Metals are used across countless industries. But one issue is a cause for concern to all manufacturers- the threat of corrosion. When the surface of metals comes into contact with oxygen and moisture in the environment, it breaks down, leading to structural consequences.
If you are searching for ways to extend the longevity of metallic structures or equipment, minimize economic loss, and circumvent safety hazards due to corrosion, hop on board. This blog discusses several techniques to help shield metals from deterioration.
1. Choose the Right Materials
Some materials are more resistant to corrosion than others. Before manufacturing a metal product, consider what metal is more suitable by analyzing the cost and durability. Often, industries opt for stainless steel, an alloy made from iron and chromium. Stainless steel with high percentages of chromium is more resistant to rust. So it’s important to select high-quality metal with appropriate surface treatments to ensure you get the most protection against corrosion.
2. Limit Exposure to Environmental Factors
Weather conditions, such as rain, sunlight, and humidity, can cause metal objects to rust. Besides this, salty sea water and hard water with high mineral content also speed up corrosion. So when possible, protect outdoor metal objects from these factors as much as possible by covering them.
Furthermore, before storing metal items, make sure to thoroughly clean the surface of dirt, debris, and moisture.
3. Paint and Lacquers
Paint is a commonly-used, affordable, and effective method of protecting metals from reacting with external environmental factors, such as moisture and oxygen. Of course, objects exposed to harsh outdoor conditions will need more protection than ones used indoors.
A protective paint system typically has several coats, such as:
Primer – The primer is the first layer to help prohibit corrosion. But besides this, it provides the necessary surface adhesion required for the subsequent coats of paint.
Intermediate coat – The intermediate coat is typically applied to build up thickness. This helps to reduce the permeability of oxygen and water, improving overall protection. So the thicker the intermediate coat, the longer the paint system lasts.
Finish coat – The finish coat helps enhance the appearance of the finished product. However, it also provides the first defense against environmental elements, such as sunlight, condensation, and the weather.
4. Oil and Grease
Much like paint systems, a layer of oil or grease acts as a protective layer on top of the metal, providing an effective first line of defense against moisture. It helps keep the metal dry, preventing it from coming in contact with humidity, water, and condensation. But besides this, oil and grease offer lubrication, which is a bonus if the metal piece is constantly in motion.
5. Apply A Protective Powder Coating Finish
Besides paint, sophisticated materials can also be used to coat metals, such as powder coatings. The dry powder is applied to the metal’s surface, then heated, causing the powder to melt and adhere to the surface. Once this cools, a hard even coating forms. This enables manufacturers to create metal products with functional and decorative surface coatings in an array of colors, finishes, and textures.
Manufacturers usually use the following two techniques to apply the powder coating:
Electrostatic spray deposition (ESD)
In electrostatic deposition, the electrically-charged particles of the powder coating material are applied to the metal using an electrostatic spray gun. They adhere to the surface of the metal (which is electrically grounded).
Fluidized bed powder coating
Preheated metal parts are dipped into a bed containing the powder coating material. The particles fuse to the metal surface to create a consistent, even finish.
6. Sacrificial Coatings
A sacrificial coating entails applying a thin metal layer onto the metal substrate as a means of protecting it from corrosion. There are two types of sacrificial coatings – it’s either more or less reactive than the metal base.
For instance, zinc is more reactive than steel. So coating the metal with a layer of zinc (a process known as galvanization) is an effective way to protect steel and iron structures from rust and corrosion. The zinc layer acts as a sacrificial coat. Since zinc is more active than the base metal (e.g., steel), it oxidizes before the metal underneath does.
On the other hand, a less active metal, such as tin, can also be used for sacrificial coatings. In this case, tin forms an unreactive protective shield over the base metal. However, this will only be possible when the tin coating remains intact. If the tin layer is damaged, the base metal will begin to corrode rather quickly.
For this reason, galvanization is a popular choice across various industries. So if you’re searching for a way to protect metal structures from corrosion, search for “metal galvanizing near me“. You’ll find local services that offer durable and affordable galvanization solutions.
7. Utilize Bluing Process
Bluing is another method that provides some resistance against corrosion. Manufacturers often paint, coat, or galvanize metal objects for comprehensive protection. However, bluing is still used by different industries to improve the appearance of steel or iron objects.
Bluing involves oxidizing the metal, typically with the help of heat. The process creates a thin layer of deep, dark-colored oxide on the surface. Common bluing techniques include hot bluing and cold bluing.
8. Focus on Creating the Right Design
Most structures have crevices and corners. However, if the design traps moisture and dirt, it can cause the structure to corrode. This can deteriorate its strength and quality. So the key is to create structural designs that prevent the accumulation of any debris or moisture on the surface.
9. Perform Routine Maintenance Checks
Inspect metal objects and structures regularly for signs of corrosion or damage to their protective coating. Detecting and eradicating issues early on prevents the problem from spreading. More importantly, it circumvents the need to replace them.
Final Thoughts
Metals face the relentless battle against corrosion daily. Innovative techniques are helping to safeguard metals from getting damaged, which could lead to economic loss and safety hazards.
The techniques mentioned above can help protect metals from corrosion. They can enable industries to preserve, enhance, and elevate the potential of metal structures and objects we use every day.