Industry News

Scientists Discover Safer Release Coating to Reduce Corrosion

Published on 2016-06-22. Author : SpecialChem

Better protection against rust and corrosion is a step closer due to a breakthrough by a Swansea University research team, who have discovered a safer, smarter way of tackling the problem.

Fig. 1: Scientists Discover Safer Release
Coating to Reduce Corrosion

Their work has won the Materials Science Venture Prize of £25,000, awarded by The Worshipful Company of Armourers and Brasiers, and presented at the University of Cambridge.

The discovery provides a boost for the steel industry, helping it to retain its focus on high-quality steel meeting the very highest standards of performance and safety. The breakthrough is of particular importance because the industry needs an alternative to the corrosion inhibitor most widely used at present, hexavalent chromate, which will be banned across the EU from 2019.

Corrosion inhibitors are commonly used in a wide range of sectors, including: coated steel products used to construct industrial, commercial and other buildings; aerospace and aircraft; and the car industry.

New Method to Replace Hexavalent Chromate

Led by Professor Geraint Williams, the team, based at the University’s College of Engineering, includes doctorate student Patrick Dodds, who made the discovery. Dodds discovered a material and manufacturing process for a smart release coating which outperforms hexavalent chromate in laboratory tests.

The new coating method:

  • The new method involves a stored reservoir of corrosion inhibitor. 
  • It works by channeling aggressive electrolyte anions into the coating
  • The release of the inhibitor ‘on demand’, prevents corrosion.

Fig. 1: The team looking at steel at the atomic level
in the imaging suite
The product has been tested with salt spray, the standard test for corrosion, outperforming hexavalent chromate.

Researchers used a scanning Kelvin probe, specially built by the team, which can detect the state of the metal beneath a coating without touching it. This allowed them to test different products much more quickly, with each test taking around 24 hours, rather than 500 hours as was previously the case.

The discovery could lead to the product taking a significant slice of a multi-million pound market. The market for coiled coated steel is potentially worth £3 billion per year in Europe alone. Initial discussions with industry have been extremely positive.

The £25,000 prize will be used to buy a Jet Mill system, a tool for overcoming the last technical barriers on the way to making the product available on the market.

Professor Geraint Williams, team leader and corrosion expert at Swansea University, said:

This is a significant breakthrough, showing a smarter and safer way of reducing corrosion. The new product is environmentally sound, economical and outperforms the market leader in laboratory tests. It illustrates that Swansea, with its close links between research and industry, remains at the heart of innovation in steel.

Patrick Dodds of Tata Steel, a doctoral researcher at Swansea University, said:

The system has been shown to prevent the onset of corrosion for over 24 hours compared to less than 2 hours for the current market leader. We have also been able to demonstrate that the rate of corrosion can be slowed down significantly once it has started. This is by far the best result seen in 15 years of research on this topic.

Professor Bill Bonfield, chairman of the Armourers and Brasiers Venture Prize judging panel, said:

This is a significant discovery and shows how the UK is still a driving innovation force in industry. Our prize looks to encourage scientific entrepreneurship in the UK and provide funding, which is often difficult to source, to help discoveries like this realize their potential.

Founded to help meet the needs of the metal industries, Swansea University remains at the heart of innovation in steel. Swansea-led innovations are already demonstrating that steel is a 21st century industry, with academics and the industry working hand in hand on tomorrow’s technologies, including:

New steel-based products which turn buildings into power stations that store and release their own energy

Using nano-level technology to develop lighter steel for more energy-efficient cars, improving the way blast furnaces are loaded and stirred, already saving over £5 million a year at Port Talbot

Brand-new research and testing facilities at the University’s new Bay Campus, situated across the bay from the giant Port Talbot steelworks, cement Swansea’s role as the natural home for innovation in steel.

About Swansea University

Swansea University is a public research university located in Swansea, Wales, United Kingdom. It was chartered as University College of Swansea in 1920, as the fourth college of the University of Wales and in 1948 became the first campus university in UK. In 1996, it changed its name to the University of Wales Swansea following structural changes within the University of Wales. The title of Swansea University was formally adopted on 1 September 2007 when the University of Wales became a non-membership confederal institution and the former members became universities in their own right.

Source: Swansea University

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