Closed-Cell Polymer Foams for Corrosion Control in Confined Metal Spaces

• Published in: Corrosion (Houston, Tex.) Vol. 55; no. 5; pp. 530 - 539
• Main Authors: Trzaskoma-Paulette, P.P., Lambrakos, S.G., Jones, H.N.
• Format: Journal Article
• Language: English
• Published: Houston, TX NACE International 01.05.1999; NACE
• Subjects: 360105 - Metals & Alloys- Corrosion & Erosion; ALLOYS; Applied sciences; CAVITIES; Chemical analysis; COATINGS; COLLOIDS; Corrosion; Corrosion control; Corrosion environments; Corrosion prevention; CORROSION PROTECTION; DISPERSIONS; Exact sciences and technology; Foamed metals; FOAMS; HYDROGEN COMPOUNDS; IMPREGNATION; INTERFACES; IRON ALLOYS; IRON BASE ALLOYS; MATERIALS SCIENCE; Metals; Metals. Metallurgy; ORGANIC COMPOUNDS; ORGANIC POLYMERS; OXYGEN COMPOUNDS; Paraffin; Paraffins; Plastic foam; PLASTIC FOAMS; POLYMERS; Polyurethane; Polyurethane foam; SEAWATER; STEELS; Structural steels; WATER; Water analysis; Hollow shape; Automobile industry; Foam(plastics); Polymer; Filling; Structural steel; Shipbuilding; Foam flooding; Corrosion protection; Application; Sea water corrosion
• ISSN: 0010-9312; 1938-159X
• DOI: 10.5006/1.3284016

INTRODUCTIONHollow cavities are an intrinsic design feature of metallic structures. In marine environments, these cavities tend to collect salt-laden moisture that, in turn, promotes accelerated corrosion of the internal surfaces. Corrosion damage inside structural voids results in premature component failures, significantly shortened lifetimes, and high repair or replacement costs. Commonly, internal cavity corrosion is observed on automobile and truck bodies. For example, extensive corrosion-related deterioration has been observed in the hollow steel frame rails of military ground vehicles.1-2 This problem causes some vehicles to be removed from service in less than one quarter of their design lifetimes and results in repair costs that average ~ $6,000/vehicle. At one military facility alone, more than 100 vehicles were anticipated to be in need of rail replacement during 1997.3 The use of corrosion control treatments such as paints, oils, or inhibiting coatings for hollow components often is impractical because there is inadequate accessibility for application. Inaccessibility also reduces the effectiveness of cleaning and surface preparations necessary for corrosion product removal prior to the application of coatings. Coating prior to assembly is not feasible because of the deleterious effects of welding on the coatings.4 Drainage is only effective if all moisture can be eliminated or the interior surfaces have a good corrosion preventive coating.3 The present investigation explored the use of rigid, closed-cell polymer foams to infiltrate and occupy empty metallic spaces to prevent entry and contact of corrosion active species, such as seawater and oxygen, with interior surfaces. The appeal of this method rests in the ability to fill cavities remotely