S.A.), The

Australasian Corrosion Association (Australia), Institute of Corrosion (U.K.) and the World CorrosionOrganization, which are continuously working to achieve better standards for corrosion prevention, and toincrease the awareness about corrosion effects and costs across the globe.

However, still lot remains to be done in the field of corrosion science if the disasters like the Berlin Hallof Congress, The Mississippi Bridge and Erika Ship Sinking, have to be avoided. A continuous effort toincrease awareness about the indirect costs of corrosion in various forms will help bring the muchdeserved attention to the corrosion problem.

While corrosion in the end is a simple electrochemical reaction, the forms in which it can affect the metalare varied. A lot of times the corrosion goes unnoticed because they are hidden in the form of pitting andby the time they are discovered corrosion has already done its damage. What is therefore required is, an

effort to deal with corrosion before it occurs through better designs, use of correct materials suited to theenvironment and better corrosion prevention measures, that can ensure as far as possible that corrosiondoes not occur.

There are many options available today for corrosion prevention. Choosing the most appropriate methodamong the arrays of solution available is the key to protection against corrosion. One should keep in mindthe environmental, structural, and the properties metal for an efficient corrosion resistant system. Whilesome of the systems may be costly at first, the long term benefits far outweigh the current expenditure.There are many cost effective systems also available, if chosen wisely as per the need of the product.

While corrosion prevention is the best way to go, dealing with corrosion once it is detected is also a viableoption now, with technologies such as that of Rust Bullet are available. As has been illustrated before, if

corrosion which dates back 60 years can be dealt with, so can be any other corrosion problem. The key isto take action before the structure is rendered useless.

With further progress in corrosion science, we will not only create more efficient systems and structures,we will also be generating value by reduction of wastage, thereby putting less and less pressure on ouralready depleting resources. In the words of Hoover

The elimination of waste is a total asset. It has no liabilities".


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Bibliography

http://www.nace.org/

http://www.corrosion.org/

http://corrosion-doctors.org/

http://corrosion.ksc.nasa.gov/crevcor.html

http://cathodic--protection.blogspot.in/2009/08/gas-and-microbes-corrosion.html


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Disclaimer

All the information presented in this paper, is a curated work comprised from data collected by various

organizations working to create awareness about the corrosion problem across the world. We do not claim

to have collected any data and the statistics based on which the charts of various types are made, are work

done by the organizations/institutions which have been quoted in the sources and the links from where the

information was collected has been accounted for in the Bibliography.

We do not claim complete accuracy of data and deviations from the given are possible. Rustbullet has

made this paper for informational purposes and have tried to credit all the sources possible which could

be traced back from the data. Any omission of the source is purely accidental and complete effort has

been made to give recognition to every data source.


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ember BATTLE CORROSIONAbout Rustbullet

Rust Bullet, LLC is a coatings manufacturer specializing in rust inhibitive and corrosion control coatings.Rust Bullet, LLC began operations in Reno, Nevada in 2001, conducting intensive research, testing andcertifications culminating in Rust Bullet Products reaching the consumer markets in 2003.

Rust Bullet has been awarded an unprecedented Two Patents from the United States Patent & TrademarkOffice. Never before has the U.S.P.T.O. issued Two Patents for Two New Technologies to OneRust/Corrosion Control Product. Rust Bullet is a unique single component high solids industrial coating,which provides far more than just protection. Rust Bullet's Patented Technologies are proven to be ahighly effective and efficient method to prevent the corrosion of metals. A properly applied and curedRust Bullet Coating provides protection from corrosion and prevents its return.

Rust Bullet Products have been specified as the designated coatings product by U.S. Federal Agencies forapplication on a wide variety of projects, including naval battleships and guided missile cruisers, securityscreening and armored vehicles, communication towers, bridges, commercial building roofing andconcrete flooring. Rust Bullet Automotive products have been designated worldwide as the authorized

coatings for the General Motors Aftersales market. A Woman-Owned, Small Business, Rust Bullet hasqualified as a GSA Multiple Award Schedule Contractor for the United States Government.

CORPORATE HEADQUARTERS

Rust Bul l et , LLC

Industrial, Commercial, Technical, Engineering

Kathline A. Spring

Director of Business Development

Tel: 775-829-5606 ext. 110

Fax: 775-829-5619

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Global Manufacturing and Logistics

Frank L. Ciglar

VP Global Operations

Tel: 775-829-5606 ext. 106

Fax: 775-829-5619

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