In this blog, we will be weighing up the pros and cons of anti-corrosion coatings. Corrosion protection is necessary for the safety and functionality of many applications. However, they can initially be a hefty upfront cost, which may be off-putting to some businesses.
If you’re deciding whether anti-corrosion coatings are a worthwhile investment for your business, then this blog is for you.
Understanding Corrosion
Corrosion is a destructive form of surface degradation that can be costly to fix and dangerous when left untreated.
To understand how corrosion occurs, you must first understand the process of oxidation. Oxidation is an electrochemical process, wherein an ionic chemical reaction occurs between oxygen and a metallic surface. The metal loses its electrons to oxygen, subsequently damaging its entire surface layer. Essentially, metals corrode in environments that are chemically unstable.
Some alloys are more susceptible to corrosion than others, such as iron and steel. So, why don’t we just use non-corrosive metals in engineering applications? Well, metals that do not corrode are generally in short supply and can be expensive. Therefore, methods to control corrosion are utilised- such as anti-corrosion coatings.
What Are Anti-Corrosion Coatings?
Anti-corrosion coatings are a thermal spraying solution, wherein a layer of molten particles is sprayed onto a substrate. This forms a protective barrier between the external environment and a component’s surface.
To be compatible with different metals and application needs, there are various types of anti-corrosion coatings. Here’s a breakdown of the three types of anti-corrosion coatings:
Sacrificial Coatings
The sacrificial coating will corrode, rather than the underlying material. A reactive material, like zinc or aluminium, is sprayed overtop the substrate. When an electrochemical reaction occurs, it sacrificially corrodes the sprayed surface instead of the base material.
Inhibitive Coatings
Inhibitive coatings work to prevent the process of corrosion, by gradually releasing corrosion inhibitors. Inhibitors are either incorporated into the coating blend or applied separately as a primer and work effectively at slowing the rate of corrosion.
Barrier Coatings
By forming an impermeable barrier between a metal surface and a corrosive environment, barrier coatings are successful at stilting corrosion. As opposed to sacrificial or inhibitive coatings, barrier coatings do not partake in electrochemical reactions. Instead, it physically blocks oxygen, moisture, salts, and other corrosive agents from damaging the surface material.
For more information on when to use anti-corrosion coatings, check out our previous blog post.
The Pros And Cons Of Anti-Corrosion Coatings
Pros Of Anti-Corrosion Coatings
Extended Lifespan
The effects of corrosion lead to catastrophic component failure. Bridges and structures collapsing, equipment failure, oil and chemical spills; all can be boiled down to the impact of corrosion.
By administering anti-corrosion coatings, the service life and integrity of metal structures and equipment can be extended. Preventing oxidation will overall increase the durability of components.
Reduced Maintenance Costs
Usually, if a component is corroded, it requires replacing. This can be to prevent mechanical failure and/or for health and safety reasons. Maintenance or part replacement in any case is costly and interruptive.
Preventing corrosion is therefore an economic solution for many industries. Anti-corrosion coatings will minimise both the expenses and downtime accrued due to maintenance.
Improved Safety
Corrosion can compromise the structural integrity of buildings, marine structures, and infrastructures. Failure of any one of these could be life-threatening.
Anti-corrosion coatings help to maintain the strength and reliability of components, thereby enhancing the overall safety of structures for a prolonged time.
Adaptability
There are multiple variations of anti-corrosion coatings, so they are suitable for a range of applications. There are also alternative methods of application, which achieve different results. This means that anti-corrosion coatings can be used for industrial applications, buildings & structures, marine plants, aerospace and automotive models, and anywhere else corrosion protection may be required.
Read our guide to different metal spraying processes here.
Environmental Benefits
Replacing corroded components can be extremely detrimental to the environment. Corroded parts must be disposed of, contributing to the ever-increasing impact of landfills. To then replace those parts means the consumption of raw materials, which are sparing as it stands.
Conserving components for prolonged periods by improving its surface technology is an environmentally beneficial solution.
Cons Of Anti-Corrosion Coatings
Initial Cost
The initial sum to invest in anti-corrosion coatings can be expensive for businesses. While anti-corrosion coatings do promise significant savings down the line, the product itself and expert application require a significant upfront investment, especially for large-scale projects.
Complex Application
For an expert in anti-corrosion coatings and thermal spraying methods, the application process is straightforward. That’s because they have access to specialised skills, knowledge, and equipment. It is necessary that a professional administer the coatings, and it can rarely be done effectively in-house.
Impacts To Performance
In relation to the point above, poor application or incompatible materials may lead to ineffective results. Substrates must be prepared prior to application for optimal results. For more information, read our blog on Thermal Spray Coating Surface Preparation.
Weighing Up The Pros And Cons Of Anti-Corrosion Coatings
Once we’ve weighed up the pros and cons of anti-corrosion coatings, it is clear that they are a necessary and advantageous investment for businesses.
To prevent inadequate results, we recommend professional application. That’s something we can help with.
Alphatek offers propriety corrosion protection coatings and will administer them ourselves. We ensure that all our clients achieve the best results.
If you need any more reasons to invest in high-performance anti-corrosion coatings or would like to enquire about our services, please contact us today.
