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Corrosion protection for unpainted metal in highly corrosive environments
Tests demonstrate the amazing properties of SuperCORR A corrosion protection spray to protect unpainted metal surfaces from corrosion
These are photographs of 3 unpainted copper components that were exposed for a month next to the “digester” at a Pulp and Paper Mill. The part marked #1 was the control and not sprayed with SuperCORR A corrosion protection spray. Half of part marked #2 was sprayed with SuperCORR A and half left uncoated. Component #3 was completely treated with SuperCORR A. The main atmospheric corrosion was from hydrogen sulphide (H2S) gas, produced during the cellulose digestion process, which combines with the atmospheric humidity to form a mild acid. Any unpainted or untreated metal surface, copper, brass, mild steel or alloys of zinc and manganese or magnesium will be corroded by this acid when it condenses on the metal surfaces.
This is especially important in electrical motors and power control systems where these metals are used as conductors or switch contacts on printed circuit tracks and all types of connectors which although sealed in control panels will be exposed whenever the boxes are opened or contactors operated and connectors plugged and unplugged. In most cases it is not possible to paint these conductive surfaces or apply other forms of protection without loss of conductivity leading to arcing or supply failures.
These tests demonstrate the amazing properties of SuperCORR A to protect unpainted surfaces from acidic corrosion. As an example, copper and aluminium condensers on water coolers usually last about a month in the acidic environment of pulp production facilities because the corrosive atmosphere around the plant corrodes the metal surfaces on fins and connections.
A trial was set up by the works engineering department at the plant who sprayed a new condenser with an aerosol of SuperCORR A corrosion protection spray. This applies a very thin protective film of a proprietary formulation containing extremely long-lasting anticorrosion inhibitors, which also give superior lubrication coefficients and protect components against moisture. This unique, water displacing lubricant, with synthetic corrosion prevention compounds is tested and proven non-flammable and environmentally friendly without sulphates, chlorides, or other halogens
After a few months the treated condenser showed so little signs of corrosion that further controlled trials were set up to test for long term protection of untreated metal in this extremely corrosive environment experienced in paper and pulp mills, water processing plants and oil drilling rigs.
The improvement is clear and demonstrates the savings in costs of parts and labour for maintenance and replacement untreated metal components exposed to these corrosive conditions.
For more information please visit www.envirotech-europe.com/supercorr-a
To discuss the use of SuperCORR A to solve your problems please use the website contact form or phone us, we look forward to hearing from you.
We can provide you with a Material Safety Data Sheets, independent laboratory reports, product samples and technical assistance.
For more information or advice please telephone us on +44 (0) 20 8281 6370 or use our contact form.
All products are supplied and supported by EnviroTech Europe Ltd. Manufactured in the United Kingdom and available on short delivery times through our dedicated team of distributors worldwide.
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Cleaning solvent for vapour degreasing in the aerospace industries
ProSolv® 5408 sustainable, economical cleaning solvent for vapour degreasing in the aerospace industries
The aircraft and aerospace component manufacturing industries face many critical cleaning applications during manufacturing processes and for finishing where surfaces need to be completely degreased leaving no residues. Although aqueous cleaning would seem to be the method of choice for environmental reasons with new advancements in cleaning solvent chemistry this is often not the case. Vapour degreasing is the most effective process, economical in use with lower energy uses, one tank needing less floor space than multi tank water-based systems and safe for users.
ProSolv 5408e has been developed to be used in place of the traditional chlorinated hydrocarbon solvents, trichloroethylene and perchloroethylene and those based on n-propyl bromide (nPb) which have been phased out for use as vapour degreasing solvents in the EU. The ProSolv 5408e advanced formulation, based on sustainable solvents, has been extensively tested with oils, soils greases and other contaminants from the manufacturing process and with is high KB value all these materials are easily removed to comply with aircraft standards for cleaning and degreasing to the highest levels. No titanium surface cracking or deleterious effects on other metals or composites commonly used for aircraft and aerospace component manufacture have been identified.
