Nanotech in the Metal Processing Industry: Maximising Efficiency and Profitability

📌   By Lotus Nano

Executive Summary

Introduction

The metal processing industry plays a crucial role in the global economy, producing a wide array of metal products for various applications. One of the significant challenges faced by this industry is corrosion, which can lead to material degradation, shortened product lifespan, and increased maintenance costs.

Corrosion issues often emerge in intricate, multi-location production processes that involve lengthy storage periods and transportation between factories or on the shelves of distributors.

Nano-anticorrosion coatings present a potential solution to these challenges by offering quick temporary protection against corrosion throughout critical production steps.

In this article, we will address corrosion concerns in the metal processing industry's supply chain, review existing corrosion protection methods, and investigate the advantages of nano-anticorrosion coatings.

Storage & Shipping Corrosion Issues in the Metal Processing Industry

Corrosion can occur at various stages of the metal processing supply chain, from the initial processing of raw materials to the transportation and storage of finished products. Factors such as moisture, oxygen, and corrosive substances can accelerate the corrosion process, leading to reduced product quality, increased production costs, and potential safety hazards.

Long storage periods and transportation between factories and to the customer can further exacerbate corrosion issues. During these periods, metal products may be exposed to fluctuating temperatures, humidity, and other environmental factors that can promote corrosion. Additionally, the movement of products between different locations can result in physical damage, such as scratches or abrasions, which can compromise the integrity of existing corrosion protection measures.

Common Corrosion Protection Practices in the Metal Processing Industry

To mitigate corrosion risks during the supply chain process, companies in the metal processing industry employ various corrosion protection methods. Some common practices include:

Methods for Preventing Corrosion in Metal Products

• Protective Packaging: Metal products can be packaged in moisture-resistant materials, such as plastic films or barrier coatings. This method is generally effective at minimising exposure to environmental factors that can promote corrosion but has significant environmental impacts due to the production and disposal of packaging materials. Most Protective Packaging are made of non-renewable materials which produce considerable emissions of greenhouse gases during production and massive often non-recyclable waste.
• Vapour Corrosion Inhibitors (VCIs): VCIs are chemicals that release a protective vapour that forms a thin, invisible layer on the metal surface, inhibiting corrosion. This method is generally effective at providing temporary corrosion protection but has significant environmental impacts due to the production, use, and disposal of chemicals. VCI’s are known to release of harmful chemicals into the environment and the potential for accidental exposure.
• Traditional Anticorrosion Coatings: Traditional anticorrosion coatings, such as paints or galvanic coatings, are also used to protect metal products from corrosion. These coatings provide a physical barrier against corrosive substances. However, these coatings can be time-consuming to apply and may not be suitable for products that do not require permanent corrosion resistance. In addition, they can release harmful chemicals into the environment during the manufacturing process and disposal.
• Mineral and Synthetic Oils: To bridge potential corrosion gaps temporarily between process steps, certain oils are used to prevent corrosion. These oils, also known as rust preventatives or corrosion inhibitors, form a protective film on the metal surface, preventing oxidation and corrosion. Examples of these oils include mineral oil, naphthenic oil, and synthetic oil. These oils can be messy and difficult to remove, and they may not provide long-term protection. In addition, they can be harmful to the environment and health at all stages of their life-cycle.
• Cathodic Protection: Cathodic protection is a method that involves using a sacrificial metal to protect another metal from corrosion. This method is generally effective at providing long-term corrosion protection but has significant environmental impacts due to the production and disposal of sacrificial metals. Drawbacks include the use of non-renewable resources and the potential for sacrificial metals to corrode quickly, requiring frequent replacement.

There are several methods available for preventing corrosion in metal products, each with its own advantages and drawbacks. It's important to consider the environmental impact of these methods and choose the most sustainable option for your specific application.

Nanotechnology: A viable Anti Rust / Corrosion Option

Nano anticorrosion coatings have gained significant interest from the manufacturing industry in recent years due to their ability to provide excellent protection against corrosion while maintaining an invisible film thickness and low weight gain. This counts especially for corrosion issues that may occur during the pr

These coatings can greatly extend the life span of metal surfaces by providing superior barrier properties against aggressive media such as salt sprays, acids, alkalis, high temperatures, moisture, and other environmental factors that cause corrosion.

Nano-anticorrosion coatings are set to become a go-to solution to bridge potential corrosion gaps temporarily between process steps. These coatings are composed of nanoparticles that form a thin, protective film on the metal surface, preventing corrosion effectively.

Unlike traditional anticorrosion coatings, nano-anticorrosion coatings are applied in a single layer, saving time and nearly eliminating waste.

Nanomaterials can also be customised to provide different levels of corrosion resistance, depending on the specific application. Corrosion Resistance Levels can be arranged to last from between several months up to 10 years.

High Durability, Unique Properties, Ultra Thin

Industrial-grade nano-anticorrosion materials used for substrate coatings are generally known for their superior durability compared to traditional coatings. This is because they are designed to provide a highly protective layer that is resistant to wear and tear, exposure to chemicals, and extreme environmental conditions.

The unique properties of nano-anticorrosion coatings, such as their high flexibility, enhanced adhesion, and resistance to UV radiation, make them highly effective at preventing corrosion and other forms of material degradation.

In addition, nano-anticorrosion coatings are often extremely thin, with thicknesses ranging from a few nanometers to a few micrometers. This makes them highly effective at protecting materials without adding significant weight or thickness to a surface.

Advantages of Nano-Anticorrosion Coatings

1. Enhanced corrosion resistance: Nano-anticorrosion coatings provide superior short, medium or long-term protection against rust and corrosion, especially in harsh environments.
2. Increased durability: These coatings are resistant to wear and tear, and can withstand exposure to chemicals and extreme temperatures.
3. Reduced maintenance costs: Nano-anticorrosion coatings can significantly reduce maintenance costs over the long term, as they require less frequent repairs or replacements.
4. Improved aesthetics: These coatings can be customised to match the colour and texture of the surface they are applied to, enhancing the appearance of the material.
5. Environmentally friendlier: The majority of industrial grade nano-anticorrosion coatings contain fewer harmful chemicals than traditional coatings, making them more environmentally friendly and sustainable.
6. Simple application: Nano-anticorrosion coatings can be easily applied to metal substrates, such as spray coating, dip coating, or brush coating, and can be integrated into the manufacturing process at various stages, such as after machining, prior to assembly, or during final finishing processes.
7. Industry Agnostic: Nano-anticorrosion coatings can be used in various industries, including automotive, aerospace, marine, and oil and gas, to protect metal components from corrosion and wear, making them versatile and applicable to a wide range of industries.
8. Thin film coating: Nano-anticorrosion coatings are thin film coatings, which means they add minimal weight or thickness to the material they are applied to.
9. High flexibility: These coatings offer high flexibility, which makes them suitable for use on materials that undergo frequent changes in shape or size.
10. Enhanced adhesion: Nano-anticorrosion coatings adhere strongly to the surface they are applied to, providing a long-lasting protective layer.
11. Better cost-effectiveness: Over the long term, nano-anticorrosion coatings can be more cost-effective than traditional coatings, as they offer superior protection and require less frequent maintenance.