Protective coatings and methods of forming same
AssigneeSulzer Metco (US), Inc.
InventorsRonald J. Molz, James Frank Leach, Jr., Christopher Wasserman
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Abstract
Coatings on a substrate and application methods result in coatings that can withstand different types or groups of bulk cargo and operations. This novel approach includes use of a combination of layers of coating materials at certain thicknesses and applied with certain techniques. In certain embodiments, the coating system includes coatings applied to a pretreated substrate, e.g., blasted steel cargo hold plates of an oceangoing vessel. The coatings include a bond layer and a resistance layer, e.g., an anti-corrosive layer tailored to resist at least one of corrosion, erosion, impact and wear of the substrate.
Claims25
A multi-layer transportation vessel hold surface protective coating arranged in or on a transportation vessel, comprising:
- a thermal sprayed bonding layer formed on and in contact with a first face of the transportation vessel hold surface prepared in a manner to allow the bonding layer to adhere, the bonding layer having a hold surface face and a non-hold surface face;
- a resistance layer made of a material resistant to impact forces and corrosion caused by a corrosive environment in a vicinity of the transportation vessel hold surface arranged in or on the transportation vessel, the resistance layer formed on and in contact with the non-substrate face of the bonding layer, the resistance layer having a bond face and a non-bond face;
- and
- a sealant layer formed on and in contact with the non-bond face of the resistance layer.
A transportation vessel hold surface substrate arranged in or on a transportation vessel having a multi-layer protective coating resistant to impact forces and corrosion, comprising:
- a thermal sprayed bonding layer that bonds to the transportation vessel hold surface substrate, wherein the bonding layer is formed on and in contact with a first side of the transportation vessel hold surface substrate from which contamination has been removed;
- a resistance layer formed directly on and in contact with the bonding layer, wherein the resistance layer is structured to be resistant to the impact forces and corrosion caused by a corrosive environment in a vicinity of the transportation vessel hold surface substrate arranged in or on the transportation vessel;
- and
- a sealant layer formed directly on and in contact with the resistance layer for sealing pores of the resistance layer.
A method of forming a multi-layer transportation vessel hold surface protective coating in or on a transportation vessel, comprising the steps of:
- preparing a first substrate surface of the transportation vessel hold surface by removing corroded surface material from the first substrate surface and roughening the first substrate surface;
- thermal spraying a bonding layer on and in contact with the first substrate surface;
- forming a resistance layer on and in contact with the bonding layer, the resistance layer being resistant to impact forces and corrosion caused by a corrosive environment in a vicinity of the transportation vessel hold surface arranged in or one the transportation vessel and comprising at least one of an iron-based alloy and a nickel-based alloy;
- and
- forming a sealant layer on and in contact with the resistance layer, wherein the sealant layer penetrates pores of the resistance layer.
Dependencies are inferred from the claim text.