US20060000183A1 - Method and apparatus for anticorrosive coating - Google Patents
Method and apparatus for anticorrosive coating Download PDFInfo
- Publication number
- US20060000183A1 US20060000183A1 US11/165,852 US16585205A US2006000183A1 US 20060000183 A1 US20060000183 A1 US 20060000183A1 US 16585205 A US16585205 A US 16585205A US 2006000183 A1 US2006000183 A1 US 2006000183A1
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- United States
- Prior art keywords
- coating
- workpiece
- metal
- anticorrosive
- zinc
- Prior art date
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- Abandoned
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- 238000000576 coating method Methods 0.000 title claims abstract description 39
- 239000011248 coating agent Substances 0.000 title claims abstract description 30
- 238000000034 method Methods 0.000 title claims abstract description 30
- 229910052751 metal Inorganic materials 0.000 claims abstract description 30
- 239000002184 metal Substances 0.000 claims abstract description 30
- 239000011253 protective coating Substances 0.000 claims abstract description 6
- 238000005507 spraying Methods 0.000 claims abstract description 6
- 229910000831 Steel Inorganic materials 0.000 claims description 17
- 239000010959 steel Substances 0.000 claims description 17
- 239000004593 Epoxy Substances 0.000 claims description 15
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 14
- 229910052725 zinc Inorganic materials 0.000 claims description 13
- 239000011701 zinc Substances 0.000 claims description 13
- 229910052782 aluminium Inorganic materials 0.000 claims description 7
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 7
- 239000002245 particle Substances 0.000 claims 2
- 238000010891 electric arc Methods 0.000 claims 1
- 238000010791 quenching Methods 0.000 abstract description 5
- 230000000171 quenching effect Effects 0.000 abstract description 4
- 239000000843 powder Substances 0.000 description 12
- 239000007921 spray Substances 0.000 description 11
- 229910045601 alloy Inorganic materials 0.000 description 7
- 239000000956 alloy Substances 0.000 description 7
- 238000002679 ablation Methods 0.000 description 6
- 230000007797 corrosion Effects 0.000 description 5
- 238000005260 corrosion Methods 0.000 description 5
- 229920006334 epoxy coating Polymers 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 239000004576 sand Substances 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 3
- 238000001465 metallisation Methods 0.000 description 3
- 238000002360 preparation method Methods 0.000 description 3
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 2
- 239000011780 sodium chloride Substances 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- 230000000007 visual effect Effects 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 229910001294 Reinforcing steel Inorganic materials 0.000 description 1
- 229910000611 Zinc aluminium Inorganic materials 0.000 description 1
- 239000003082 abrasive agent Substances 0.000 description 1
- HXFVOUUOTHJFPX-UHFFFAOYSA-N alumane;zinc Chemical compound [AlH3].[Zn] HXFVOUUOTHJFPX-UHFFFAOYSA-N 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N iron oxide Inorganic materials [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 1
- 235000013980 iron oxide Nutrition 0.000 description 1
- VBMVTYDPPZVILR-UHFFFAOYSA-N iron(2+);oxygen(2-) Chemical class [O-2].[Fe+2] VBMVTYDPPZVILR-UHFFFAOYSA-N 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 239000003129 oil well Substances 0.000 description 1
- 238000010422 painting Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 238000005488 sandblasting Methods 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
- E04C5/01—Reinforcing elements of metal, e.g. with non-structural coatings
- E04C5/015—Anti-corrosion coatings or treating compositions, e.g. containing waterglass or based on another metal
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
- B05D1/04—Processes for applying liquids or other fluent materials performed by spraying involving the use of an electrostatic field
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/02—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
- B05D3/0218—Pretreatment, e.g. heating the substrate
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/12—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by mechanical means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/14—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to metal, e.g. car bodies
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/02—Coating starting from inorganic powder by application of pressure only
- C23C24/04—Impact or kinetic deposition of particles
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
- C23C28/021—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material including at least one metal alloy layer
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/18—After-treatment
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
- B05D1/12—Applying particulate materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D2350/00—Pretreatment of the substrate
- B05D2350/60—Adding a layer before coating
- B05D2350/65—Adding a layer before coating metal layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/007—After-treatment
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12014—All metal or with adjacent metals having metal particles
- Y10T428/12028—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.]
- Y10T428/12049—Nonmetal component
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12014—All metal or with adjacent metals having metal particles
- Y10T428/12028—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.]
