"Corrosion, Impact and Abrasion Protection of Boat Hulls and Marine ...
Corrosion, Impact and Abrasion Protection of Boat Hulls and Marine Surfaces Presented at
MACC 2016
Multi Agency Craft Conference American Society of Naval Engineers The U.S. Coast Guard Yard, Baltimore, MD June 8-9, 2016 Presented by
Eduard A. Stefanescu, Ph.D. June 9, 2016; 1000 EST
Building Value through Discovery & Innovation
1
Presentation Overview 1. Introduction to Polymer Thermal Spray (PTS)
2. Motivation for boat hull protection 3. Boat-hull deposition case study 4. Applications for boat hulls 5. More DOD and commercial applications of PTS coatings and systems
Building Value through Discovery & Innovation
2
Process The deposition of semi-molten polymer particles onto a pre-heated surface where the process heat causes the particles to flow and coalesce into a complete cohesive polymer coating.
Splats – unit building blocks of thermally sprayed coatings Polymer rheology Degree of melting Impact velocity
Define the coating formation process
Building Value through Discovery & Innovation
3
PTS Technology PTS Systems currently available at Resodyn Corporation
PTS 30kW Propane fueled
PTS 5kW Electric unit
Building Value through Discovery & Innovation
PTS 2kW Electric unit
4
PTS-30 Equipment Propane/Compressed Air powered
Electronic Ignition 25 or 50 pound powder hopper 23 ft. hose length Easy set-up and operation Fast clean-up and color change Patented technology
Building Value through Discovery & Innovation
5
PTS 30 Applicator Equipment technology designed specifically for polymeric materials Cooling Air
Tempering Air Powder particles onto substrate Heat Zone
Flame locked onto burner plate “Flameless” Powder Path Only hot air contacts the polymer particles
No Burned Powder with Resodyn System
Flame Spray
Building Value through Discovery & Innovation
6
Motivation
Mechanical attachments -
Bolts corrode
-
Welds are difficult to service
-
Corrosive water can seep between attachments
Combatant Craft, Norfolk, VA
Adhesive attachments -
Adhesives can fail at bond lines
-
Limited shelf life for chemical mixes
-
Can be difficult to repair
Chemical spray on systems -
Harsh chemicals
-
Equipment is difficult to clean
-
Coatings are not easily repairable Line-X polyurethane and polyurea
Building Value through Discovery & Innovation
7
Boat-Hull Deposition Case Study Resodyn received a 26ft. long boat from the U.S. Navy for PTS coating trials.
Building Value through Discovery & Innovation
8
Boat-Hull Deposition Case Study Thermal study
Pictures and schematics showing the positioning of thermocouples (inside the hull) relative to the area selected for PTS deposition on the outside of the hull (starboard).
Sanding (left), priming (center) and PTS deposition (right) on the delimited starboard section of the GFE hull.
Building Value through Discovery & Innovation
9
Boat-Hull Deposition Case Study Thermal study
Finished PTS-deposited section; the thickness of the material is highlighted at the right.
Time-temperature plot for the data generated by the TCs during PTS deposition.
Thermal sensitization plot for various aluminum alloys. It would take about 5.5days at 150oC to sensitize Al5086.
Building Value through Discovery & Innovation
10
Boat-Hull Deposition Case Study Preparing the hull for PTS deposition Sanded hull – port side.
Technician sanding away the paint.
Technician priming the hull. Building Value through Discovery & Innovation
11
Boat-Hull Deposition Case Study PTS deposition
Two PTS applicators were employed for the deposition of the hull coating. An IR (FLIR) camera was used to monitor the temperature.
Building Value through Discovery & Innovation
12
Boat-Hull Deposition Case Study Monitoring the temperature
Thermal images taken during preheat of the GFE boat hull. The temperature recorded in the spot indicated by the crosshairs is maintained below 140oC
IR images from the PTS deposition process; both guns are depositing material simultaneously. The spray spots (indicated by black arrows) are observed to move in relation to the stationary crosshair.
Building Value through Discovery & Innovation
13
Boat-Hull Deposition Case Study Finished coated hull
PTS Coated Starboard Side
Building Value through Discovery & Innovation
PTS Coated Port Side
14
Boat-Hull Deposition Case Study Repair of large dents
A dent was detected on the keel of the boat. An area around the dent was delimited and the paint was sanded off; next the area was primed.
The PTS coating material deposited on one half of the dent. The other half was intentionally left uncoated to highlight the size of the dent. At the deepest point in the dent the deposited PTS material reached a thickness of 1.25in.
