A review of techniques for the monitoring of cathodic shielding and corrosion under disbonded coatings

The mitigation of external corrosion of energy pipelines by a combination of barrier coatings and Cathodic Protection (CP) is not always effective. Even when design specifications are properly met, the shielding of cathodic protection current from reaching steel surface by disbonded barrier coatings, often referred to as cathodic shielding, may lead to severe corrosion problems such as deep pitting, high and near neutral pH Stress Corrosion Cracking (SCC) and Microbiologically Induced Corrosion (MIC). Unfortunately, current indirect assessment methods used in the pipeline industry have serious difficulties in detecting such corrosion problems. This paper provides a brief review of current techniques and their limitations when being applied under complex buried pipeline environmental conditions. The main purpose is to identify potential methods that could be utilised in the design of new monitoring probes specific for the monitoring of cathodic shielding and corrosion of disbonded coatings in the pipeline industry.

Thermal conductivity studies on wool fabrics with conductive coatings

Methods of improving the thermal conductivity of wool fabrics have been investigated. Thermal conductivity measurement techniques, influence of synthesis parameters on the thermal conductivity of polypyrrole (PPy)-coated wool fabrics, and the relationship between electrical conductivity and thermal conductivity of PPy-coated wool fabrics are presented. An improvement in thermal conductivity was observed when fabrics were coated with the PPy. The thermal conductivity increased with the increase of pyrrole concentration and synthesis time. Anthraquinone-2-sulfonic acid and ferric chloride showed an optimal concentration for their influence on the thermal conductivity of the coated fabric. The improvement of thermal conductivity of wool fabrics is also investigated by Physical Vapor Deposition technique.

Colloid probe AFM study of thermal collapse and protein interactions of poly(N-isopropylacrylamide) coatings

Graft coatings of poly(N-isopropylacrylamide) (pNIPAM) are of considerable interest for the reversible control of bio-interfacial interactions. In this study, graft coatings were prepared by free radical polymerisation from surface-bound polymerisable groups, on silicon wafers and quartz crystal microbalance (QCM) sensors. QCM with dissipation monitoring showed a gradual, extended phase change as the temperature increased. Colloid probe atomic force microscopy (CP-AFM) revealed a marked change in the compressibility of the coating below and above the lower critical solution temperature (LCST). Force curves showed an approximate 9-fold reduction in thickness between 24 °C and 38 °C, yet the collapsed coating at 38 °C still had a thickness significantly higher than the ellipsometrically determined dry thickness, indicating a residual extent of hydration above the LCST. At all temperatures, interaction force curves showed steric repulsion, though over different distances. There was little hysteresis between approach and retract force curves, which is evidence for almost instantaneous relaxation of the coating upon decompression. CP-AFM using a probe coated with bovine serum albumin (BSA) showed repulsive interactions with little approach/retraction hysteresis below the LCST, indicating lack of adhesion between the pNIPAM coating and the BSA-coated probe. In contrast, above the LCST the force curves on retraction were characteristic of adhesion, while the approach curves were still repulsive, and the adhesion increased in strength as the temperature was increased further beyond the LCST. Thus, QCM-D and CP-AFM data correlated well in showing a gradual nature of the phase transition and a concomitant gradual change in the interaction force with BSA.

Improving thermal conductivity of cotton fabrics using composite coatings containing graphene, multiwall carbon nanotube or boron nitride fine particles

Graphene, multi-wall carbon nanotube (MWCNT) and fine boron nitride (BN) particles were separately applied with a resin onto a cotton fabric, and the effect of the thin composite coatings on the thermal conductive property, air permeability, wettability and color appearance of the cotton fabric was examined. The existence of the fillers within the coating layer increased the thermal conductivity of the coated cotton fabric. At the same coating content, the increase in fabric thermal conductivity was in the order of graphene > BN > MWCNT, ranging from 132 % to 842 % (based on pure cotton fabric). The coating led to 73 %, 69 % and 64 % reduction in air permeability when it respectively contained 50.0 wt% graphene, BN and MWCNTs. The graphene and MWCNT treated fabrics had a black appearance, but the coating had almost no influence on the fabric hydrophilicity. The BN coating made cotton fabric surface hydrophobic, with little change in fabric color.

Boron carbide nanowires with uniform CNχ coatings

Boron carbide nanowires with uniform carbon nitride coating layers were synthesized on a silicon substrate using a simple thermal process. The structure and morphology of the as-synthesized nanowires were characterized using x-ray diffraction, scanning and transmission electron microscopy and electron energy loss spectroscopy. A correlation between the surface smoothness of the nanowire sidewalls and their lateral sizes has been observed and it is a consequence of the anisotropic formation of the coating layers. A growth mechanism is also proposed for these growth phenomena.

