Materials Performance

SEP 2018

Materials Performance is the world's most widely circulated magazine dedicated to corrosion prevention and control. MP provides information about the latest corrosion control technologies and practical applications for every industry and environment.

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MATERIALS PERFORMANCE: VOL. 57, NO. 9 SEPTEMBER 2018 A29 A29 SEPTEMBER 2018 MATERIALS PERFORMANCE: VOL. 57, NO. 9 Roundtable Panelists Share Historical Milestones in Corrosion Control Automobile corrosion, such as through- the-wall perforations on doors, fenders, hoods, and trunks, was common in the 1960s and earlier. The application of computer/ digital technology in corrosion engineering and science has impacted the way field data is gathered, recorded, analyzed, and processed into reports for further analysis. Coatings Advances that Control Corrosion of Auto Body Panels Joe H. Payer, FNACE United States A couple of major advances come to mind. First, the huge success in controlling the corrosion of auto body panels was remark- able. In the 1960s and earlier, through- the-wall perforations were common for car doors, fenders, hoods, and trunks. Not only was this corrosion damage unsightly, it often led to high repair bills and early scrapping of cars. The auto industry, encouraged by public outrage, took on this problem, and now it is common to have 7- to 10-year warranties against this cor- rosion damage. for further analysis. Data are no longer entered into handwritten notebooks for later transcription and processing. The procedure is now more productive, confident, and effective. Apps have been developed to carry out much of the corrosion analysis and report- ing. Corrosion information is now available in the field, at the work station, in the lab, or at the desk to be called up on a tablet or smart phone. In the laboratory, apps are available to set up test protocols and procedures, gather and report data, and carry out sophisticated analyses. Corrosion experts can now be queried in real-time from remote locations to make observations and participate in delibera- tions. Communication packages are available for real-time team meetings, video conferences, and online education and training. I'm fairly certain that in 10 years the next generation will look at our current communication technologies as comparable to the Wright brothers in aviation. Additionally, a refreshing and productive change has been the movement from pre- scriptive corrosion control prac- tices to a more holistic develop- ment of corrosion mitigation strategies. The NACE IMPACT study identified the need, and developed a blueprint, to incorporate corrosion mitiga- tion strategies into a company's overall corporate management system. We need to stop "talk- ing to ourselves" and learn to speak to decision-makers in terms and language that they use and understand. When I speak to folks outside of our profession on corrosion technology, their eyes can glass over. However, when I speak of safety, reliability, risk reduction, and costs, often they want to hear more. The Corrosion Policy and Oversight Office of the U.S. Depart- ment of Defense is an exemplar for the development, dissemina- tion, and application of corrosion mitigation strategies for the benefit of a large and complex organization. NACE has been an effective partner in several of these initiatives. Lessons learned are being applied to a number of industries. During my 50 years as a NACE member and the 30-plus years since I was NACE president, there has been remarkable growth by NACEā€”from a primarily pipeline, coatings, and CP association in the United States and Canada to a truly international association dealing with corrosion mitigation in a broad range of industries and membership around the world. There has been increased emphasis on professional development. Education, training, and certifica- tion programs have expanded to cover entry level through subject matter expert recognition in specific technologies. Best industry practices have been documented and disseminated through NACE standards and recommended practices, which are now applied throughout the world. n Joe H. Payer, FNACE, is Chief Scientist Emeritus of The Corrosion Center (NCERCAMP) and former research professor of corrosion and reliability engineering at The University of Akron (UA) (Akron, Ohio, USA). He is an internationally recognized expert in corrosion and ma- terials performance. He directed the University Corrosion Collaboration at UA for the U.S. Department of Defense Office of Corrosion Policy and Oversight. At Case Western Reserve University, Payer directed the U.S. Department of Energy multi-university Corrosion and Materials Performance Cooperative for improved performance assessment for long-term disposal of spent nuclear fuel. He is a Fellow and past presi- dent of NACE, a recipient of the NACE Foundation Founders Award, and a Fellow of ASM International. Three corrosion control methods in combination led to this suc- cess: design, protective coatings, and sacrificial CP. In design, tight pockets that would trap moisture, salt, and debris were eliminated. Other spaces were opened to enhance air circulation and drying. In the mid-1960s, electrophoretic deposition was developed and applied to automotive bodies. The auto body is immersed in a bath containing charged particles, an electric field is applied, and the particles are electrodeposited onto the steel surface. The coverage is much more complete than could be achieved with spray coating processes. Electrogalvanizing to deposit zinc onto sheet metal for automo- tive applications was developed in the 1970s. The zinc provides corrosion protection as a barrier and by sacrificial CP once the coating is penetrated. In the mid- to late-1980s, improve- ments of hot-dip galvanized products in metallurgy, coating quality, and surface texture led to coated products for automo- tive outer panels. Success was achieved by designs to eliminate susceptible areas, ad- vanced protective coatings, the means to apply them by elec- trodeposition, and the develop- ment of industrial processes to deposit protective zinc coatings onto steel. A second major advance has been the application of computer/digital technology in corrosion engineering and science. In the field, data is gathered, recorded, analyzed, and processed into reports

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