Building Value through Discovery & Innovation
15
Boat Applications Corrosion Resistant Coatings 9,750hrs salt fog
Specimens exposed to extended salt fog are in excellent condition as no blistering or delaminating can be detected. PSX 700/Amerlock 2
Interpon 100
ResoCoat system
Salt fog chamber at Resodyn Corporation
2,500hrs salt fog on steel coupons Building Value through Discovery & Innovation
16
Boat Applications Durable Tough Coatings
1/4” thick aluminum, uncoated
DNV drop impact (760ft-lbs) 20ft. long tube guide (pipe) setup
Building Value through Discovery & Innovation
1/4” thick aluminum, PTS coated
17
Boat Applications Durable Tough Coatings
Conforms to various hull shapes
Bond coated parts
Water tight
Building Value through Discovery & Innovation
18
Other DOD Applications ResoF010 coating
Thermal Insulating Coating ResoCoatTM F010
Evolution of back-face temperature
Building Value through Discovery & Innovation
19
Other DOD Applications Abrasion resistant coatings for LC-130 skis
Coating of an LC-130 ski
Building Value through Discovery & Innovation
20
Other DOD Applications Corrosion and impact resistant coatings for SPS-48 radar arrays
Resodyn developed a coating and applied it over three SPS-48 antenna slats that are currently undergoing testing at U.S. Navy Crane.
Building Value through Discovery & Innovation
21
Other DOD Applications Spraying in confined spaces using external nozzles
Nozzle configurations
Coated nut narrow space
Pipe section being PTS coated at a wall clearance of 2cm
inside Finished pipe specimen that was coated at a wall clearance of 2cm Building Value through Discovery & Innovation
22
Other DOD Applications Resodyn is designing corrosion resistant coatings for louvers and watertight doors in a project with the NRL
Pictures and schematics of louvers of different sizes and configurations
Various watertight doors Building Value through Discovery & Innovation
23
Potential DOD Applications
Tie-downs coated at Resodyn Corporation
USS Bataan Visit, Fall 2013
The bow-ramp of LCUs could benefit from durable corrosion resistant coatings.
Building Value through Discovery & Innovation
24
Concluding Remarks
Resodyn is a total solution provider, covering the equipment and coating needs for field applications
Resodyn can provide coating solutions for a variety of cutting-edge applications
Resodyn works closely with the customer to understand the problem and provide one or several tailored solutions
Building Value through Discovery & Innovation
25
Thank You !!! Please visit us www.resodyncoatings.com www.resodynmixers.com Building Value through Discovery & Innovation
A Veteran Owned Small Business 26
MACC 2016
Multi Agency Craft Conference American Society of Naval Engineers The U.S. Coast Guard Yard, Baltimore, MD June 8-9, 2016 Presented by
Eduard A. Stefanescu, Ph.D. June 9, 2016; 1000 EST
Building Value through Discovery & Innovation
1
Presentation Overview 1. Introduction to Polymer Thermal Spray (PTS)
2. Motivation for boat hull protection 3. Boat-hull deposition case study 4. Applications for boat hulls 5. More DOD and commercial applications of PTS coatings and systems
Building Value through Discovery & Innovation
2
Process The deposition of semi-molten polymer particles onto a pre-heated surface where the process heat causes the particles to flow and coalesce into a complete cohesive polymer coating.
Splats – unit building blocks of thermally sprayed coatings Polymer rheology Degree of melting Impact velocity
Define the coating formation process
Building Value through Discovery & Innovation
3
PTS Technology PTS Systems currently available at Resodyn Corporation
PTS 30kW Propane fueled
PTS 5kW Electric unit
Building Value through Discovery & Innovation
PTS 2kW Electric unit
4
PTS-30 Equipment Propane/Compressed Air powered
Electronic Ignition 25 or 50 pound powder hopper 23 ft. hose length Easy set-up and operation Fast clean-up and color change Patented technology
Building Value through Discovery & Innovation
5
PTS 30 Applicator Equipment technology designed specifically for polymeric materials Cooling Air
Tempering Air Powder particles onto substrate Heat Zone
Flame locked onto burner plate “Flameless” Powder Path Only hot air contacts the polymer particles
No Burned Powder with Resodyn System
Flame Spray
Building Value through Discovery & Innovation
6
Motivation
Mechanical attachments -
Bolts corrode
-
Welds are difficult to service
-
Corrosive water can seep between attachments
Combatant Craft, Norfolk, VA
Adhesive attachments -
Adhesives can fail at bond lines
-
Limited shelf life for chemical mixes
-
Can be difficult to repair
Chemical spray on systems -
Harsh chemicals
-
Equipment is difficult to clean
-
Coatings are not easily repairable Line-X polyurethane and polyurea
Building Value through Discovery & Innovation
7
Boat-Hull Deposition Case Study Resodyn received a 26ft. long boat from the U.S. Navy for PTS coating trials.
