Innovative coatings that protect metals from rust

In many applications, the physical integrity of a metal coating is as important as its chemical shielding properties. Choosing the best metal coating for a specific purpose requires assessing all environmental impacts, including thermal and mechanical conditions. The coating is exposed to three main types: atmospheric, immersion and underground exposure. The main difference between atmospheric exposure, immersion and underground exposure is weather resistance.
exposed to the atmosphere must endure a variety of conditions, including heating and cooling, oxidation, wetting and drying. Coatings under immersion conditions are mainly affected by aqueous solutions, from pure water to high concentrations of various chemical solutions. Coatings used in underground uses must be resistant to groundwater and soil influences, so they are usually thicker than coatings under atmospheric or immersion conditions.
general, the corrosive environment contains a variety of active substances and the coating must be resistant to penetration caused by various oxidants, solvents or a combination of both. Therefore, the best barrier is against "wide range" corrosion.
anti-corrosion coatings market, like many other mature markets, is influenced by the old view of long experience. Most "old protection" engineers insist that corrosion-resistant coatings must be zinc-rich, which is effective. In fact, zinc has been the gold standard for corrosion prevention in ships, bridges, rigs, aircraft towers and many other structural corrosion prevention for marine, industrial and agricultural purposes for decades.
is easy and cheap to produce, but vulnerable to wear and chemical erosion. Although zinc can be used as a good cathode protector, zinc oxide is permeable and can be lost from the metals it wants to protect. In recent years, studies have shown serious environmental risks associated with zinc, so the demand for alternatives is growing. This has led to the emergence of multi-layer epoxy coatings and conventional polyurethane coatings filled with zinc to mitigate and control corrosion. However, the market acceptance lags behind. The hassle associated with labor-thrombing surface treatment and the time required to apply multiple catalytic layers has created resistance. In addition, companies concerned about environmental impacts may hesitate because many of these coating alternatives also contain zinc and other ingredients that are harmful to humans.
Rust Bullet has created a new solution to deal with all causes of corrosion and prevent further damage. Based on new chemicals, the new coating uses wet-cured polyurethanes to penetrate the rust layer and dehydrate the rust until it reaches the metal surface below, rather than simply protecting the metal under a zinc-containing film or zinc-free resin layer. Using a sheet of metal made of alumina, a protective micro-layer of metal sheet is formed in the resin substate. When the coating is cured, these sheet metals are arranged in a directional arrangement to form a layer of armor that strengthens the coating and provides a physical shielding effect on the underlying metal.
do that?
in many ways, aluminum is better than zinc. Alumina is impermeable and denser than the membrane produced by zinc oxide. Producing aluminum requires more energy than zinc, so alumina requires more energy than zinc oxidation. Each side of the Rust Bullet-coated Type 2 aluminum strip is resistant to atmospheric corrosion and is five times more durable than a zinc-coated plate in an industrial environment. Typical uses of painted steel plates include industrial and commercial roofs, railway forks, drying furnaces, silo roofs, outdoor lighting fixtures and air-conditioned exterior enclosures.
also play an important role. Rust Bullet uses an aromatic polyurethane, but has a fatty properties. The difference between fat and aromatic coatings is that the types of polyols and isocyanates used in formulations are different, so their stability under atmospheric conditions is significantly different.
adipose coatings are a priority for outdoor protection because they are very stable when exposed to UV rays, weathering and hydrolysed conditions. The raw materials used to make the adipose family system are generally more expensive and have a higher viscosity than their aromatic family.
aromatic coating is more heat- and chemical-resistant than adipose coatings. Aromatic coatings do not withstand atmospheric exposure well because ultraviolet light can cause yellowing and powdering.
due to the crosslink density (short chain and branching) of the polyurethane coating, it has a high degree of chemical and wet resistance, as well as excellent adhesion. These properties position polyurethane coatings as the best choice for protecting metals from corrosion. Because elastomer coatings do not perform well in these areas, they are better at abrasion resistance, impact resistance, and protection of substrates with more telescopic motion than metals such as concrete. Rust Bullet coatings show excellent flexibility, impact resistance and wear resistance (Figure 1).
Rust Bullet is not a paint in the ordinary sense. It eliminates the need to treat the substrate, except to remove large flaky rust by gently scraping or brushing. When applied, the coating does not immediately form a coating film, but penetrates the porous rust layer to reach the metal below. It dehydrates or drys the corrosive layer through chemical activity, allowing the resin to cure into a tough coating with amazing adhesion.
corrosive particles in the resin substation become a permanent part of the coating. The back coating fills any pinholes in the first layer, creating an indestructible coating. Special aluminum layers form a new surface that protects the substrate from corrosion and is also used as a sacrificial anode. Polyurethane parts provide a moisture barrier. When cured, polyurethane captures the dehydrated rust layer, making it part of the resin substrate - permanently removing the rust. By combining all the components, Rust Bullet becomes a corrosion-free, flame retardant, chemically resistant, UV-resistant armor-like coating.
construction process is
Rust Bullet is a single-component process that accepts any subsequent coating within 2 to 4 hours. Although Rust Bullet does not require catalyst curing, curing can be accelerated by up to 80% by using rust Bullet Rapid Fire accelerators. If the desired color rather than metallic gray, the paint can be constructed within 24 to 48 hours of the final coating construction. The coating continues to cure for about 5 to 7 days. Epoxy coatings typically take 7-10 days to fully cure and volatileize the solvent, some even requiring mandatory curing.
the heating properties of the reaction during urethane curing, the coating can cure at almost any ambient temperature, even during cold seasons. Epoxy coatings require a curing temperature above 50 degrees F.
if applied incorrectly or if there is a problem with the surface treatment, the Rust Bullet coating has the unique function of "self-checking" almost immediately when it fails. As a result, polyurethane coatings can be inspected immediately after construction, and any defects will be visible and can be quickly remedied. This is not the case with epoxy coatings, which require extended curing times and multi-step processes to remedy them. The remediation work after the destruction of epoxy coating is labor-intensive and requires extensive repair outside the crack. Rust Bullet coatings have few cracks, and when they occur, they are easy to repair, as long as they are simply scraped and coated with additional products.
precise mixing ratio is required for the construction of multi-component epoxy coatings to avoid coating defects and damage. The use of Rust Bullet coatings does not have this problem, as it is a single component, one step to complete the multi-coat process.
Rust Bullet coating applied to military vehicles
If the desire is color rather than metallic gray, the paint can be constructed within 24 to 48 hours of the final Rust Bullet coating construction
there is significant corrosion at the bottom of the Mustang car
The coating does not require the substrate to be treated, except for the removal of large flaky rust by gently scraping or brushing.
In addition to corrosion protection operations, the coating has many advantages:

is free of lead, zinc, chromate or heavy metals;
. Fire spread index is 0, smoke formation index is 0.5;
. approved by the U.S. Food and Drug Administration for use in primary and secondary drinking water storage or handling equipment;
. Encapsulated molds to prevent further growth of microorganisms;
. UV-resistant, stone-resistant, scratch-resistant, and chemical-resistant media;
. Can be constructed with a single multi-process coating.
conclusion is
Rust Bullet coatings have been tested in independent laboratories and university studies and have proven to be an effective alternative to zinc-rich antiseptic products in adverse environments. It can be used in a wide range of applications, such as automotive, oil and gas, marine and construction industries. By protecting metals, it ensures longer service life of equipment and property, improves structural integrity, and helps maintain the performance value of the product.
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