Surface engineering projects
Completed projects
14661: Thermally sprayed aluminium coatings for prevention of corrosion of duplex stainless steels at elevated temperature
Started June 03. Cost per sponsor £20 000 pa, 2 paymentsContact D Harvey
There are increasing concerns regarding external chloride stress corrosion cracking (SCC) of duplex stainless steels on topsides, and crevice/pitting corrosion of umbilicals and immersed facilities, at elevated temperatures up to 150°C. Furthermore, there are doubts regarding the reliability of organic coatings at this temperature, and it is known that under certain conditions cathodic protection (CP) has led to hydrogen embrittlement induced component failure. To address these issues, this project evaluated the suitability of thermally sprayed aluminium (TSA) coatings on duplex stainless steel for prevention of SCC and crevice/pitting corrosion allowing provision of key recommendations for successful specification.
13458: Improving the reliability and cost performance of thermally sprayed aluminium coatings
Buy back fee £28 000Completion date April 2003
Contact D Harvey
Thermally sprayed aluminium (TSA) coatings are widely specified for protection of steel structures and components against saline aqueous corrosion, but there is increasing industrial requirement to extend its application to very severe environments including deep water, and to reduce the cost for existing applications. The objective of the project is to develop improved TSA coatings through evaluation and validation of recently developed thermal spray equipment and sealant compositions. Benefits will include improved coatings, reduced application and maintenance costs, and a reduction in the operator exposure to respirable fume and the risk of fire or explosion from residual fine metal dust.
13946: Validation of KERONITE ® - A novel coating for light metal alloys
Buy back fee £15 000Project Leader D Harvey
Completion date January 03
KERONITE ® is a new surface treatment for aluminium, magnesium, titanium and other light metal alloys that transforms the metal surface to a hard and dense ceramic layer. The process offers an environmentally friendly coating method for enhancing the wear, tribology and corrosion properties of a component surface, including access to restricted surfaces, whilst retaining initial component dimensions. This project demonstrated the application of novel KERONITE ® coatings to components selected from industries including aerospace and automotive and validated improved surface performance compared to conventional hard anodised and chrome plated coatings.
12514: Metal ceramic graded composite coatings by HVOF spraying for improved protection in corrosive environments
Buy back fee £30 000Project Leader A J Sturgeon
Completion date October 2002
The high velocity oxy-fuel (HVOF) spraying process allows for the deposition of very low porosity, high quality coatings of ceramic and graded ceramic-metal materials. Because of their chemical stability and high hardness these coatings are attractive candidates for the protection, or repair, of components that experience high temperature corrosive environments, often with wear occurring. The aim of this project was be to determine how coating structures can be prepared by HVOF spraying that give optimum protection in realistic corrosive environments, and to measure both corrosion performance and coating costs.
13309: New processes for wear and corrosion resistant coatings for internal cladding of small bore components
Buy back fee £15 000Contact A J Sturgeon
Completion date April 02
Damage by wear and corrosion is a major factor determining the life of components such as pumps, valves and tubular sections used in the extraction and transportation of petroleum, gas and related products. In particular, current surface engineering solutions are unable to provide adequate coatings on the internal surfaces of small-bore components. This Group Sponsored Project investigated the production and evaluation of coatings on the internal surfaces of tubular components (50-150mm internal diameter) using laser powder surfacing, rotational arc spraying and laser fusion of rotational arc spray coatings.
5676: Improved corrosion resistant coatings by HVOF spraying.
Buy back fee £28 000Contact A J Sturgeon
Completion date September 1998
HVOF spraying offers a lower cost alternative to weld overlays for the deposition of corrosion resistant metallic coatings. A cost study has estimated potential savings of 25% to 60% over conventional processes. The aim of this project was to identify the most cost-effective routes to reliable corrosion protection for four coating materials using HVOF.
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