- Y10T428/12063—Nonparticulate metal component
Definitions
- the present invention relates generally to the application of anticorrosive coatings, and more particularly, to application of anticorrosive coatings to metal surfaces.
- a method and apparatus provide an anticorrosive coating on a metal surface.
- FIG. 1 is a flow chart illustrating an anticorrosive coating process according to an embodiment of the present invention
- FIG. 2 is a flow chart illustrating an anticorrosive process according to a second embodiment of the present invention
- FIG. 3 is a side view of a section of “black bar” rebar as it may be received from a steel manufacturing facility;
- FIG. 6 is a side view of a section of rebar, as shown in FIGS. 1, 2 and 3 , after a thermal epoxy application process in accordance with an embodiment of the invention.
- the metal object to be coated is cleaned and surfaced.
- preparing steel rebar with a “near white” finish such as is described in the Painter's Council Handbook, or the specifications known as “Visual Reference SP10” or “SS Visual 1 ” in the Steel Structures Painting Council (SSPC)
- SSPC Steel Structures Painting Council
- One technique for accomplishing such surface preparation is by wheel ablation. Wheel ablation may be accomplished by employing a wheel that includes plural vanes, or blades. The wheel may be rotated at a high rate of speed and sand, or other abrasive material (“sand”), introduced into the rotating wheel. The sand may then be expelled from the wheel at a high rate of speed and impinge on the metal object.
- sand abrasive material
- the object being treated may be rotated, or otherwise manipulated, and drawn through the, path of the impinging sand to achieve a substantially consistent surface topology.
- a standard anchor profile which is known, may be achieved when preparing the surface of steel rebar with wheel ablation.
- wheel ablation may be employed, and the invention is not limited to the use of wheel ablation.
- conventional sandblasting techniques may be employed, as one alternative.
- Such surface preparation may remove any corrosion on the surface of the metal object and also provide a surface that improves adhesion of subsequent materials applied to the object, as is discussed below.
- the object may be heated. Such heating may be accomplished using a furnace, oven or heat induction coil. Such heating may further improve the adhesion of materials applied in subsequent operations of the process.
- the temperature to which the bar is heated will depend on the specific embodiment and materials used. Typically, temperatures for embodiments in accordance with the invention may range from 430-550° F., though the invention is not limited in this respect. As indicated above, the specific temperature may depend on the particular materials used to coat the metal object, such as metallization alloy and epoxy powder, for example.
- a metal object being coated may be metalized, or coated with an anticorrosive metal.
- an arc spray system may be employed and is well known.
- Such a system that may be used is the Model BP400 Arc Spray System, available from Praxair Surface Technologies, Inc., Thermal Spray Products, N670 Communication Drive, Appleton, Wis. 54915. According to a datasheet for such spray system (Revision A Apr. 1, 1998) included as Exhibit A in applicant's parent U.S. patent application Ser. No. 10/326,610, filed Dec.
- such arc spray system is used in handheld and robotic applications in industries including tubing and extrusion, general machine and maintenance, automotive, cookware, aerospace, pulp and paper, and medical industries, among others.
- a spray system has previously been used to coat oil-well pump sucker rods with a stainless steel coating, which is then covered by an epoxy coating.
- an anticorrosive metal may be sprayed over the surface of the metal object being coated.
- a gun of such a spray system would, during operation, be slid back and forth in a parallel path to the metal object being coated. This motion of the gun may improve uniformity of the coating, which is desired, but such motion is not essential.
- wire is typically employed as the metal source. Compositions for such wires may vary. For example, wire composed of an alloy of ninety-eight percent zinc and two percent aluminum by weight has been discovered to be preferable for the present invention, but compositions principally of zinc, for example from one hundred percent zinc to about eighty-five percent zinc by weight with a balance principally of aluminum, may be used.
- compositions principally of zinc are preferred for this application because, in the event of damage to an outer polymeric protective coating which covers the zinc coating as described hereafter, zinc corrosion products such as zinc oxide occupy much less volume than iron oxides and can also diffuse into surrounding concrete, thereby reducing tensile stresses between the concrete and the coated metal object, such as steel rebar, to prevent cracked concrete.
- a pseudo-alloy spray may be applied.
- a pure zinc wire and a pure aluminum wire may be employed, with the amount of each wire consumed during application to an object controlled to achieve a desired alloy ratio.
