Corrosion costs for United States (U.S.) Army ground vehicles are estimated at $2 billion per year. A study was conducted to evaluate how sacrificial metallic coatings applied on steel by electroplating, galvanizing, spray painting, flame spray (FS), arc spray (AS) and high-velocity particle consolidation (HVPC) enhance the corrosion protection afforded by coating systems. The coatings in this study were Zn, Zn-1Co and Zn-12Ni electroplates; Zn, Zn-5Al and Al-44Zn-1.6Si galvanized coatings, zinc-rich primers, Zn, Al, and Zn-15Al thermal sprays and Zn and Al HVPC. Thickness of the metallic coatings ranged from 4.8 μm for electroplated Zn-1Co to 279.4 μm for FS Zn-15Al. A salt fog test and a cosmetic corrosion laboratory test were carried out on scribed steel panels with the above coatings. Atmospheric exposure tests of these metallic coating systems are underway at an oceanfront test site. The top twelve coatings in the cosmetic corrosion laboratory test included eight thermal sprayed Zn, two HVPC-Zn, and a flame sprayed Zn-15Al and Al.

Subject
Zinc nickel coatings, Primers, Zinc rich coatings, Coatings, Top coats, Galvanized coatings, Steel, Metallic coatings, Corrosion protection, Zinc, Barrier coatings, Coating systems, Thermal spray coatings
Keywords:
electroplate, galvanize, flame spray, arc spray, high-velocity particle consolidation, zinc, aluminum, nickel, cobalt, chromate
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2005
Association for Materials Protection and Performance (AMPP)
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