The innovative ProSolv 5408e formulation produced by Envirotech Europe ticks all the boxes with the perfect profile for vapour degreasing Soft on the environment with near zero ozone depletion potential (ODP) and very low global warming potential (GWP) its lower boiling point at 48C minimises energy requirements giving reduced process times for greater throughput and comfortably handled critically cleaned parts. The incredibly low surface tension guarantees penetration into micron sized through and blind holes and between close contact surfaces.
Stable in use ProSolv 5408eis safe for users with a high 8hr occupational exposure level of 220ppm. The solvent needs no additives or stabilisers and requires no testing. Sustainable, safe and secure for future use as your forever solvent.
CRITICAL CLEANING FOR THE AIRCRAFT INDUSTRY
A few examples of the many uses are discussed below, our technical service engineers can offer information and advice on critical cleaning in the multitude of other applications experienced in the precision engineering industries.
BONDING OF HONEYCOMB SECTIONS FOR COMPOSITES
An instance of critical cleaning is removal of all contamination from aluminium honeycomb prior to epoxy resin bonding of the formed aluminium skin to produce lightweight high tensile structures for applications such as leading edges on aircraft wings and wind turbine blades. This is an extremely demanding application, as any residues will prevent the adhesion of the adhesives leading to delamination with potentially disastrous effects.
Due to the high standards of cleaning which are required this process is usually carried out by vapour/liquid degreasing with the traditional chlorinated solvents however due to the increasingly stringent controls on these materials ProSolv 5408e which is fully tested to aircraft industry standards and with its greatly improved environmental and user profile is now increasingly used as the sustainable and safer replacement.
CLEANING FOR CRACK AND FAULT TESTING OF WELDS AND CASTINGS
Another common use in the aircraft industry is in the cleaning of castings and metal fabrications before the use of NDT crack detection fluids. Removal of all surface contamination from manufacturing processes is vital to expose faults. Vapour degreasing and vapour liquid cleaning with ultrasonics is a favoured method due to the excellent solubility of oils and greases and other soils using one tank with very fast processing and parts emerging completely clean and dry. Crack and fault detection in casting and welds is also important in other industries such as railways, automotive engines, and turbines where castings or critical welded fabrications are used. This is particularly relevant as part of the maintenance procedure for refurbishment of aircraft landing gear where surfaces can be heavily contaminated by hard to remove hydraulic oils, rubber and cement dust and grease.
Because this application needs completely degreased, residue free and dry surfaces, the use of slow drying cleaners such as hydrocarbons or water-based cleaners may cause problems as the cracks need to be dry to allow penetration of the detection fluids. Vapour degreasing is the most effective cleaning system for all NDT applications as parts emerge dry from the cleaning process. ProSolv 5408e conforms to SaE-AMS2664 and E1417 99-1/7-1-1 solvent precleaning standard for Penetrant testing in aerospace applications.
CRITICAL CLEANING OF OXYGEN AND GAS SYSTEMS
Critical cleaning of oxygen lines and tanks where no organic residues can be tolerated is another ideal use for this new sustainable cleaning solution. ProSolv 5408e conforms to CGA, ELIGA and Compressed Gas Association standards for this application. We have a series of guides to using ProSolv 5408e for component cleaning to Oxygen standards and recommended cleaning methods involved, available on request.
ProSolv 5408e is produced to consistent quality standards worldwide and is available through a network of experienced and qualified suppliers.
For full product information please visit www.vapour-degreasing.com/prosolv5408e
We can provide you with a Material Safety Data Sheets, independent laboratory reports, product samples and technical assistance.
For more information or advice please telephone us on +44 (0) 20 8281 6370 or use our contact form.
All products are supplied and supported by EnviroTech Europe Ltd. Manufactured in the United Kingdom and available on short delivery times through our dedicated team of distributors worldwide.
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Corrosion protection for electrical control systems in Wastewater Treatment Plants
SuperCORR A protects electrical control systems against corrosive environments
Wastewater treatment plants are subject to corrosion and rust from a variety of causes, one of which is Hydrogen Sulphide gas, (H2S). Corrosion is an insidious and costly problem that causes just about every metal and metal alloy to fail over time. Metals in electrical and electronic control systems, components, connectors, and switches are of most concern.
