When operators see an orange shade creeping around their machines or products, they know it means one of their biggest concerns is present: rust. This chemical reaction occurs when metal reacts to the exposure of oxygen and water. It can be accelerated by factors including water, salt, humidity, and acids.
A study conducted by NACE International, now part of the Association for Materials Protection and Performance, estimates that corrosion costs the United States $276 billion dollars a year.
In addition to its unsightly appearance, this costly complication can lead to a host of other problems. These issues can weaken machines, create holes in the metal, result in inefficient machine performance, and cause full machine failure.
Rusty products headed to customers can decrease paint adhesion, lower their lifespan, impact quality, and break the trust of customers.
Luckily, there are ways to prevent rust and corrosion before they even starts. Save money, time, and energy by using products in one of the four rust prevention classifications.
Four Types of Rust Preventatives:
Most synthetic-based, also known as water-based, rust preventatives are used for indoor protection. They rely on one or more additive constituents to aid in film formation or passivation. This product class’s rust and corrosion inhibitors are designed for use on ferrous and non-ferrous metals. They offer short to long-term indoor storage protection, in-process rust prevention, and can be used in a variety of different applications including spray washing, immersion, and grinding.
Within the synthetic categorization, there are three types of water-based products: these are amine-based chemistries, nitrites, and carbonates. While they have similar properties, each possess a unique set of benefits.
The three types of amine-based chemistries include straight amines, carboxylates, and borates.
These amine-based chemistries offer good rust protection and can be diluted with water to save on cost. The resulting film is clear, dry to touch, and easy to clean off the surface. However, products with these chemistries can be prone to microbiological contamination and can form tacky residues at high concentrations.
With similar attributes to amine-based chemistries, nitrites hold a unique capability that differs them from others. The part that is being treated does not have to be completely dry for the protection to be effective. The downside to nitrite products is that they cannot be mixed with amine chemistries. This is due to the possible formation of nitrosamines.
In addition to providing superior rust protection and being dry to touch, carbonates are operator friendly, emit a low odor, have an extended tank life, and eliminate microbiological contamination. A disadvantage of this product type is that it can form white residue on parts. This residue makes it easier for water and moisture to penetrate the film.
The second type of rust preventatives are emulsion-based products. These water-soluble oils often have materials added to them to prevent rusting under short term indoor storage conditions.
The emulsifiable oil product class consists of water-soluble, emulsion-type rust preventatives which provide corrosion protection for ferrous and non-ferrous metals. It offers medium-term indoor protection that ranges from three to six months. This product class can form stable emulsions in water, even when alkaline or acidic contaminants are present.
These products can be applied through various methods including spraying, immersion, and flooding. They leave only a light, oily film on metal surfaces, are easy to clean, and provide a cost-effective solution for rust prevention in industrial settings. You must take care with emulsion-based products as they can be messy to manage and cause skin irritation.
The solvent-based product class consists of rust preventatives and corrosion inhibitors. These products provide long-term protection for ferrous and non-ferrous metals. It offers extended indoor and outdoor protection that ranges from several months to over a year.
These products are characterized by their ability to displace water and leave a thin, protective film on the metal surface. These products can be applied by various methods including spraying, dipping, and brushing. They are easily removed using conventional cleaning methods.
Solvent-based rust preventatives provide exceptional corrosion protection in challenging environments where coolants, water, alkaline cleaners, or high humidity are present. This makes them ideal for in-process or final protection applications.
However, they emit a heavy solvent odor and are high in volatile organic compounds (VOCs). Additionally, certain solvents will reject moisture from metal surfaces as they lay down the barrier film.
KEY INSIGHT: VOCs are gases released from various liquids and solids that can have short and long-term health effects, including eye, skin, or lung irritation, and environmental effects, including harm to the atmosphere.
The oil-based product class is most widely used as the basis of film formation as they create a barrier that repels moisture and corrosive elements. Additives like sulfonates and esters can be added into this product class for enhanced rust protection. It can be used in industrial applications including automotive, shipping, and manufacturing.
Oil-based rust preventatives offers superior long-term rust protection with a heavy oil film. Its high-quality formulation ensures that you will not have to dry parts before using these rust preventatives. But they could also have disadvantages. This could include heavy solvent odor, high VOCs, and a difficult handling process that can cause skin irritation.
Avoid the dread that comes with seeing rust or corrosion on your equipment parts by taking steps to protect your machinery now. By using synthetic, emulsion, solvent, or oil-based rust preventatives, you will ensure long-term performance of your operations. While each classification has different properties, all four types will work to decrease and eliminate harmful rust.
While selecting a rust preventative, it’s wise to consider all factors including your metal, storage conditions, and storage length. Your selection may differ if your process is being stored for years outdoors vs. being stored in a climate-controlled warehouse for a couple of weeks.
Looking for more information about how to prevent rust in your production? Contact DuBois’ technical experts.
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