International Symposium on International Symposium on Shipbuilding - - PowerPoint PPT Presentation

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• Fabrication and Coatings

Fabrication and Coatings – – 6 6-

• 7 September, 2007

7 September, 2007 Osaka University, Japan Osaka University, Japan Organized by Organized by

The Japan Society of Naval Architects and Ocean Engineers The Japan Society of Naval Architects and Ocean Engineers (JASNAOE) (JASNAOE) and and The Royal Institution of Naval Architects (RINA) The Royal Institution of Naval Architects (RINA)

International Symposium on International Symposium on Shipbuilding Technology Shipbuilding Technology (ISST 2007) (ISST 2007)

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The Third Generation Shop Primer The Third Generation Shop Primer and and Japanese Shipbuilding Japanese Shipbuilding Construction Process Construction Process

Yasuyuki Yasuyuki SEKI, Katsumi KONDOU, Osamu HARADA SEKI, Katsumi KONDOU, Osamu HARADA

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Shop coat system Shop coat system

[Painting process]

・ Steel plate having mill scale ↓ ・ Surface preparation / Blast cleaning (Shot blast) ↓ ・ Automatic spray (painting of shop primer) ↓ ・ Processing (cutting, welding), Construction ↓ ・ Secondary surface preparation ↓ ・ Painting of Anti-corrosive paints ↓ ・ Painting of top-coat paints

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History of Shop Primer History of Shop Primer

In 1950 In 1950’ ’s Etching primer s Etching primer In 1960 In 1960’ ’s Epoxy zinc s Epoxy zinc-

• rich primer

rich primer In 1970 In 1970’ ’s Inorganic high s Inorganic high-

• zinc shop primer (1

zinc shop primer (1st

st)

) Inorganic low Inorganic low-

• zinc shop primer (2

zinc shop primer (2nd

nd)

) In 2000 In 2000’ ’s Inorganic low s Inorganic low-

• zinc shop primer (3

zinc shop primer (3rd

rd)

)

For keep intact shop primer

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Required property as shop primer Required property as shop primer

Anti-corrosive property Zinc protection from heat oxidation Control of zinc ionization Very low level of

• rganic compounds

Selected pigments without crystalline water Control of gaseous zinc activity Ensured steel protection from rusting Ensured white-rust prevention Very low level

• f gas

generation Reduction of secondary surface preparation Faster welding speed

Higher productivity

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Composition models Composition models

*1: Silica powder (ignition loss: 2.07% 300oC, 3.87% 500oC, 4.75% 800oC) *2: Talc (ignition loss: 1.27% 300oC, 1.60% 500oC, 8.97% 800oC) *3: Fluorite powder (ignition loss: 0.10% 300oC, 1.58% 500oC, 1.66% 800oC) *4: Weldabilitive pigment (ignition loss: 0.88% 300oC, 1.02% 500oC, 1.13% 800oC)

1st 2nd 3rd

Zinc powder

(solids cont.)

Silica powder (*1)

Talc (*2)

Fluorite powder (*3)

Wax Wax Bentonite Bentonite

• Organic resin
• Added
• Zinc protector
• Added

Additives generation Base hydrolysis of ethyl silicate Paste 65%wt 55%wt 50%wt Pigments

Silica powder (*1)

(*4)

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White rust generation mechanism White rust generation mechanism

Zn Zn

hydrolysis

Zn

corrosion factor

Zn

White rust

Zn２+ Zn２+ Zn２+ Zn２+ Zn２+ Zn

２+

Excessive corrosion of zinc Contraction of silicate Formation of silicate film

+ + ２ ２ + + ２

The 3rd Generation The 1st and 2nd Generation

Zinc protection

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The surface of zinc after heating The surface of zinc after heating

(SEM Photograph, (SEM Photograph, × ×2,000) 2,000)

1st and 2nd generation 3rd generation Zinc oxide

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The actual condition/Heat resistance The actual condition/Heat resistance

1st and 2nd generation 3rd generation

Rust No rust

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The actual condition/Exposure The actual condition/Exposure

Zinc activity is controlled and kept intact parts to exposure and heating！ Zinc activity isn’t controlled and rust/white-rust generate

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Three type of

• utdoor exposure

・ Outdoor exposure (45o) ・ Horizontal outdoor exposure ・ Water splashed with horizontal

• utdoor exposure

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Anti corrosive and Anti white Anti corrosive and Anti white-

• rust

rust property (1 property (1st

st generation)

generation)

6 7 8 9 10 7days 15days 30days 60days 90days (days) (evaluation) 23℃ 300℃ 500℃ 800℃ 4 5 6 7 8 9 10 7days 15days 30days 60days 90days (days) (evaluation) 23℃ 300℃ 500℃ 800℃

Anti corrosive property Anti white-rust property

• Anti corrosive property is based on ASTM D610-01
• Anti white-rust grade is

10:<1%, 9:1-5%, 8:5-10%7:10-15%, 6:15-20%, 5:20-30%

Average of three type of outdoor exposure tests after heating at each temperature.

