UV Technology For
Corrosion Resistance
Ben Curatolo
[email protected]
Light Curable Coatings
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The Advantages Of Ultraviolet (UV) Coating
Technology Are Well Documented
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Solvent-Free
Reduction Of VOCs
Reduction Of HAPs
Faster Cure
Improved Efficiency
Source Reduction
Sustainability
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Non-Flammable
Lower Insurance Costs
Healthier Work Environment
Reduced Regulatory Impact
Reduced Scrap And Waste
Lower Applied Cost
Reduced Overall Cost
UV Coating Technology Is Widely Used For
Decoration And Protection In Many Different
Applications In A Wide Range Of Industries
The Suitability Of UV Technology For
High Performance Corrosion Resistant
Applications Has Now Been Demonstrated
• Industrial And Aerospace Applications
• Field Application And Cure Using Portable Lamps
• Protection Of Steel Surfaces And Large Structures
• Protection Of Aerospace Aluminum Alloys
Corrosion Is A Tremendous Problem For
Many Segments Of The U.S. Economy
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Aircraft
Motor Vehicles
Ships
Railroad Cars
Bridges
Electrical Utilities
Petroleum Refining
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Gas Pipelines
Liquid Pipelines
Home Appliances
Food Processing
Water Systems
Sewer Systems
Pulp & Paper Processing
Annual Corrosion Costs In The United States
• $276 Billion Annual Cost In 2001
• Office Of Infrastructure Research And Development
• U.S. Federal Highway Administration
• Report No. FHWA-RD-01-156*
• $400 Billion Annual Cost Presently
• U.S. Government Accountability Office (GAO)
*CC Technologies And NACE International, September 30, 2001
Commercial Materials Typically Used For High
Performance Corrosion-Resistant Applications
Are Epoxy And Polyurethane Paints
• Epoxy Paints As Primers And In Applications Where
Maintaining Color And Appearance Are Not Critical
• Polyurethane Paints As Topcoats And In Applications
Where Color And Appearance Must Be Maintained
Disadvantages Of Epoxies And Polyurethanes
• Limited Application Conditions - Temperature And Humidity
• Two Part Systems With Corrosive Or Toxic Components
• Limited Pot Life - Viscosity Increases From Mixing Until Cure
• Extended Period Of Time Before Full Cure Is Achieved
• Components On The Toxics Release Inventory (TRI)
• Pollution From Solvents, VOCs, HAPs, Isocyanates, Chromates
• Performance Disadvantages When Used Individually
Solvent-Free UV Coating Technology Has
Demonstrated High Performance Corrosion
Protection For Industrial Applications
• Formulation With Urethane Acrylates
• Formulation With Chromium-Free Corrosion Inhibitors
• High Intensity UV Cure For OEM Applications
• Portable UV Lamps For Field Application And Cure
• Clean, Green, Pollution-Free Corrosion Protection
Epoxy And Polyurethane Corrosion Resistance
Coating Layer
Description
Total
Wet Mils
Total
Dry Mils
Corrosion
Resistance*
Epoxy
22
16
1=Best
Epoxy
14
10
2
Polyurethane
10
6
3
Polyurethane
3
2
4=Worst
*Corrosion resistance ranking based on ASTM D 1654 ratings of scribed steel panels after 672 hours ASTM B 117 salt fog testing
Epoxy And Polyurethane Corrosion Resistance
Coating Layer
Description
Layer
Wet Mils
Total
Wet Mils
Total
Dry Mils
Corrosion
Resistance*
Epoxy
22
22
16
1=Best
Polyurethane
Epoxy
5
10
15
10
2
Epoxy
14
14
10
3
Polyurethane
10
10
6
4
Polyurethane
3
3
2
5=Worst
*Corrosion resistance ranking based on ASTM D 1654 ratings of scribed steel panels after 672 hours ASTM B 117 salt fog testing
Corrosion Resistance With Zinc-Rich Epoxy
Coating Layer
Description
Layer
Wet Mils
Total
Wet Mils
Total
Dry Mils
Corrosion
Resistance*
Polyurethane
Zinc Epoxy Primer
7
6
13
8
Epoxy
Zinc Epoxy Primer
16
6
22
15
2
Epoxy
22
22
16
3
6
6
4
4
