Mitigating Pipeline Corrosion Using A Smart Thermal Spraying Coating System
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Mitigating Pipeline Corrosion Using A Smart Thermal Spraying Coating System

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      Final Report
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      Corrosion is recognized as one major reason for the failures of on-shore underground steel pipes, which results in increase in maintenance cost and system downtime. To mitigate corrosion, a common method is to combine cathodic protection and coating techniques such as polymeric and metallic coatings. Polymeric coatings dominate the coating techniques due to their good performance on separating metal from the surrounding corrosive environments. However, corrosion may still develop beneath the polymeric coatings in random locations. In these circumstances, a strong metallic coating from high corrosive resistant materials deposited by thermal spraying techniques can be considered as a potential cost-effective alternative. These coatings can separate pipes from surrounding environments and meanwhile exhibit cathodic protection properties. For off-shore pipelines, some thermal sprayed coatings have been experimentally investigated for corrosion mitigation using aluminum and zinc, which have shown excellent performance. However, thermal sprayed metallic coatings for on-shore pipelines, which was initialized by this research team, are still under development. An initial study was carried out in the current project to study the feasibility of utilizing thermal spraying as a coating method for pipeline corrosion prevention. The experimental results demonstrated very positive corrosion resistance improvements using a thermal sprayed Al-Bronze coating. Although, the cost of coating material is relatively higher in this method, the long-term application can justify this technique with cost reduction associated with maintenance. Based on the gained valuable experiences from the current project, constant needs to further promote more fundamental studies in developing an effective and low cost thermal spraying coating system are noted for practical applications of on-shore pipeline corrosion mitigation.
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