Engineering/Applied

Chemistry

CODE NO: 07A1BS07/07A1BS04

I B.TECH
MECHNICAL/CIVIL ENGINEERING
Unit No: IV
Nos. of slides: 58
 Engineering/Applied
Chemistry
PROTECTIVE COATINGS & THEIR
APPLICATIONS
Term: 2008-09

Unit-IV Power Point Presentations

Text Books:
 A text book of Engineering Chemistry by
Jain & Jain,
 Chemistry of Engineering Materials by C.P.
Murthy, C.V. Agarwal and A. Naidu
 INDEX
UNIT-IV PPTS
Srl. Module as per Lecture PPT
No. Session Planner No. Slide No.
-------------------------------------------------------------------------------------------------
1. Surface Preparation L-1,2 L1,2-1 to
L1,2-19
2. Metallic Coatings L-3,4 L3,4-1 to
L3,4-28
3. Cathodic Coatings L-5,6 L5,6-1 to
L5,6-18
4. Chemical Conversion Coatings L-7,8 L7,8-1 to
L7,8-18
 SURFACE
PREPARATIONS

L1,2-1
 SOLVENT CLEANING
ALKALI CLEANING
SAND-BLASTING
MECHANICAL CLEANING

PICKING AND
ETCHING
L1,2-
 SOLVENT CLEANING:
Solvent cleaning is used to remove oils,
greases, buffing compounds and fatty
substances.
This involves in cleaning the surfaces by
the application of organic solvents like
naphtha, chlorinated hydrocarbons
(CCl4), toluene, xylene or acetone.
This is followed by cleaning with steam
and hot water, containing wetting agents
and alkalis.
This treatment provides a metal
surface,
L1,2-
readily wetted by aqueous
 ALKALI CLEANING:
Alkali cleaning is particularly
well-adapted for the removal of
old paint coating from metal
surfaces.
Alkali cleaning agents are
trisodium phosphate along with
soaps and wetting agents like
caustic soda.
An alkali treatment is always to
be followed by a very thorough
rinsing with water and then
immersion in a slightly acidic
solution of 0.1% chromic acid or
L1,2-
 ALKALI CLEANING:
Alkali cleaning method can be
made more effective by the
application of an electric current,
and making the “metal cathodic”
in alkaline medium.
The copious evolution of
hydrogen at the cathode metal
results in strong agitation, which
helps to dislodge the oily
substances.
L1,2-
 SAND-BLASTING:
Sand blasting is used or removing
oxide scales, particularly when a
slightly roughened surface is
desired.
Paint coatings on sand-blasted
surface are, particularly, more
durable than those on metal
surfaces cleaned by other
methods.
Sand-blasting is especially
suitable for large steel surfaces
L1,2-
 SAND-BLASTING:
However, the proves required
expensive equipment and the sand-
blasting operation is dangerous to
health of workers, because of the
possibility of disease, silicosis, unless
special protective measures are taken.
The process consists in introducing the
sand an abrasive into an air stream,
under pressure of 25 to 100
atmospheres.
The blast is impacted on the metal
surface to be cleaned.
The sand-blast impact removes any
scale present and also causes a certain
L1,2-
MECHANICAL CLEANING:
Mechanical cleaning removes loose
rust and other impurities from the
surface.
This is, generally, done by hand
cleaning with a bristle brush plus
some abrasive like sand and
detergent like soap.
Impact tools like dull chisels, knife
scrapers, wire brushes, grinding
wheels and cutters are also used for
removing strongly adhering scales,
etc.
the remaining dust and loose
L1,2-
PICKING AND ETCHING:
Acid picking is more convenient
method of scale removal in many
cases than mechanical cleaning and
sand-blasting.
It is, usually, accomplished by
immersing the metal except Al in an
acid-pickling solution. Al is picked in
alkaline solution.
Acid-pickling of steel is
accomplished by dipping in warm
dil.H2SO4 or in cold HCl solution to
L1,2-
PICKING AND ETCHING:
For cleaning of articles made of
copper, brass or nickel, the pickling
bath consists of dilute HNO3 or a
mixture of dil Nitric acid and dil.
Sulphuric acid.
If the cleaning operation is carried
out in an efficient manner, it
provides a clean, smooth surface for
electro-deposition.
Moreover, the deposit obtained is
adherent, tough, and bright in
L1,2-
 Generally, there are two
types of metallic coatings
are protection from
corrosion.