Epoxy
14
14
10
5
Polyurethane
10
10
6
6
Polyurethane
3
3
2
7=Worst
Zinc Epoxy Primer
1=Best
*Corrosion resistance ranking based on ASTM D 1654 ratings of scribed steel panels after 672 hours ASTM B 117 salt fog testing
Corrosion Resistance Ranking For UV Coating
Coating Layer
Description
Epoxy
Layer
Wet Mils
Total
Wet Mils
Total
Dry Mils
Corrosion
Resistance*
22
22
16
2
2
2
2
Polyurethane
Epoxy
5
10
15
10
3
Epoxy
14
14
10
4
Polyurethane
10
10
6
5
Polyurethane
3
3
2
6=Worst
UV Coating
1=Best
*Corrosion resistance ranking based on ASTM D 1654 ratings of scribed steel panels after 672 hours ASTM B 117 salt fog testing
Corrosion Resistance Rankings For UV Coatings
Coating Layer
Description
Layer
Wet Mils
Total
Wet Mils
Total
Dry Mils
2
2
4
4
22
22
16
2
2
2
2
3
Polyurethane
Epoxy
5
10
15
10
4
Epoxy
14
14
10
5
Polyurethane
10
10
6
6
Polyurethane
3
3
2
7=Worst
UV Topcoat
UV Primer
Epoxy
UV Coating
Corrosion
Resistance*
1=Best
*Corrosion resistance ranking based on ASTM D 1654 ratings of scribed steel panels after 672 hours ASTM B 117 salt fog testing
Corrosion Resistance Rankings For UV Coatings
Coating Layer
Description
Layer
Wet Mils
Total
Wet Mils
Total
Dry Mils
Corrosion
Resistance*
UV Topcoat
Zinc Epoxy Primer
2
3
5
4
1=Best
Polyurethane
Zinc Epoxy Primer
7
6
13
8
2
UV Topcoat
UV Primer
2
2
4
4
3
Epoxy
Zinc Epoxy Primer
16
6
22
15
4
Epoxy
22
22
16
5
*Corrosion resistance ranking based on ASTM D 1654 ratings of scribed steel panels after 672 hours ASTM B 117 salt fog testing
Corrosion Resistance Rankings Summary
Coating Layer
Description
Layer
Wet Mils
Total
Wet Mils
Total
Dry Mils
Corrosion
Resistance*
UV Topcoat
Zinc Epoxy Primer
2
3
5
4
1=Best
Polyurethane
Zinc Epoxy Primer
7
6
13
8
2
UV Topcoat
UV Primer
2
2
4
4
3
Epoxy
Zinc Epoxy Primer
16
6
22
15
4
Epoxy
22
22
16
5
*Corrosion resistance ranking based on ASTM D 1654 ratings of scribed steel panels after 672 hours ASTM B 117 salt fog testing
Corrosion Resistance Rankings Summary
Coating Layer
Description
Layer
Wet Mils
Total
Wet Mils
Total
Dry Mils
Corrosion
Resistance*
UV Coating
2
2
2
6
Zinc Epoxy Primer
6
6
4
7
Polyurethane
Epoxy
5
10
15
10
8
Epoxy
14
14
10
9
Polyurethane
10
10
6
10
Polyurethane
3
3
2
11=Worst
*Corrosion resistance ranking based on ASTM D 1654 ratings of scribed steel panels after 672 hours ASTM B 117 salt fog testing
UV Coating Technology Is Suitable For
High Performance Industrial Applications
Requiring Corrosion Protection
• Improved Protection Of Steel Compared To Standard Coatings
• Dramatically Faster Cure With Lower Material Usage
• Can Be Multifunctional Coating Or Primer/Topcoat System
• Elimination Of Solvents, VOCs, HAPs, Isocyanates, Chromates
• Reduced Pollution And Improved Health Considerations
• Safer And More Efficient Alternative For Corrosion Protection
UV Coating Technology Is Suitable For
Corrosion Protection Of Large Structures
• Just As Any Surface Can Be Painted By A Few Individuals
Spraying Or Rolling, A UV Coating Can Be Applied And
Cured By Painting And Then Following With A UV Lamp
• Cure Is Achieved With A Motion That Can Be Described As
"Painting" The Surface With A Handheld UV Lamp
• Movement Of The UV Lamp Is Similar To That Of A Roller
Or Spray Gun - At The Same Speed As Paint Application
UV Coating Technology Is Suitable For
Corrosion Protection Of Large Structures
UV Technology Is Suitable For Cold Temperatures
• UV Cure Is
Tolerant Of
Adverse
Conditions
(34°F)
• Maintains
Fast Cure
In Seconds
UV Technology Is Suitable For A Wider Range Of
Application Conditions Than Standard Coatings
• When Compared To Conventional Paints, UV Cure Is
Relatively Independent Of Temperature And Humidity
• UV Coatings Cured Completely In Seconds With Good
Performance In A Field Application At 34°F - No Standard
Paint Would Have Cured Under Those Conditions
