Thesis (MTech (Mechanical Engineering))--Cape Peninsula University of Technology. / For the last few decades, methods to improve the engine efficiency and reduce the fuel consumption of jet engines have received increased attention. One of the solutions is to increase the operating temperature in order to increase the exhaust gas temperature, resulting in an increased engine power. However, this approach can be degrading for some engine parts such as turbine blades, which are required to operate in a very hostile environment (at ≈ 90% of their melting point temperature). Thus, an additional treatment must be carried out to protect these parts from corrosion, oxidation and erosion, as well as to maintain the substrate’s mechanical properties which can be modified by the high temperatures to which these parts are exposed. Coating, as the most known protection method, has been used for the last few decades to protect aircraft engine parts. According to Wolfe and Co-workers [1], 75% of all engine components are now coated. The most promising studies show that the thermal barrier coating (TBC) is the best adapted coating system for these high temperature applications. TBC is defined as a fine layer of material (generally ceramic or metallic material or both) directly deposited on the surface of the part In order to create a separation between the substrate and the environment to reduce the effect of the temperature aggression. However, the application of TBCs on surfaces of components presents a challenge in terms of the consistency of the thickness of the layer. This is due to the nature of the processes used to apply these coatings. It has been found that variations in the coating thickness can affect the thermodynamic performance of turbine blades as well as lead to premature damage due to higher thermal gradients in certain sections of the blade. Thus, it is necessary to optimise the thickness distribution of the coating.

Sacrificial metallic coatings have been used in the past, for protecting steel in industrial and urban developments. It has been suggested that thermally sprayed aluminium coatings, immersed in marine environments, are also capable of protecting steel by providing galvanic protection. Researchers have also speculated that the growth of inert oxide products, on top of the coating as well as inside pores and cracks, could enhance even further its protective “shielding” properties. In addition, the self-healing abilities of the coatings, in case of mechanically induce damage, are still a matter of debate. This research project takes a critical look at these assumptions, focusing on the electrochemical response of aluminium metal sprayed (AMS) coatings immersed in 0.6 M NaCl and 0.6 M Na2SO4 solutions, in order to investigate how the presence of chlorides can alter the corrosion behaviour of these coatings. For such, a thin aluminium protective coating was deposited over two different panels (aluminium 1050 and low carbon steel), by the steel making company Fairfield-Mabey, using electric arc thermal spraying (TS). Subsequently, the coated panels were sectioned into smaller specimens, and with the aid of a SEM/EDS, and XRD, observations and analysis were conducted in their surfaces and cross sections, in order to determine the morphology, quality of deposition, and chemical composition of the coatings. Internal porosity/oxide growth after immersion, was studied using 3-D X-ray tomography scanning. Furthermore, the electrochemical behaviour of the coatings (intact and scribed) was also investigated, initially by analyzing the evolution of the open circuit potential in time, when immersed in chloride rich and chloride free environments. Additionally, the anodic polarization behaviour of the substrate and coatings were simultaneously analyzed, by connecting a zero resistance ammeter (ZRA) with the W.E. terminal of a potentiostat. To conclude, EIS and Rp vs. time plots were made in order to corroborate the data obtained from other tests. Results show that although the coating can generate superficial and internal corrosion products, these oxides are not isolating in nature nor will enhance its protective properties. On the other hand, the corrosion potential behaviour of the coatings revealed that AMS coatings have a more active than the substrate; regardless of the environment in which they were immersed or their substrate. Nevertheless, it was also observed that AMS coatings deposited onto steel will corrode faster than their substrates, and for that matter capable of offering corrosion protection, exclusively if chlorides are present in the solution.

Please read the abstract in the section 00front of this document / Dissertation (MSc (Agric) Food Sience and Technology)--University of Pretoria, 2005. / Food Science / unrestricted

Research has focused on the influences of flowing fluid on the corrosion of bare metals, but there is little emphasis on the degradation of metal-protective coating. Evaluating the metal-protective coating usually uses the Electrochemical Impedance Spectroscopy (EIS) method. This paper presents a new impedance-based wireless sensor network for metal-protective coating evaluation. This wireless sensor network consists of two parts: impedance-based wireless sensor nodes and a wireless data base that are equipped with a network analyzer (AD5933) and a RF transceiver (CC1111/CC1110). In the experiment, three coating panels are immersed in flowing deionized water (DI water) and one coating panel immersed in stationary DI water. Experimental results demonstrate that this wireless sensor network is capable of evaluating the coating degradation.