- An electrical arc typically vaporizes wire in such a system. This vapor is then sprayed on the surface of the metal object being coated. Preferably, the resulting coating thickness is in a range from about 1.5 mils to about 2.0 mils. This ensures against too thin a coating, which would have poor corrosion resistance, and too thick a coating, which would have a tendency to crack if bent in a manner commonly required with steel rebar.
- the invention is not limited to the particular alloys or techniques discussed above, and other equipment, material, or approaches may be employed, such as the use of plasma or cold spray systems.
- an epoxy powder may be sprayed onto the heated, metalized object being coated in a chamber.
- Epoxy powders suitable for such an application are available and are well known.
- NAP-GARD® 7-2719 is available from DuPont Powder Coatings, 9800 Genard, Houston, Tex. 77041. According to a datasheet for this powder previously included as Exhibit B in applicant's parent U.S. patent application Ser. No. 10/326,610, filed Dec. 20, 2002, which is hereby incorporated herein by reference, NAP-GARD® 7-2719 is a thermosetting epoxy powder designed to coat reinforcing steel rebar to provide corrosion protection, and is designed specifically for application to straight bars that are subsequently bent.
- Epoxy powder may be sourced for such application from a vat, where pumping dry air through the powder may fluidize it to facilitate spraying. Additionally, an electrostatic charge may be introduced into the epoxy powder to improve attraction of the powder with an object being coated, such as grounded steel rebar.
- the melted epoxy may gel.
- a gel time is typically employed to allow a thermal-setting epoxy to harden, in order to prevent damage from the first roller encountered after the epoxy is applied.
- Gel times may vary depending on the particular epoxy employed, and on the ambient environment conditions. In this regard, gel times may be in the range of three to twelve seconds, though the invention is not so limited and longer or shorter gel times may be possible. However, shorter-gel times are typically desirable to allow for increased manufacturing line speed.
- the epoxy coating is cured.
- wet canted rollers may be used to prevent damage to the coating and to rotate the rebar for facilitating earlier coating operations on the object being coated.
- Cure time is the time employed to complete the thermosetting of the epoxy coating. While the cure time depends on the particular embodiment, cure times typically range from twenty to thirty-five seconds.
- the object such as rebar
- Quenching may be accomplished by passing the coated rebar through a series of low-pressure water streams. Quenching reduces the temperature of the rebar and further hardens the epoxy coating to prevent damage from handling after the completion of the coating process. It is noted that quenching and curing are distinct operations and applying a water stream prior to the completion of the epoxy cure may result in damage to the coating.
- FIG. 2 An alternative method for applying an anticorrosive coating is shown in FIG. 2 and indicated generally at 30 .
- Method 30 is similar to method 10 and, therefore, only the differences in the two processes will be discussed below.
- heating of the object being coated is done in two operations, 36 and 38 , rather than one operation as was the case with method 10 .
- an object to be coated may be preheated at 36 .
- the temperature of preheat at 36 would typically be a lower temperature than indicated above for heating at 16 .
- an object may be preheated to ⁇ 300° F. at 36 . This lower temperature may be employed to improve adhesion of the metallization applied at 38 for certain alloy compositions.
- An object being coated may then be reheated to a temperature appropriate for applying epoxy coating at 42 . These temperatures may be in the range of those discussed above with respect to method 10 .
- the preheating operation 36 could be eliminated.
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Abstract
Description
- This application is a continuation-in-part of U.S. patent application Ser. No. 10/326,610, filed Dec. 20, 2002, which is hereby incorporated herein by reference, and which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/343,462, filed Dec. 20, 2001.
- The present invention relates generally to the application of anticorrosive coatings, and more particularly, to application of anticorrosive coatings to metal surfaces.
- A method and apparatus provide an anticorrosive coating on a metal surface.
