1st Annual Eastern Coatings Show & Conference 2013

Atlantic City, NJ

Corrosion Control Without the Use of Heavy Metal Toxins

A Division of ICL Performance Products LP

Challenges in the Corrosion World

Overview

1

2

3

4 Heavy Metal Free Organic Corrosion Inhibitor

Heavy Metal Free Inorganic Corrosion Inhibitor

Background on Corrosion

5 Hybrid Technology

6 Summary

Corrosion Inhibitors

Chromate salts

Zinc salts

Barium salts

Nitrites & Nitrates

Risk (Humans) High Low Low High

Risk (Environment) High High

Aquatic toxin Harmful if inhaled

or swallowedHigh

Challenges in the Corrosion World

2. BACKGROUND ON CORROSION

1.

2. 3.

Iron Substrate Anodic Region Cathodic Region

Water Droplet

2 Fe 4 e-

4 H+ O2

2 H2O n H2O

3/2 O2

2 Fe2+

Fe2O3 . H2O

Rust

CORROSION CELL DIAGRAM

1. Oxidation of Fe yields electrons which travel through the metal. 2. Electrons at the Fe (inactive) cathode reduce O2 to H2O. 3. The Fe2+ migrates through the drop and reacts with O2+ and H2O to form rust.

Types of Corrosion

Flash Rust

Galvanic

Filiform

Rapid, widespread corrosion seen during initial application.

Contact between two alloys which promotes oxidation of the less noble metal.

Differential aeration promotes this unique form of corrosion.

Of concern in coatings…

Lambourne, R. (1999); Paint and Surface Coatings: Theory and Practice, 2 ed. (Lambourne, R. and Strivens, T.) England: William Andrew Publishing

So Many Choices

Identifying the correct inhibitor quickly can save you time and money

Direct Active

Indirect Ion- Scavenging

Organic

3. HEAVY METAL FREE INORGANIC CORROSION INHIBITOR

NON-TOXIC HEAVY METAL FREE ANTICORROSIVE PIGMENTS

Description Composition Anticorrosive Mechanism

Ions released

End Use Coatings

Applications

Inorganic A Calcium Borosilicate

Anodic passivation & Saponification

Calcium & Borate

Solvent borne, High Solids, 100% solids

Inorganic B Calcium Phosphate

Magnesium, Aluminum

Double Layer Hydroxide

Cathodic passivation &

anion exchange

Calcium, Phosphate

& Carbonate

Water-borne, Solvent borne,

High Solids, 100% solids,

Powder coatings

+

+

+

+

+

+

-- --

--

+

-

M(PO4)2

+

-

Hydrolysis

Anode

Insoluble FePO4

Cathode e-

Fe2+ H2O

Precipitate Mx(OH)x

Substrate Fe

Passivation Mechanism Active-Direct Inhibitor

Paint Film

Inorganic B – Dual Mechanism

SUBSTRATE

PASSIVE OXIDE LAYER

+

+

+

+

+

+

+

-- --

--

+

-

H2O Cl-aq

+ O+O+ O + O+ O

+ O +O +

O+

O+

O

O2

O2

+O

O2

Cl-SO4

2-

SO42-

aqH2O

+

Passivation

Ion Scavenging

Active Anti-Corrosive Pigment Mechanisms

NON-TOXIC HEAVY METAL FREE ANTICORROSIVE PIGMENTS

SEM (1000×) for Inorganic B showing platy morphology

2K Solvent-borne Epoxy Primer on Hot Rolled Steel Dry Film Thickness: 4.0-4.5 mils (100-113 microns)

Sample Salt Spray (Hours)

PVC (%) Blistering Field Scribe

Creep (mm) Scribe Rating

Blank Control 1995 40 2-6M 8G 2-6 5 10% Zinc Chromate 1995 40 8F 10 1-2 5.5 10% Zinc Phosphate 1995 40 10 9G 1-2 7

10% Inorganic B 1995 40 10 8G 0.5-1 8

STATIC SALT SPRAY ASTM B117 1995 HOURS

Blank Inorganic B Zn Chromate Zn Phosphate

4. HEAVY METAL FREE ORGANIC CORROSION INHIBITOR

HEAVY METAL FREE ORGANIC CORROSION INHIBITOR

Description Composition Anticorrosive Mechanisms Function End Use Coatings

Applications

Organic A Amino

Carboxylate

Anodic Long-term, flash rust & in can rust

inhibitor, adhesion

Water-based Acrylics,

Polyurethane, Alkyds

Organic B Organic Acid

Amine Complex

Anodic Long- term, flash rust, adhesion

Water-based Acrylics,

Polyurethanes, UV, Polyester Alkyds

Galvanic Corrosion Inhibition

Flash Rust Inhibited

Galvanic & Flash Rust Inhibition

Uninhibited

Sodium Nitrite

Organic Inhibitors

Weld Seams

Galvanic & Uniform Corrosion

5. HYBRID TECHNOLOGY

Synergy with Inorganic Pigments

SOL-GEL TECHNOLOGY IN COATINGS

An additive for protective primers (S/B & W/B) General primers High gloss DTM Wash primers Clear coats

Liquid adhesion promoter & corrosion inhibitor Excellent for white rust mitigation on HDG Excellent for black rust mitigation on Galvalume

BENEFITS

Substrate: CRS DFT: 1.7 mils Salt Spray- 336 hrs

Gloss: 20°- 59.8 60°- 83.7

Gloss: 20°- 38.5 60°- 78.5

5% Inorganic A 2% Hybrid 2% Organic A 5% Inorganic B Blank

SUMMARY Non-toxic heavy metal free inorganic and organic corrosion inhibitors can be used in place of heavy metal based products such zinc phosphate and zinc chromate.

Performance achieved by these products meets or exceeds that of heavy metal products in solvent-borne and water-borne coating applications.

Key to this success is to capitalize on the multi-mechanism aspects of the new technologies namely, the combination of passivation, ion exchange, and barrier enhancement.

NOTICE: Although the information and recommendations set forth herein (hereinafter “information”) are presented in good faith and believed to be correct as of the date hereof, ICL Performance Products LP (“ICL”) makes no representations or warranties as to the completeness or accuracy thereof. Information is supplied upon the condition that the persons receiving same will make their own determination as to its suitability for their purposes prior to use. In no event will ICL be responsible for damages of any nature whatsoever resulting from the use or reliance upon information or the product to which information refers. Nothing contained herein is to be construed as a recommendation to use any product, process, equipment or formulation in conflict with any patent, and ICL makes no representation or warranty, express or implied, that the use thereof will not infringe any patent. NO REPRESENTATIONS OR WARRANTIES, EITHER EXPRESSED OR IMPLIED, OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR OF ANY OTHER NATURE ARE MADE HEREUNDER WITH RESPECT TO INFORMATION OR THE PRODUCT TO WHICH INFORMATION REFERS. © 2013 ICL Performance Products LP. All rights reserved.