1. Anodic coatings
2. Cathodic coatings

And some other coatings like

Chemical conversion coatings
Organic coatings
 ANODIC COATINGS:
Anodic coatings are those in
which, the metal used for is more
anodic than the metal which is to
be protected.
For example, coating of
Aluminum, Cadmium and Zinc on
steel surface are anodic, because
their electrode potentials are
lower than that of the base metal
iron.
Therefore sacrificially, anodic
coatings protect the underlying
 ANODIC COATINGS:
Zinc being anodic is attacked, leaving
the underlying cathodic metal like iron
or steel unattacked.
 Even if it is exposed when pores,
breaks or discontinuities occur in such
type of coating.
Zinc dissolves anodically,
since being anodic to iron while the
iron is protected,
Hence, an anodic coating when
properly prepared give high electrical
insulation to the base metal and
imparts good corrosion resistance and
resistance to abrasion and stain.
 Galvanization:
Galvanization is a process in which the
iron article is protected from corrosion by
coating it with a thin layer of zinc.
In this process, at first iron or steel is
cleaned by pickling with dilute sulphuric
acid solution (H2SO4) at a temperature
range of 60-900C for 15 to20 minutes.
Therefore, it removes scale, rust and
other impurities present if any and then
washed well and dried.
Then after, dipped in the bath molten
zinc which is at 425-4500C. To prevent it
from oxide formation, the surface of bath
is covered with a flux (NH4Cl).
 Galvanization:
When the iron piece is taken
out it is coated with a thin layer
of zinc. And to remove excess
zinc, it is passed through a pair
of hot rollers;
 lastly, it is annealed at a
temperature of 4500C and then
cooled slowly
. For the protection of iron and
steel products, it is most widely
used in the form of wires, pipes,
nails, bolts, screws, buckets,
CATHODIC COATINGS:
TINNING:
The process of coating tin over the
iron or steel articles to protect it from
corrosion is known as tinning.
Tin is a nobler metal than iron,
therefore, it is more resistance to
chemical attack. In this process, at
first Iron sheet is treated in dilute
sulphuric acid (pickling) to remove
any oxide film if present.
A cleaned Iron sheet is passed
through a bath molten flux. Like Zinc
chloride, then through molten tin and
finally through a suitable vegetable
oil.
 CATHODIC COATINGS:
METAL CLADING:
The surface to be protected is
sandwiched between two thin
layers of coat metal and pressed
between rollers.
The finished product may be
welded at the edges or riveted at
some points.
The coat metal has to be anodic to
the base metal and only plain
surfaces can be cladded.
 ELECTOPLATING;
Electroplating is the process or
method of coating metals and non-
metals, to change their surface
properties such as to improve the
appearance, to properties such as
to improve the appearance to
corrosion and wear or chemical
attack.
Electroplating is the electro-
deposition of metal, by means
electrolysis over surface of metals,
 ELECTOPLATING;
The wear resistance of a metal part
can be improved by electroplating a
harder metal on its surface.
The metals most often plated on
base metals or materials are
chromium, Nickel and Rhodium.
For example metals like Iron which
are easily corroded by atmospheric
air, moisture and CO2 are coated
electrolytically with base metals
such as nickel or chromium which
 Some of the
applications of
electroplating are,
1. Plating for protection from corrosion and
chemical attack.
2. Plating for decoration.
3. Plating for special for special surface and
engineering effects.
4. Electroforming
5. Plating on non-metallic materials.
Therefore, this process is widely used in
automobiles, aircrafts, refrigerators, jewellery,
 METAL SPRAYING:
In this process, the coating
metal in the molten state is
sprayed on the roughened
surface of the base metal. The
metal thus sprayed adheres t be
the base metal surface.
The sprayed-coatings are
continuous, but some what
porous. Consequently, a sealer-
oil or paint is applied on such a
 METAL SPRAYING:
The process offers certain advantages over the
other methods, due to its:
1. greater speed of work
2. Applicability to large surfaces and
3. Ease of application,
even of thick coatings to restricted area.
However, adhesion strength of such coatings
is, usually, lesser than those obtained by hot-
dipping or electroplating. It is, therefore,
essential to have a clean and roughened metal
surface on which a proper adhesion is to be
secured. The surface is, generally, roughened
Sprayed-coatings
can be applied by
the following 2
techniques.

