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Development of Ceramic Rust Converter Coating for Direct Application on Rusted Steel
Status: New
Lab/Organization
| Name & address of the Laboratory/Organization | CSIR - National Metallurgical Laboratory (NML) | |
| Website address | https://nml.res.in | |
| Affiliated to which Department/Ministry | Council of Scientific and Industrial Research (CSIR) | |
| CSR Registration Number | CSR00017422 | |
| Registration under 12A | ||
| Registration under 80G | ||
| Name of the CSR Nodal | Dr. S K Pal | |
| Contact information of CSR Nodal | 0657-2345211, skp@nml.res.in | |
| Principal Investigator | Dr. Ashok Kumar Mohanty, akm@nml.res.in | |
| Co- Principal Investigator (Co-PI) | Dr. Alok Kumar Meher , alok.kumarmeher@nml.res.in | |
Project Detail
| Objective on the basis of need | Surface preparation (rust removal) is a critical requirement prior to paint application on corroded steel structures. Practically, it is difficult to remove the rust completely on large industrial structures and it is the primary cause of premature paint failures. The objective of this project proposal is to develop a primer suitable for direct application on rusted steel. The primer will convert rust to a ceramic coating strongly adherent to the steel surface and will provide long-term corrosion protection. |
| Executive summary of the proposed project (In 250 words) | An inorganic-organic hybrid primer will be formulated in which magnesium hydrogen phosphate will be used as the inorganic component and polymeric resin will be used as the organic component. The magnesium hydrogen phosphate will react with iron oxide (rust) to form Iron Magnesium Phosphate Ceramic. The ceramic coating being inert to acids, alkali, and chlorides, will provide good corrosion protection to the steel surface. The coating will have several advantages (i) Direct application on rusted steel surface (ii) Eliminates costly and tedious surface preparation processes (iii) Prevent paint delamination and paint failures (iv) Reduce maintenance costs and increase the life of steel structures (v) Can be applied by brushing or spraying (Field applications) (vi) Water-based coating (Environment friendly) (vii) High Temperature Resistant (Up to 500-degree C) |
| Technology Readiness Level (If not a new project but an advancement of existing know how) | TRL 4 |
| Outomes or Deliverables | Ceramic rust converter primer composition (product) |
| Project aligned with which most relevant UN SDGs | Goal 9 - Industry, Innovation & Infrastructure |
| Duration (In years) | 3 years |
| Expected Impact | The ceramic rust converter coating will help industries reduce corrosion maintenance costs, prevent shutdowns, improve safety, and increase the service life of the steel structures. |
| Implementation model (self- implemented/ outsourced partnership) | The Ceramic rust converter coating technology will be transferred to the coating industry for commercialization. |
| Total Budget (Recurring +Non-Recurring Expenses) | Rs 45 lakhs (Recurring Rs. 30 lakhs, Non-recurring Rs 15 lakhs) |