Marine biofouling is the accumulation of organisms onto surfaces immersed in sea water. Fouling of ships causes an increase in hydrodynamic drag which leads to performance issues such as increased fuel consumption and a reduced top operating speed. Fouling-release (FR) coatings are one way that paints have been used in combating biofouling by allowing for the easy removal of settled organisms. Traditional FR coatings are silicone elastomers which are soft, easily damaged, and require a tie coat for adhesion to marine primers. Siloxanepolyurethane FR coatings have shown promise as FR coatings, providing enhanced durability and toughness, better adhesion to marine primers, and comparable FR performance to commercial coatings. Preliminary studies were conducted to explore the use of PDMS macromers in the preparation of siloxane-polyurethane FR coatings. Attachment and removal of fouling organisms on the siloxane-polyurethane coatings based on PDMS macromers was comparable to commercial FR coatings. Extended water aging was also carried out to determine effects of extended water immersion on the fouling-release performance of the coatings. At up to four weeks of aging, the FR performance of the coatings was not affected. Static immersion marine field testing was performed to determine the fouling-release performance of siloxane-polyurethane coatings prepared with PDMS macromers. The performance was found to be comparable to commercial FR coatings for up to one year, including water jet removal of slimes, barnacle push-off removal, and soft sponging. The coatings showed good fouling-release performance until extremely heavy fouling was allowed to settle. Underwater hull cleaning was conducted for one siloxane-polyurethane composition identified as a top performer from static field testing. The coating was easily cleaned of fouling with rotating brushes for six months. The cleaning capability of the coating was reduced when large barnacles and other extremely heavy fouling was present. A commercial FR coating became heavily damaged with brush cleaning while the siloxane-polyurethane coating remained mostly undamaged. With more frequent cleaning, it is suspected that siloxanepolyurethane coatings would show cleaning capability for longer periods of time. Pigmentation of siloxane-polyurethane coatings based on difunctional PDMS and PDMS macromers was explored to investigate the effect on FR performance. Pigmentation with titanium dioxide caused a slight decrease in FR performance in some cases, but this was easily overcome by the addition of slightly more PDMS in the coating binder, thus illustrating the feasibility of siloxane-polyurethane coatings as effective, pigmented FR coatings. Finally, the exploration of unique PDMS polymer architectures has been explored for the development of additional, novel, fouling-release coatings. The incorporation of end-functional PDMS homopolymer molecular brushes and branched PDMS macromers into siloxane-polyurethane fouling-release coatings shows promise for the development of unique coatings where improved FR performance may be obtained. / Office of Naval Research (U.S.)

Polymeric coatings are being used in a growing number of applications, contributing to protection against weather conditions and localized corrosion, reducing the friction and erosion wear on the substrate. In this study, various polypropylene (PP) coatings were applied onto steel substrates by compression molding. Chemical modification of PP has been performed to increase its adhesion to metallic surfaces by grafting of maleic anhydride (MAH) onto PP in the presence of dicumyl peroxide (DCP). Influence of different concentrations of MAH and DCP on the properties of resulting materials have been examined. The coated steel samples are characterized by scanning electron microscopy (SEM), shear adhesion testing, FTIR and tribometry. The coatings with 3 wt. % MAH have shown the maximum adhesion strength due to maximum amount of grafting. The wear rates increased with increasing the amount of MAH due to simultaneous increase in un-reacted MAH.

No description available.

The purpose of this study is to determine whether chlorinated polymers such as polyvinylchloride (PVC) and polyvinylidenechloride (PVDC) degrade in a fretting interface. Polymer coated 52100 steel balls are fretted against a polished 1045 steel plate for 30 minutes in air and nitrogen at 25-30 percent and greater than 95 percent relative humidity. ESCA analysis is used to determine interface chemistry and help conclude that the color formation observed in the polymer coating is due to polymer degradation. Additional tests of thermally stabilized PVC on a steel plate supported this theory and aided in understanding the polymers performance in the interface. Experiments with the “pure” PVC on a glass plate showed that iron at the interface can initiate and catalyzes the polymer degradation. The effects of the different atmospheres, as well as the effect of humidity is also presented. / M.S.

N-type GaAs is a potentially useful semiconductor in liquid junction type solar cells. Corrosion and corrosion suppression on an n-type GaAs semiconductor in both light and dark has been studied. The application of non-electroactive layers for corrosion suppression on semiconductor electrodes is a relatively new field. GaAs corrodes to form Ga(III) and As(III) solution species during photocurrent generation. The corrosion rate is determined electroanalytically in acidic media by measuring As(III) using differential pulse polarography (DPP). In neutral electrolytes a rotating ring-disc experiment measured the efficiency of hole-transfer to a redox couple. Two protecting processes have been utilized. Silanization and electrochemical polymerization of divinylbenzene and phenol were used to deposit non-electroactive layers on the electrode surface. The polyphenylene oxide coating partially suppressed corrosion in acid electrolytes. However, the coatings did not improve hole transfer efficiency in neutral electrolytes. / Master of Science

A fundamental study was conducted to investigate the ability of thin polymeric coatings to prevent metallic contact and fretting corrosion in steel-on-steel systems. Ten polymer types were chosen for study: polymethylmethacrylate (PMMA), polytetrafluoroethylene (PTFE), polyimide (PI), polyvinylidene fluoride (PVDF), polyvinylidene chloride (PVDC), polyvinyl chloride (PVC), low-density polyethylene (LOPE), high-density polyethylene (HDPE), polysulfone (PSO) and polystyrene (PS). These polymers were applied as thin films to a steel disk which was in turn fretted by a normally-loaded steel sphere. The experimental investigation consisted of two phases. In the first phase, the lives of the ten polymer types were evaluated over a range of normal loads from 11.1 to 44.5 N. In the second phase, optical and electron microscopy were used to document the fretting process at the sphere-film interface as a function of time. / Master of Science