Building Value through Discovery & Innovation
8
Boat-Hull Deposition Case Study Thermal study
Pictures and schematics showing the positioning of thermocouples (inside the hull) relative to the area selected for PTS deposition on the outside of the hull (starboard).
Sanding (left), priming (center) and PTS deposition (right) on the delimited starboard section of the GFE hull.
Building Value through Discovery & Innovation
9
Boat-Hull Deposition Case Study Thermal study
Finished PTS-deposited section; the thickness of the material is highlighted at the right.
Time-temperature plot for the data generated by the TCs during PTS deposition.
Thermal sensitization plot for various aluminum alloys. It would take about 5.5days at 150oC to sensitize Al5086.
Building Value through Discovery & Innovation
10
Boat-Hull Deposition Case Study Preparing the hull for PTS deposition Sanded hull – port side.
Technician sanding away the paint.
Technician priming the hull. Building Value through Discovery & Innovation
11
Boat-Hull Deposition Case Study PTS deposition
Two PTS applicators were employed for the deposition of the hull coating. An IR (FLIR) camera was used to monitor the temperature.
Building Value through Discovery & Innovation
12
Boat-Hull Deposition Case Study Monitoring the temperature
Thermal images taken during preheat of the GFE boat hull. The temperature recorded in the spot indicated by the crosshairs is maintained below 140oC
IR images from the PTS deposition process; both guns are depositing material simultaneously. The spray spots (indicated by black arrows) are observed to move in relation to the stationary crosshair.
Building Value through Discovery & Innovation
13
Boat-Hull Deposition Case Study Finished coated hull
PTS Coated Starboard Side
Building Value through Discovery & Innovation
PTS Coated Port Side
14
Boat-Hull Deposition Case Study Repair of large dents
A dent was detected on the keel of the boat. An area around the dent was delimited and the paint was sanded off; next the area was primed.
The PTS coating material deposited on one half of the dent. The other half was intentionally left uncoated to highlight the size of the dent. At the deepest point in the dent the deposited PTS material reached a thickness of 1.25in.
Building Value through Discovery & Innovation
15
Boat Applications Corrosion Resistant Coatings 9,750hrs salt fog
Specimens exposed to extended salt fog are in excellent condition as no blistering or delaminating can be detected. PSX 700/Amerlock 2
Interpon 100
ResoCoat system
Salt fog chamber at Resodyn Corporation
2,500hrs salt fog on steel coupons Building Value through Discovery & Innovation
16
Boat Applications Durable Tough Coatings
1/4” thick aluminum, uncoated
DNV drop impact (760ft-lbs) 20ft. long tube guide (pipe) setup
Building Value through Discovery & Innovation
1/4” thick aluminum, PTS coated
17
Boat Applications Durable Tough Coatings
Conforms to various hull shapes
Bond coated parts
Water tight
Building Value through Discovery & Innovation
18
Other DOD Applications ResoF010 coating
Thermal Insulating Coating ResoCoatTM F010
Evolution of back-face temperature
Building Value through Discovery & Innovation
19
Other DOD Applications Abrasion resistant coatings for LC-130 skis
Coating of an LC-130 ski
Building Value through Discovery & Innovation
20
Other DOD Applications Corrosion and impact resistant coatings for SPS-48 radar arrays
Resodyn developed a coating and applied it over three SPS-48 antenna slats that are currently undergoing testing at U.S. Navy Crane.
Building Value through Discovery & Innovation
21
Other DOD Applications Spraying in confined spaces using external nozzles
Nozzle configurations
Coated nut narrow space
Pipe section being PTS coated at a wall clearance of 2cm
inside Finished pipe specimen that was coated at a wall clearance of 2cm Building Value through Discovery & Innovation
22
Other DOD Applications Resodyn is designing corrosion resistant coatings for louvers and watertight doors in a project with the NRL
Pictures and schematics of louvers of different sizes and configurations
Various watertight doors Building Value through Discovery & Innovation
23
Potential DOD Applications
Tie-downs coated at Resodyn Corporation
USS Bataan Visit, Fall 2013
The bow-ramp of LCUs could benefit from durable corrosion resistant coatings.
Building Value through Discovery & Innovation
24
Concluding Remarks
Resodyn is a total solution provider, covering the equipment and coating needs for field applications
Resodyn can provide coating solutions for a variety of cutting-edge applications
Resodyn works closely with the customer to understand the problem and provide one or several tailored solutions
Building Value through Discovery & Innovation
25
Thank You !!! Please visit us www.resodyncoatings.com www.resodynmixers.com Building Value through Discovery & Innovation
A Veteran Owned Small Business 26
