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Graphene anticorrosive coating

Anti-corrosive of anti-corrosive graphene coating

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Anti-corrosive of anti-corrosive graphene coating

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Graphene anticorrosive coating

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As a new revolutionary heavy-duty coating developed based on graphene, an epoch-making new material, the anti-corrosive graphene coating features super-strong anti-corrosive performance, excellent base material adhesion, extremely high cost performance and convenient construction. Anti-corrosive graphene coating, a new generation of anti-corrosive coating, will surely substitute traditional epoxy zinc rich coating gradually and become a mainstream product of heavy-duty engineering coating.

For traditional heavy-duty coating, supporting coating represented by epoxy zinc rich primer is a mainstream application product of heavy-duty coating but it has several disadvantages:

(1) Corrosion resistance is insufficient and thicker coating is needed to achieve designed anti-corrosive effect;

(2) Adhesion on base material is not good and painted base material has high requirement for surface treatment level;

(3) Construction is inconvenient, easy to have clogging and coating sediment;

(4) Long construction period, low cost performance and excessive manpower and storage costs incurred during construction.

Anti-corrosive principle of anti-corrosive graphene coating

Anti-corrosive principle of anti-corrosive graphene coating is based on two physicochemical characteristics of graphene:

(1) Laminated single molecule structure

Regular hexagonal structure of graphene single molecule layer provides excellent physical shield effect for film.

(2) Excellent electrical conductivity

Graphene, a new material with extremely excellent electrical conductivity, acts as a carrier of electronic transfer in original battery reaction in film. It improves utilization ratio of active metal zinc and achieves better anode loss protection effect.

Anti-corrosive graphene coating makes breakthroughs in the following aspects:

1. Anti-corrosive effect is greatly improved comparing with traditional heavy-duty coating

GB\T1766-2008之规定判定结果与交通部标准JT/T722标准要求对比

For the matching of anti-corrosive graphene coating with acrylic polyurethane and fluorocarbon finish paint, the salt fog resistance test is conducted as per provisions of GB/T1771-2007, and the test result obtained as per GB/T1766-2008 is compared with the requirements of JT/T722 standard from Ministry of Communications.

Salt fog resistant test result of super-heavy-duty graphene primer and epoxy zinc rich primer (80% zinc powder content). The left figure shows salt fog resistant result of single-layer film of super-heavy-duty graphene primer at 1,000 h and 2,000 h; the right figure shows salt fog resistant result of single-layer film of epoxy zinc rich primer (80% zinc powder content) at 800 h.

Test panel of salt fog resistant test of supporting coating of super-heavy-duty graphene primer (dry film 100 um) and acrylic polyurethane finish paint (dry film 80 um) after 2,600 h. Fig. 8 shows test panel of salt fog resistant test of supporting coating of super-heavy-duty graphene primer (dry film 100 um) and fluorocarbon finish paint (dry film 80 um) after 4,500 h.

2. Adhesion and mechanical strength of paint film are greatly improved comparing with traditional heavy-duty coating

Since graphene powder is added to anti-corrosive graphene coating, mechanical strength of its paint film is improved and stress of the film is changed to improve adhesion of paint film and painted base material greatly, comparing with traditional heavy-duty coating.

(1) Adhesion comparison between anti-corrosive graphene coating and epoxy zinc rich primer

We carry out pull test for anti-corrosive graphene coating and epoxy zinc rich primer on base material with Sa2.5 roughness.

Adhesion of anti-corrosive graphene coating on standard work-piece doubles that of epoxy zinc rich primer.

(2) Adhesion comparison between anti-corrosive graphene coating and epoxy zinc rich primer on base material with low surface treatment

Base material with low surface treatment is divided into two types: one is classified as per roughness of steel base material, for instance, Sa1.0, Sa2.5 and Sa3.0; the bigger the value is, the better the roughness is. The other is classified as per rust of base material, for instance, A, B, C and D; the lower one has more rust.

Pull test comparison between anti-corrosive graphene coating and epoxy zinc rich primer on unground steel plate and steel base material with roughness Sa1.0.

Adhesion of anti-corrosive graphene coating on unground base material and base material with roughness Sa1.0 is over 12 Mpa; adhesion of epoxy zinc rich primer on base material with low surface treatment is below 5 Mpa. Therefore, epoxy zinc rich primer has high requirement for base material treatment level and anti-corrosive graphene coating has obvious advantage in engineering application.

Adhesion test comparison is conducted in pull method between anti-corrosive graphene coating and epoxy zinc rich primer on base material with A, B and C rust levels.

Excellent base material adhesion of anti-corrosive graphene coating is reflected in adhesion of rusted base material. Its adhesion on Class B rusted steel is over 10 MPa and that on Class C steel is also above 6 MPa. The characteristics greatly simplify pre-treatment of painted base material. It not only saves pre-treatment cost of base material but also shortens the entire pre-treatment period of base material.

Besides, anti-corrosive graphene coating also has good adhesion on some base materials that are hard to adhere to, for instance, adhesion of super-heavy-duty graphene primer on stainless steel and ceramics is up to Class 0. This is unrealizable for traditional anti-corrosive primer.

3. Coating cost advantage

Coating cost of anti-corrosive graphene coating is reduced greatly comparing with supporting system of epoxy zinc rich coating (traditional heavy-duty coating) because one layer of coating can substitute two layers of coating (i.e. epoxy zinc rich primer and micaceous iron epoxy intermediate paint) and it has lowered requirement for pre-treatment of base material.

A、Base material just needs to have rust and loose oxide skin removed, reducing pre-treatment cost greatly.

B、One layer of anti-corrosive graphene coating can achieve corrosion resistance of two layers of coating (i.e. epoxy zinc rich primer and micaceous iron epoxy intermediate paint), reducing material and manpower costs greatly.

C、Two layers of coating substitutes three layers of coating, shortening coating period greatly, reducing storage cost and improving coating efficiency.

4. Less environmental pollution

Environmental pollution from coating is mainly reflected in in-organized VOC emission during construction. One pass of anti-corrosive graphene coating can achieve the anti-corrosive effect of traditional anti-corrosive primer and intermediate paint. VOC from anti-corrosive graphene coating in construction and that from traditional heavy-duty primer and intermediate paint are obtained through calculation.

VOC from anti-corrosive graphene coating in construction is only about 60% of that from traditional heavy-duty coating. With constantly improved national requirements for environmental protection in the coating industry, traditional heavy-duty coating, a product from the 1990s, is about to be phased out, and the new generation of revolutionary anti-corrosive graphene coating will occupy considerable market in the heavy-duty coating field.

Currently, treatment of base material can only adopt shot blasting treatment, which will generate plenty of fine particulate matter (PM2.5) and pollute the environment greatly. Anti-corrosive graphene coating requires no Sa2.5 for pretreatment of base material, omitting shot blasting process directly. This reduces pollution to the environment greatly.

Besides, contacting VOC and dust from shot blasting will greatly affect health of relevant employees. Application of anti-corrosive graphene coating will minimize the impact on occupational health greatly during coating. It is good news for relevant employees and possesses great social benefit.

5. Construction convenience

Besides main effects above, anti-corrosive graphene coating has other advantages of construction performance in coating process, comparing with traditional heavy-duty coating, for instance, hard to have clogging, hard to have coating sediment, less “zinc mist” in construction and greatly improved coating efficiency.

Keyword:

coating

graphene

anti-corrosive

base

material

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