-
FIG. 1 is a flow chart illustrating an anticorrosive coating process according to an embodiment of the present invention; -
FIG. 2 is a flow chart illustrating an anticorrosive process according to a second embodiment of the present invention; -
FIG. 3 is a side view of a section of “black bar” rebar as it may be received from a steel manufacturing facility; -
FIG. 4 is a side view of a section of rebar, such as shown inFIG. 1 , after a wheel ablation process in accordance with an embodiment of the invention; -
FIG. 5 is a side view of a section of rebar, as shown inFIGS. 1 and 2 , after a spray coating process in accordance with an embodiment of the invention; -
FIG. 6 is a side view of a section of rebar, as shown inFIGS. 1, 2 and 3, after a thermal epoxy application process in accordance with an embodiment of the invention. - Referring to
FIG. 1 , a flowchart illustrating a method of applying an anticorrosive coating according to an embodiment of the present invention is shown generally at 10. At 12, a “raw” metal workpiece is provided. Such a metal piece may be an object formed from metal that may be susceptible to corrosion, such as steel. In one embodiment, a section of steel rebar may be loaded on a coating manufacturing line via rollers. While the embodiments of the invention described herein are generally directed to an anticorrosive coating process for steel rebar, the invention may be applied to coat numerous other types of metal objects, such as structural beams, steel bridge components or motor vehicle frames, as some examples. - At 14, the metal object to be coated is cleaned and surfaced. In this regard, preparing steel rebar with a “near white” finish, such as is described in the Painter's Council Handbook, or the specifications known as “Visual Reference SP10” or “SS Visual 1” in the Steel Structures Painting Council (SSPC), may be desired. One technique for accomplishing such surface preparation is by wheel ablation. Wheel ablation may be accomplished by employing a wheel that includes plural vanes, or blades. The wheel may be rotated at a high rate of speed and sand, or other abrasive material (“sand”), introduced into the rotating wheel. The sand may then be expelled from the wheel at a high rate of speed and impinge on the metal object. In this regard, the object being treated may be rotated, or otherwise manipulated, and drawn through the, path of the impinging sand to achieve a substantially consistent surface topology. In this regard, a standard anchor profile, which is known, may be achieved when preparing the surface of steel rebar with wheel ablation. Of course, other techniques may be employed, and the invention is not limited to the use of wheel ablation. For example, conventional sandblasting techniques may be employed, as one alternative. Such surface preparation may remove any corrosion on the surface of the metal object and also provide a surface that improves adhesion of subsequent materials applied to the object, as is discussed below.
- At 16, the object may be heated. Such heating may be accomplished using a furnace, oven or heat induction coil. Such heating may further improve the adhesion of materials applied in subsequent operations of the process. The temperature to which the bar is heated will depend on the specific embodiment and materials used. Typically, temperatures for embodiments in accordance with the invention may range from 430-550° F., though the invention is not limited in this respect. As indicated above, the specific temperature may depend on the particular materials used to coat the metal object, such as metallization alloy and epoxy powder, for example.
- At 18 in
FIG. 1 , a metal object being coated may be metalized, or coated with an anticorrosive metal. Various techniques for performing such coating are possible. For example, an arc spray system may be employed and is well known. Such a system that may be used is the Model BP400 Arc Spray System, available from Praxair Surface Technologies, Inc., Thermal Spray Products, N670 Communication Drive, Appleton, Wis. 54915. According to a datasheet for such spray system (Revision A Apr. 1, 1998) included as Exhibit A in applicant's parent U.S. patent application Ser. No. 10/326,610, filed Dec. 20, 2002, which is hereby incorporated herein by reference, such arc spray system is used in handheld and robotic applications in industries including tubing and extrusion, general machine and maintenance, automotive, cookware, aerospace, pulp and paper, and medical industries, among others. For example, such a spray system has previously been used to coat oil-well pump sucker rods with a stainless steel coating, which is then covered by an epoxy coating. - Employing such a spray system, an anticorrosive metal may be sprayed over the surface of the metal object being coated. Typically, a gun of such a spray system would, during operation, be slid back and forth in a parallel path to the metal object being coated. This motion of the gun may improve uniformity of the coating, which is desired, but such motion is not essential. In such a system, wire is typically employed as the metal source. Compositions for such wires may vary. For example, wire composed of an alloy of ninety-eight percent zinc and two percent aluminum by weight has been discovered to be preferable for the present invention, but compositions principally of zinc, for example from one hundred percent zinc to about eighty-five percent zinc by weight with a balance principally of aluminum, may be used. Compositions principally of zinc are preferred for this application because, in the event of damage to an outer polymeric protective coating which covers the zinc coating as described hereafter, zinc corrosion products such as zinc oxide occupy much less volume than iron oxides and can also diffuse into surrounding concrete, thereby reducing tensile stresses between the concrete and the coated metal object, such as steel rebar, to prevent cracked concrete. In other embodiments, a pseudo-alloy spray may be applied. In such applications, a pure zinc wire and a pure aluminum wire may be employed, with the amount of each wire consumed during application to an object controlled to achieve a desired alloy ratio.