Corrosion is found in almost all process industries including wastewater treatment plants, pulp and paper mills, fertilizer plants, and numerous other industries and is not going away. Establishing a ‘Preventative Maintenance Program’ that includes corrosion prevention makes it a problem that can be cost effectively dealt with.
One proven and positive way to reduce, if not prevent, corrosion altogether from causing electrical, electronic systems and component failures is by using an ultra-thin film water displacing lubricant material with corrosion inhibiting compound, SuperCORR A has all these properties.
A proprietary formulation packaged in aerosol cans it uses a non-flammable fast drying carrier solvent. The aerosol is supplied with a flexible tube applicator which allows the protective coating to be applied accurately even in difficult to get to components.
Removal of surface contamination from the metallic contact surfaces on switches and circuit breakers is essential to ensure fault free operation. The aerosol uses the unique
SuperCORR A formulation to lift and remove dust and soils from the metal contact surfaces. An inert compound that neither reduces nor increases the electrical conductivity. SuperCORR A also provides long term protection from corrosion and electrical arcing that can lead to shorts and subsequent circuit failures.
Testing SuperCORR A in corrosive environments
SuperCORR A (MIL-DTL-87177B (Revised MIL-L-87177A) Type 1 Grade B lubricant was subjected to extensive and vigorous Mixed Flowing Gas (MFG) testing at Battelle Laboratories under a U.S. Government contract.
Specifications ASTM B827 and ASTM B845 Class III MFG testing protocol were used. This included gases with high corrosion potentials including Hydrogen Sulphide (H2S), Nitrous Oxide(NO2), and Chlorine (Cl2).
ASTM B845 refers to techniques for mixed flowing gas (MFG) tests containing gases that are applied to evaluate devices containing electrical contacts such as slip rings, separable connectors, electromechanical relays or switch contacts. The MFG tests accelerate corrosive degradation processes. Connectors and contacts within closed electronic cabinets may be affected by an environment of different severity than the outside of these cabinets. ASTM B827 outlines procedures for conducting environmental tests involving exposures to controlled quantities of corrosive gas mixtures. Equipment and methods for gas, temperature, and humidity control for tests to be conducted in a reproducible manner are described.
Reproducibility is measured using control coupons whose corrosion films are evaluated by mass gain, coulometry, or by various electron and X-ray beam analysis techniques. Reproducibility can also be measured by in situ corrosion rate monitors using electrical resistance or mass/frequency change methods. Full copies of these tests can be made available on request.
Industrial applications
SuperCORR A has a proven performance record in protecting electrical components, systems, connectors and electronics. The coating will also prevent the ingress of moisture and other contaminants onto the connector surfaces. These initiate corrosions and cause intermittent component failure or a premature degradation of component performance.
The Battelle Laboratories studies provided data and related processing information validating the benefits of using SuperCORR A. to protect the electrical connectors of line replacement units (LRUs) used in military aircraft avionic applications.
The results of the laboratory and field-testing activities conducted in these studies confirm that SuperCORR A is an extremely effective coating to protect electronics, electrical components and systems including switches and connectors with no compromise of the integrity of the electrical component/system even in very corrosive environments.
As a result of testing on site at a number of private and public companies with the confirmatory work at Battelle Laboratories SuperCORR A is being used to reduce maintenance and repair costs in a range of different industrial applications – wastewater treatment plants, pulp and paper mills, automotive and heavy equipment industries and in the power production sector oil and gas and renewable energy and in both the aviation and maritime industries.
FURTHER INFORMATION
Please visit our website www.envirotech-europe.com/supercorr-a for information about other uses and applications. For more advice, please telephone us on +44 (0) 20 8281 6370 or use our website contact form.
All products are supplied and supported by EnviroTech Europe Ltd. Manufactured in the United Kingdom and available on short delivery times through our dedicated team of distributors worldwide.
We can provide you with a Material Safety Data Sheets, independent laboratory reports, product samples and technical assistance.
For more information or advice please telephone us on +44 (0) 20 8281 6370 or use our contact form.
All products are supplied and supported by EnviroTech Europe Ltd. Manufactured in the United Kingdom and available on short delivery times through our dedicated team of distributors worldwide.
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