• wire-gun method
2. Powder metal method
 1. wire-gun method
wire-gun method is more
widely used for common
metals. In this, the wire of
the coating metal is
melted by an oxy-
acetylene flame and
atomized by a blast of
compressed air.
 2. Powder metal
method
inthis, finely divided powdered
metal is sucked from the powder
chamber and then heated as it
passes through the flame of the
blow-pipe.
The blow-pipe disintegrates the
metal into a cloud of molten
globules, which are then
adsorbed on the base metal
surface.
 CEMENTATION:
Cementation is the process in which
base metal is packed in the powdered
coating metal and heated to the
temperature just below the melting
point.
Resulting in the formation of layers
of alloys of varying composition.
Generally an inert or reducing
atmosphere is usually maintained
during this process.
Due to the diffusion of coating metal
into base metal, an alloy of two
 CEMENTATION:
Itis also suitable for coating
small articles of uneven surfaces
and shapes such as screws,
bolts, valves and gauge tools.
The coating metals used in this
process such as zinc, chromium
and aluminum are those which
can alloy even with iron.
 COLORISING:
Colorizing is carried out by first
sand-blasting the metal objects and
then heating then in a tightly-packed
drum with a mixture of aluminium
powder and aluminium oxide,
together with a trace of ammonium
chloride as a flux.
Air is excluded and in some process,
a reducing atmosphere of hydrogen is
used.
The layer formed has an approximate
composition of Al3Fe2, corresponding
to about 25% al by weight.
Colorizing is frequently applied,
especially for the protection of
 CHROMIZING:
Chromizing is carried out by heating
together a mixture of 55% chromium
powder and 45% alumina, together
with the base metal parts at about
1300 to 14000C for 3 to 4 hours.
The use of alumina prevents the
coalescence of chromium particles.
Chromizing is also produced by the
interaction of a mixture of volatile
chromous chloride and hydrogen with
steel parts at about 10500C.
The diffusion of chromium into iron
 The process is believed to
occur in three stages: The
process is believed to occur
in three stages:

1. Fe + CrCl2 FeCl2 + Cr
(Displacement)
2. CrCl2 + H2 Cr + 2HCl
(Reduction)
3. CrCl2 Cr + Cl2 (Thermal
The corrosion-resistance of
chromized coatings corresponds
to that of ferrite stainless steels.
The chromium content in the
diffusion layers varies, generally,
from 10 to 20%.
The layers are supposed to be
solid solutions of iron and
chromium.
Chromizing process is fairly
extensively applied for the
protection of gas turbine blades.
 SHERADIZING:
Sheradizing is the process of
cementation, using zinc powder
as coating metal.
The iron articles to be coated
are first cleaned and then packed
with “zinc dust” in a drum.
The drum is then sealed tightly
so that oxidation of zinc is
minimum.
 SHERADIZING:
The drum is slowly rotated for 2
to 3 hours and its temperature is
kept between 350 to 3700C,
either by gas heating or
electricity.
During this process, zinc gets
diffused into iron forming Fe-Zn
alloy at the surface.
At the end of the process, the
surface of the articles becomes
 Applications of
SHERADIZING:
sherardizing is used especially
for small steel articles like bolts,
screws, nuts, threaded-parts,
washers, valves and gauge tools.
The main advantage of
sherardizing is that coating is
quite uniform, even if the surface
has crevices or depression.
 Moreover, there is practically
no change in the dimension of
CHEMICAL CONVERSION
COATINGS:
 PHOSPHATE
COATING:
Phosphate coating is obtained
by the chemical reaction of
aqueous solution of phosphate of
iron, manganese and Zinc with
base metals such as Iron, Steel
and Zinc.
The chemical reaction produces
a surface film consisting of
manganese iron phosphates or
Zinc-iron phosphates.
For increasing the reaction rate,
 PHOSPHATE
COATING:
Application of phosphate coating on
the base metal surface can be done by
brushing or spraying.
This coating so not offers corrosion
resistance but offer excellent bases for
painting, impregnation with oils etc.
Iron and Manganese coatings are
generally used to reduce wear caused
by friction.
Phosphate coating can be done on
other metals such as Aluminum,
Cadmium and Tin.
 CHROMATING:
ORGANIC COATINGS Chromating is
the process of coating a surface film
with a mixture of trivalent and
hexavalent chromium for protection
from corrosion.
Chromating is generally used for the
protection of Zinc, Aluminum,
Magnesium and Cadmium-plated
parts.
They are produced by immersion of
the article in a bath of acid potassium
chromate, followed by immersion in a
 CHROMATING:
The properties of chromate
coatings are amorphous, non-
porous and more corrosion
resistant than phosphate
coatings.
These are also sometimes used
as base for paints, lacquers and
enamels.
 Anodizing:
The process of formation of
conversion coating on a metal surface
by anodic oxidation is known as
Anodizing.
This formation of an oxide coating by
anodizing may be used to improve the
wear resistance of certain metals.
This process is usually applied to
aluminum, magnesium, zinc and their
alloys.
And in anodizing, the work is the
anode, and oxide layers are built up
ORGANIC COATINGS
 PAINTS:
Paint may be defined as the
mechanical dispersion mixture of
pigments and fillers which are in a
liquid medium and later becomes film
forming oil. The volatile liquids such
as thinners are again added to these
liquids.
CONSTITUENTS OF PAINT
 CONSTITUENTS OF
PAINT:
Pigment
Vehicle or drying oil
Thinners d. Driers
Fillers or extenders
Plasticizers
Antiskinning agents
 Pigment:
Itis solid constituent present in paint
which provides a decorative colour
effect to protect it from ultraviolet
rays. Pigment is one of the essential
constituents of paint.
The essential functions of pigments
are-
To provide desired color, opacity and
strength to the paint.
To give aesthetical appeal to the
paint film,
To give protection the paint film by
reflecting harmful ultraviolet light,
 Vehicle or drying oil:
Itis a film-forming constituent of the
paint. The liquid portion of the paint
in which the pigment is dispersed is
called as vehicle or drying oil.
The important functions of vehicle oil
are:
They hold the pigment on the metal
surface
They form the protective film,