- An electrical arc typically vaporizes wire in such a system. This vapor is then sprayed on the surface of the metal object being coated. Preferably, the resulting coating thickness is in a range from about 1.5 mils to about 2.0 mils. This ensures against too thin a coating, which would have poor corrosion resistance, and too thick a coating, which would have a tendency to crack if bent in a manner commonly required with steel rebar. The invention is not limited to the particular alloys or techniques discussed above, and other equipment, material, or approaches may be employed, such as the use of plasma or cold spray systems.
- At 20, in
FIG. 1 , an epoxy powder may be sprayed onto the heated, metalized object being coated in a chamber. Epoxy powders suitable for such an application are available and are well known. For example NAP-GARD® 7-2719 is available from DuPont Powder Coatings, 9800 Genard, Houston, Tex. 77041. According to a datasheet for this powder previously included as Exhibit B in applicant's parent U.S. patent application Ser. No. 10/326,610, filed Dec. 20, 2002, which is hereby incorporated herein by reference, NAP-GARD® 7-2719 is a thermosetting epoxy powder designed to coat reinforcing steel rebar to provide corrosion protection, and is designed specifically for application to straight bars that are subsequently bent. It has been certified to meet the specifications known as 775-97 and AASHTO M284. It is a green powder having a specific gravity of 1.27±0.05, a coverage of 152 square feet per pound per mil, a shelf life of six months, a gel time of 8-10 seconds in accordance with ASTMD-3451-92 at 205° C., a flexibility in accordance with D. P. C. 10.227 which passes a 4d bend on number 4 bar at 23° C. at 7-11 mils, a Knoop hardness number in accordance with AASHTO M284 A. 1.4.8 of 15.0 average at 10 mils thickness, and a chemical resistance in accordance withASTM G 20 of forty-five days at 24° C. in 3 molar NaCl and 7% NaCl. Such a powder is typically applied dry, and melts upon contact with the heated metal object, such as steel rebar. Epoxy powder may be sourced for such application from a vat, where pumping dry air through the powder may fluidize it to facilitate spraying. Additionally, an electrostatic charge may be introduced into the epoxy powder to improve attraction of the powder with an object being coated, such as grounded steel rebar. - At 22, the melted epoxy may gel. Because rollers may be employed for such coating processes, such as for coating steel rebar, a gel time is typically employed to allow a thermal-setting epoxy to harden, in order to prevent damage from the first roller encountered after the epoxy is applied. Gel times may vary depending on the particular epoxy employed, and on the ambient environment conditions. In this regard, gel times may be in the range of three to twelve seconds, though the invention is not so limited and longer or shorter gel times may be possible. However, shorter-gel times are typically desirable to allow for increased manufacturing line speed.
- At 24, the epoxy coating is cured. For steel rebar coating processes, wet canted rollers may be used to prevent damage to the coating and to rotate the rebar for facilitating earlier coating operations on the object being coated. Cure time is the time employed to complete the thermosetting of the epoxy coating. While the cure time depends on the particular embodiment, cure times typically range from twenty to thirty-five seconds.
- At 26, the object, such as rebar, may be quenched. Quenching may be accomplished by passing the coated rebar through a series of low-pressure water streams. Quenching reduces the temperature of the rebar and further hardens the epoxy coating to prevent damage from handling after the completion of the coating process. It is noted that quenching and curing are distinct operations and applying a water stream prior to the completion of the epoxy cure may result in damage to the coating.
