February_AMP

ne of the many

threats the U.S. mil-

itary must con-

stantly defend against is

particularly insidious and ad-

vances imperceptibly as it

silently erodes the integrity

of military, municipal, and

global infrastructures—cor-

rosion. It is an ever present

and relentless enemy that varies in both intensity and hos-

tility, and combating it requires considerable time and ex-

pense.

Based on extensive research, the U.S. Army and Army

Corps of Engineers recently coordinated a new front in the

war against corrosion by employing potent emerging tech-

nologies that promise a more effective, yet lower-cost de-

fense than current protective methods achieve. Considered

the military’s center of expertise for corrosion prevention

based on its responsibility for structures such as locks,

dams, and bridges, the Army Corps of Engineers is

presently conducting these procedures under the most rig-

orous conditions because its interests include a vast infra-

structure constructed in some of the world’s most extreme

environments.

Challenges

In the past, anti-corrosive approaches used almost ex-

clusively by the military to protect steel structures con-

sisted of a three-part process that was proven to be

effective, but costly. This technology, largely unchanged

for three decades, begins with a base coat heavily loaded

with zinc as the primary defense. However, the density of

the zinc results in an inherently unstable and brittle base

coat. The second, intermediate coat provides a barrier to

moisture and oxygen, reducing the brittleness issue. The

third and final coat imparts color and surface finish.

Surface preparation and material application represent

the major expenses related to painting large structures. The

traditional, three-coat system is both cumbersome and

costly. Another drawback is the high lead content, which

can create environmental issues during application and

often requires extensive precautions when being removed

or in preparation for repainting. While not common, issues

with adhesion failure related to high zinc levels also can

occur. Other problems can arise when inadequate or incor-

rect surface preparations cause serious and sometimes cat-

astrophic peeling after a relatively short time due to poor

bonding between the surface and zinc-rich base layer.

Solutions

As a result of these challenges, the

Army and the Army Corps worked

with Tesla NanoCoatings to develop

an enhanced defense against corro-

sion. Over the past eight years, this

included the testing and documenta-

tion of a new carbon nanocoating

that provides superior corrosion pro-

tection through a two-coat system

that is applied like paint, acts like

plating, and relies on a much lower

zinc content to eliminate an interme-

diate coat.

Lost conductivity resulting from

reduced zinc content is offset by

highly conductive carbon nanotubes

(CNTs) that self-assemble into rope

structures. In addition to enhanced

conductivity, nanotechnology also

imparts 5-10 × the adhesion strength

compared to traditional methods. This

builds stability into an inherently un-

stable primer, making adhesion fail-

ure far less likely.

CNTs help create a base layer that

is not only highly conductive, but also

abrasion-resistant, tough, and flexi-

ble. In addition, it is cost effective as it eliminates an entire

application step, features a lifecycle that can last twice as

long as traditional coating systems, and requires no special

training to apply. It is also compatible with conventional

paint application equipment and is formulated with a lower

lead content to reduce environmental issues in application

and removal.

Results and conclusions

Based on the results of initial standardized testing, the

Army Corps of Engineers deployed the Teslan coating

from Tesla NanoCoatings in a number of field demonstra-

tion projects such as fuel tanks, pipelines, water towers,

and bridges at military installations throughout North Car-

olina and Washington. Due to the significance of Tesla’s

technology, the U.S. Army identified its corrosion technol-

ogy as a “technical solution.”

While the Army Corps of Engineers continues to moni-

tor the performance of its present demonstration projects,

Teslan has begun test applications in various other indus-

tries including petrochemical facilities and oil and gas well

sites where corrosion is a common problem.

iTSSe

For more information:

Todd Hawkins is president of Tesla

NanoCoatings Inc., 1311 20th St SW, Massillon, OH 44647,

330/837-1840,

www.teslanano.com

ADVANCED MATERIALS & PROCESSES •

FEBRUARY 2014

Nanocoating Provides

Superior Corrosion Protection

Via Two-Coat System

Todd Hawkins

Tesla NanoCoatings Inc.

Massillon, Ohio

Fig. 2 —

Standard 3-coat

system, 12.9 total mils.

Fig. 1 —

Teslan 2-coat

system, 8.5 total mils.