• Good Cure Performance Has Also Been Demonstrated
Under Typical Ambient Summertime Conditions
UV Technology Is Suitable For Aerospace
Applications Requiring Corrosion Resistance
• Multifunctional UV Coating Can Replace Both The
Strontium Chromate Epoxy Primer Layer And The
Polyurethane Topcoat Layer Of Current Systems
• Solvent-Free UV Technology With A Chromate-Free
Corrosion Inhibitor Eliminates All Toxic Components
• Immediate Cure Increases Efficiency And Dramatically
Reduces Dry-To-Fly Time For Painting Operations
Chromate-Free Multifunctional UV Coatings
Provide ASTM B-117 Corrosion Resistance
0 Hrs
500 Hrs
1000 Hrs
1500 Hrs
2000 Hrs
2500 Hrs
3000 Hrs
Coated 2024-T3 Aerospace Aluminum Alloy Panels After ASTM B-117 Salt Fog Testing
Chromate-Free Corrosion Resistance Is
Maintained With Different Pigments
0 Hrs
500 Hrs
1000 Hrs
1500 Hrs
2000 Hrs
2500 Hrs
3000 Hrs
UV Coated 2024-T3 Aluminum Alloy Panels After ASTM B-117 Salt Fog Testing
Chromate-Free Corrosion Resistance Is
Maintained With Different Oligomers
0 Hrs
500 Hrs
1000 Hrs
1500 Hrs
2000 Hrs
2500 Hrs
3000 Hrs
UV Coated 2024-T3 Aluminum Alloy Panels After ASTM B-117 Salt Fog Testing
Chromate-Free Corrosion Resistance Is
Maintained With Lower Inhibitor Level
0 Hrs
500 Hrs
1000 Hrs
1500 Hrs
2000 Hrs
2500 Hrs
3000 Hrs
UV Coated 2024-T3 Aluminum Alloy Panels After ASTM B-117 Salt Fog Testing
Chromate-Free Corrosion Resistance Is
Maintained With Different Surface Treatment
0 Hrs
500 Hrs
1000 Hrs
1500 Hrs
2000 Hrs
2500 Hrs
3000 Hrs
UV Coated Anodized 2024-T3 Panels After ASTM B-117 Salt Fog Testing
Multifunctional UV Coating Corrosion Resistance
Compared To Unprotected Al 2024-T3 Surface
UV Coated:
Unprotected:
3000 Hrs
24 Hrs
2024-T3 Panels After ASTM B-117 Salt Fog Testing
UV Technology Is Suitable For
Aerospace Applications Requiring:
Multifunctional Coating
Fast Cure
Long Pot Life
Low VOCs
Low Gloss
Flexibility
Corrosion Resistance
Solvent Resistance
Skydrol Resistance
- Replaces Primer/Topcoat
- Seconds To Minutes
- Unlimited
- Solvent-Free, Zero VOC
- 20°= 0.4, 60°= 3.0, 85°= 7.0
- 10%-20% Elongation
- 3000 Hrs ASTM B-117
- > 200 MEK Double Rubs
- Pass
UV Coating Technology Is Also Suitable For
High Performance Applications That Do Not
Require Corrosion Resistance
Automobile Headlamps
After Refurbishing
Before Refurbishing
UV Coating Technology Is Suitable For
High Performance Applications That
Require Excellent Weatherability
Clear UV Coating ∆ E Values After QUV Accelerated Weathering
∆E=
1000 Hrs
2000 Hrs
3000 Hrs
4000 Hrs
5000 Hrs
6000 Hrs
0.35
0.23
0.25
0.60
0.35
0.47
UV Coating Technology Is Suitable For
High Performance Applications That
Require Excellent Weatherability
Clear UV Coating ∆ E Values After QUV Accelerated Weathering
∆E
Hours
UV Coating Technology Is Also Suitable For
High Performance Applications That Do Not
Require Corrosion Resistance
Fast Cure Flooring Applications
UV Coating Technology Is Also Suitable For
High Performance Applications That Do Not
Require Corrosion Resistance
Fast Cure Flooring Applications
Summary – UV Technology Is Suitable For
Applications Requiring Corrosion Resistance
And Other High Performance Properties
• Improved Performance Compared To Current Systems
• Dramatically Faster Cure With Lower Material Usage
• Excellent Cure At Temperatures Too Low For Standard Paints
Summary – UV Technology Is Suitable For
Applications Requiring Corrosion Resistance
And Other High Performance Properties
• Reduced Pollution And Improved Health Considerations
• Safer And More Efficient Alternative For Corrosion Protection
• Markets Include Major Infrastructure Of The United States
Summary – UV Technology Is Suitable For
Applications Requiring Corrosion Resistance
And Other High Performance Properties
• From Weatherability To Corrosion Resistance
• From The Ground To The Sky