They impart water-repellency,

durability and toughness to the film,
and
 Thinners:
 Viscosity (or consistency) of the paints are
reduced by the addition of thinners. So that the
paints can be easily applied on the metal
surface.
The important functions of thinners are:
Thinners reduce the viscosity of the paint to
suitable consistency, so that it can be easily
handled and applied to the metal surface.
They dissolve the film-forming material and
also the other desirable additives in the
vehicle.
They evaporate rapidly and help the drying of
the paint film.
They suspend the pigments in the paint film.
They increase the elasticity of the paint film,
 Driers:
The drying of the oil is accelerated or
catalyzed by driers. They do this by
oxidation, polymerization and
condensation. In fact, driers are
oxygen carrier catalysts.
The important functions of the driers
are-
Linileates, borates, naphthalene’s,
resonates and tungstates of heavy
metals like Pb, Zn, Co and Mn.
Surface driers: Cobalt substances,


 e. Fillers or
 extenders:
Fillers are inert materials which are used
to improve the properties and reduce the
cost of the paint.
The important functions of fillers are:
They reducing the cost of the
paint.(Expensive pigments which have
excellent hiding power (like TiO2 and
ZnSO4) are used in a admixture with
cheap extenders for reducing the cost
without reducing the efficiency),
They serve to fill the voids in the film,
They increase random arrangement of
the primary pigment particles, and act as
carriers for the pigment color,
They improve the durability of the film
 f. Plasticizers:
Plasticizers are added to the
paint film to give elasticity to the
paint film and to prevent
cracking of the film.
Ex: Tri cresyl phosphate,
triphenyl phosphate, dibutyl
tartarate, and tributyl phthalate.
 g.. Antiskinning
agents:

antiskinning agents
prevent the gelling and
skinning of the paint
film. E.g. Polyhydroxy
phenols
 Requirements of a
Paint:
The adhesion capacity of the
paint should be high to the
material on which it is to be
used.
The paint should spread easily
over the surface to be protected.
On drying, the paint film should
not be cracked.
 Requirements of a
Paint:
The paint film should
have high corrosion
resistance property so as
to protect the painted
surface from the corrosion
environment.
The paint film should be
stable.
 Requirements of a
Paint:
The paint film should
be prepared such a way
as to be applicable
easily by spraying or
brushing.
The paint film should
yield a smooth and
 Requirements of a
Paint:
 The paint film obtained on
the surface should be
tough, uniform and
adherent.
 The colour of the film
should be stable and
should not get affected by
the environment
conditions.