- An alternative method for applying an anticorrosive coating is shown in
FIG. 2 and indicated generally at 30.Method 30 is similar tomethod 10 and, therefore, only the differences in the two processes will be discussed below. Formethod 30, heating of the object being coated is done in two operations, 36 and 38, rather than one operation as was the case withmethod 10. In this respect, an object to be coated may be preheated at 36. The temperature of preheat at 36 would typically be a lower temperature than indicated above for heating at 16. For example, an object may be preheated to ˜300° F. at 36. This lower temperature may be employed to improve adhesion of the metallization applied at 38 for certain alloy compositions. An object being coated may then be reheated to a temperature appropriate for applying epoxy coating at 42. These temperatures may be in the range of those discussed above with respect tomethod 10. As a further alternative, the preheatingoperation 36 could be eliminated. -
FIGS. 3-6 show sections of rebar at various points in a coating process such as those just discussed. In this regard,FIG. 3 shows a section of “raw” or “black”rebar 50.Rebar 50 appears as it may be received from a steel manufacturer, prior to any processing.FIG. 4 shows a section ofrebar 52 after cleaning and surface preparation, such as may be done with wheel ablation.FIG. 5 shows a section ofrebar 54 after metallization with a zinc-aluminum alloy using an arc spray system, as previously discussed.FIG. 6 shows a section ofrebar 56 after epoxy powder application, gel, cure and quench.Rebar 56 appears as it may be shipped to a customer for use in various structural or construction applications. - While the invention has been discussed in its preferred form, the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense, because numerous variations are possible. The subject matter of the invention includes all novel and nonobvious combination and subcombinations of the various components, features, functions, and/or properties disclosed herein. No single feature, function, element, or property of the disclosed invention is essential.
Claims (13)
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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US11/165,852 US20060000183A1 (en) | 2001-12-20 | 2005-06-23 | Method and apparatus for anticorrosive coating |
US12/203,121 US20100015461A1 (en) | 2001-12-20 | 2008-09-02 | Method and Apparatus for Anticorrosive Coating |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US34346201P | 2001-12-20 | 2001-12-20 | |
US10/326,610 US20070178236A1 (en) | 2001-12-20 | 2002-12-20 | Method and apparatus for anti-corrosive coating |
US11/165,852 US20060000183A1 (en) | 2001-12-20 | 2005-06-23 | Method and apparatus for anticorrosive coating |
Related Parent Applications (1)
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US10/326,610 Continuation-In-Part US20070178236A1 (en) | 2001-12-20 | 2002-12-20 | Method and apparatus for anti-corrosive coating |
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US12/203,121 Division US20100015461A1 (en) | 2001-12-20 | 2008-09-02 | Method and Apparatus for Anticorrosive Coating |
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US20060000183A1 true US20060000183A1 (en) | 2006-01-05 |
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US11/165,852 Abandoned US20060000183A1 (en) | 2001-12-20 | 2005-06-23 | Method and apparatus for anticorrosive coating |
US12/203,121 Abandoned US20100015461A1 (en) | 2001-12-20 | 2008-09-02 | Method and Apparatus for Anticorrosive Coating |
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Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
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US20090011123A1 (en) * | 2007-07-06 | 2009-01-08 | United Technologies Corporation | Corrosion protective coating through cold spray |
US20110077337A1 (en) * | 2009-09-25 | 2011-03-31 | Yeh Yun-Chao | Method for preparing a high thermal conductivity and low dissipation factor adhesive varnish for build-up additional insulation layers |
US20150218815A1 (en) * | 2014-01-31 | 2015-08-06 | Mortar Net Usa, Ltd. | Corrosion resistant structural reinforcement member |
CN113231287A (en) * | 2021-05-07 | 2021-08-10 | 福建辉丰环境工程科技有限公司 | Manufacturing method of insulating anti-corrosion prestressed steel bar |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
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US20130209192A1 (en) | 2010-06-24 | 2013-08-15 | Nucor Corporation | Tensionable threaded rebar bolt |
US9010165B2 (en) | 2011-01-18 | 2015-04-21 | Nucor Corporation | Threaded rebar manufacturing process and system |
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Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20090011123A1 (en) * | 2007-07-06 | 2009-01-08 | United Technologies Corporation | Corrosion protective coating through cold spray |
US8597724B2 (en) | 2007-07-06 | 2013-12-03 | United Technologies Corporation | Corrosion protective coating through cold spray |
US20110077337A1 (en) * | 2009-09-25 | 2011-03-31 | Yeh Yun-Chao | Method for preparing a high thermal conductivity and low dissipation factor adhesive varnish for build-up additional insulation layers |
US20150218815A1 (en) * | 2014-01-31 | 2015-08-06 | Mortar Net Usa, Ltd. | Corrosion resistant structural reinforcement member |
CN113231287A (en) * | 2021-05-07 | 2021-08-10 | 福建辉丰环境工程科技有限公司 | Manufacturing method of insulating anti-corrosion prestressed steel bar |
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US20100015461A1 (en) | 2010-01-21 |
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