Residual thermal stresses in a Fe3Al/Al2O3 gradient coating system

To combine the merits of both metals and ceramics into one material, many researchers have been studying the deposition of alumina coating using plasma spray on metal substrates. However, as the coatings are deposited at a high temperature, residual thermal stresses develop due to the mismatch of thermal expansion coefficients of the coating and substrate and these are responsible for the initiation and expansion of cracks, which induce the possible failure of the entire material. In this paper, the residual thermal-structural analysis of a Fe3Al/Al2O3 gradient coating on carbon steel substrate is performed using finite element modelling to simulate the plasma spray. The residual thermal stress fields are obtained and analyzed on the basis of temperature fields in gradient coatings during fabrication. The distribution of residual thermal stresses including radial, axial and shear stresses shows stress concentration at the interface between the coatings and substrate. The mismatch between steel substrate and composite coating is still the dominant factor for the residual stresses

Novel sphene coatings on Ti–6Al–4V for orthopedic implants using sol–gel method

Hydroxyapatite (HAp) is commonly used to coat titanium alloys (Ti–6Al–4V) for orthopedic implants. However, their poor adhesion strength and insufficient long-term stability limit their application. Novel sphene (CaTiSiO₅) ceramics possess excellent chemical stability and cytocompatibility. The aim of this study is to use the novel sphene ceramics as coatings for Ti–6Al–4V. The sol–gel method was used to produce the coatings and the thermal properties, phase composition, microstructure, thickness, surface roughness and adhesion strength of sphene coatings were analyzed by differential thermal analysis–thermal gravity (DTA–TG), X-ray diffraction (XRD), scanning electron microscopy (SEM), atom force microscopy (AFM) and scratch test, respectively. DTA analysis confirmed that the temperature of the sphene phase formation is 875 °C and XRD analysis indicated pure sphene coatings were obtained. A uniform structure of the sphene coating was found across the Ti–6Al–4V surface, with a thickness and surface roughness of the coating of about 0.5–1 μm and 0.38 μm, respectively. Sphene-coated Ti–6Al–4V possessed a significantly improved adhesion strength compared to that for HAp coating and their chemical stability was evaluated by testing the profile element distribution and the dissolution kinetics of calcium (Ca) ions after soaking the sphene-coated Ti–6Al–4V in Tris–HCl solution. Sphene coatings had a significantly improved chemical stability compared to the HAp coatings. A layer of apatite formed on the sphene-coated Ti–6Al–4V after they were soaked in simulated body fluids (SBF). Our results indicate that sol–gel coating of novel sphene onto Ti–6Al–4V possessed improved adhesion strength and chemical stability, compared to HAp-coated Ti–6Al–4V prepared under the same conditions, suggesting their potential application as coatings for orthopedic implants.

Cooling effect of MWCNT-containing composite coatings on cotton fabrics

Multiwalled carbon nanotubes (MWCNTs) were dispersed in an aqueous solution of epichlohydrin based resin with the aid of a surfactant. The MWCNT-resin solutions were applied onto cotton fabrics to form a thin coating with different MWCNT contents (0, 11.1, 20.0, 33.3, and 50%). The thermal conductivity of the fabrics was measured based on the Newton’s law of cooling. The coating containing 50% MWCNTs showed 151% increase in the thermal conductivity. Infrared thermography was used to characterize the heating/cooling behavior of the fabrics. On contact with a 50°C hot surface, coated fabric that had 50% MWCNTs in the coating layer showed a 3.9°C lower equilibrium surface temperature than the untreated fabric. The cooling rate increased with increasing the MWCNT content within the coating layer. Such an effective cooling performance was attributed to the increased thermal conductivity and surface emissivity of the MWCNT-containing coating layer. The coating showed little influence on water contact angle of the coated fabrics, but slightly decreased the air permeability.

Thermal management of cotton fabrics by surface coating

Thermal management of cotton fabrics by applying thermal conductive and insulative coatings has been done successfully.

The surface finish of thermally aged carbon fibre reinforced composites using E-glass as a surface barrier

This work investigated the effect of woven E-glass mass (25 g/m2, 50 g/m2, 85 g/m2, 135 g/m2) on the painted surface finish of various thermoset (EPIKOTETM RIM935, EPIKOTETM 04434, Ultratec LpTM ES300, Ultratec LpTM SPV6035) carbon fibre composite laminates, before and after aging at 95 °C for 168 h. The as-moulded laminate surfaces were evaluated using surface profilometry techniques and the painted and aged surfaces were evaluated using a wave-scan distinctness of image (DOI) instrument. It was found that the 25 g/m2 E-glass surface layer assisted with reducing the roughness of the as-moulded surfaces and the long-term waviness of the painted surfaces due to the increase in resin-richness at the surface. The EPIKOTETM 04434 resin system that contained diglycidyl ether of bisphenol F (DGEBF) epoxy had the least change in long-term waviness with thermal aging due to the rigid fluorene-based backbone in comparison to the diglycidyl ether of bisphenol A (DGEBA) systems.

Finite element analysis of residual stresses in metallic coatings through a compound casting

Al and Mg alloys are widely used in industry as main lightweight alloys. They have excellent properties, such as low density, high ductility, and high specific strength, and so on. Generally speaking, Mg alloys are better than Al alloys. However the corrosion of Mg alloys is much more difficult to control compared Al alloys. Therefore to combine these two lightweight alloys, a composite-like structure is an ideal solution since Al alloys can be used as protective coatings for Mg alloys. Compound casting is a realistic technique to get this coating system. In the current study, we numerically study the compound casting using finite element method (FEM) to make these two alloys, a composite-like structure, satisfy requirements to resist corrosion required from industry, in which the aluminum layer is acting as a protective coating for the magnesium substrate. Several finite element models have been developed by using the birth and death element technique and we focus on compound casting-induced residual stresses in the compounded structure. The numerical results obtained from the proposed finite element models show the distribution profiles of thermal residual stresses. We found the major factors influencing the residual stresses are the temperature to pre-heating the Al substrate and the thickness of Mg deposits. © (2014) Trans Tech Publications, Switzerland.