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Anti corrosive and Anti white Anti corrosive and Anti white-

• rust

rust property (2 property (2nd

nd generation)

generation)

4 5 6 7 8 9 10 7days 15days 30days 60days 90days (days) (evaluation) 23℃ 300℃ 500℃ 800℃ 6 7 8 9 10 7days 15days 30days 60days 90days (days) (evaluation) 23℃ 300℃ 500℃ 800℃

Anti corrosive property Anti white-rust property

Average of three type of outdoor exposure tests after heating at each temperature.

• Anti corrosive property is based on ASTM D610-01
• Anti white-rust grade is

10:<1%, 9:1-5%, 8:5-10%7:10-15%, 6:15-20%, 5:20-30%

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Anti corrosive and Anti white Anti corrosive and Anti white-

• rust

rust property (3 property (3rd

rd generation)

generation)

6 7 8 9 10 7days 15days 30days 60days 90days (days) (evaluation) 23℃ 300℃ 500℃ 800℃

Average of three type of outdoor exposure tests after heating at each temperature.

• Anti corrosive property is based on ASTM D610-01
• Anti white-rust grade is

10:<1%, 9:1-5%, 8:5-10%7:10-15%, 6:15-20%, 5:20-30%

Anti corrosive property

4 5 6 7 8 9 10 7days 15days 30days 60days 90days (days) (evaluation) 23℃ 300℃ 500℃ 800℃

Anti white-rust property

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Protective potential Protective potential

1st 2nd 3rd (at 23oC)

For keep balance between anti rust property and anti white-rust property

6 0 0 6 5 0 7 0 0 7 5 0 8 0 0 8 5 0 9 0 0 9 5 0 1 0 0 0 1 0 5 0 0 . 1 0 . 5 1 2 4 8 2 4 4 8 7 2 1 6 8 (h o u rs ) (-mV) 2 3 ℃ 3 0 0 ℃ 5 0 0 ℃ 8 0 0 ℃

1st generation

6 0 0 6 5 0 7 0 0 7 5 0 8 0 0 8 5 0 9 0 0 9 5 0 1 0 0 0 1 0 5 0 0 . 1 0 . 5 1 2 4 8 2 4 4 8 7 2 1 6 8 (h o u rs ) (-mV) 2 3 ℃ 3 0 0 ℃ 5 0 0 ℃ 8 0 0 ℃

2nd generation

6 0 0 6 5 0 7 0 0 7 5 0 8 0 0 8 5 0 9 0 0 9 5 0 1 0 0 0 1 0 5 0 0 . 1 0 . 5 1 2 4 8 2 4 4 8 7 2 1 6 8 (h o u rs ) (-mV) 2 3 ℃ 3 0 0 ℃ 5 0 0 ℃ 8 0 0 ℃

3rd generation

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Anti Anti-

• white rust performance

white rust performance

by an accelerated test by an accelerated test

Steel panels piled up and, when it is rainy, water penetrates into the interspaces of panel！

1 1st

st generation

generation 2 2nd

nd generation

generation 3 3rd

rd generation

generation

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Examples of welding defects Examples of welding defects

Pit Groove Blow hole Appearance Cross section inside

• utside

Second bead

18 18 Blow hole (%)= {(Blow hole’s width×height)}/{evaluation width(500mm)×hegiht (4mm)}×100 * Height (4mm) is after gouging.

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0.0 0.0 0.0 0.0

0.0 0.0

5 2 27 20 3.3 5.3 3.6 5.1

2.1 2.2

Second bead Pit (number) Groove (mm) Blow hole (%) Dry flm thickness (mic.) First bead Pit (number) Groove (mm) Blow hole (%) Welding speed (mm/min.) 600 Generation 1st 2nd

3rd

Weldability Weldability

Welding speed 600 mm/min Welding speed 600 mm/min

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Weldability Weldability

Welding speed 800 mm/min Welding speed 800 mm/min

15 25 15 25

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0.0 0.0 0.0 0.0

0.0 0.0

2 3 31 56 4.4 5.9 4.3 6.1

2.4 2.6

800 1

st

2

nd

3

rd

Second bead Pit (num ber) Groove (m m ) Blow hole (% ) W elding speed (m m /m in.) Generation Dry flm thickness (m ic.) First bead Pit (num ber) Groove (m m ) Blow hole (% )

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Weldability Weldability (appearance) (appearance)

* Welding speed: 800mm/min.

First bead Second bead

1

st

generation SY-1 (25mic.) 2

nd

generation SY-2 (25mic.) 3

rd

generation SY-3 (25mic.)

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Weldability Weldability

(Cross section: Second bead) (Cross section: Second bead)

600mm/min. 800mm/min.

1

st

generation SY-1 (25mic.) 2

nd

generation SY-2 (25mic.) 3

rd

generation SY-3 (25mic.)

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Over coatability of 3 Over coatability of 3rd

rd generation. (2 months)

• generation. (2 months)

Salt Spray at 35 Salt Spray at 35℃ ℃

n o p e e l

s o m e tim e s ru s t

◇ R e s is t a n c e t o c o n t in u o u s s a lt s p r a y a t 3 5 oC ( 5 % N a C l a q ) ( J I S K 5 6 0 0 - 7 - 1 ) T e s t I te m A p p e a r a n c e

K n ife c u t t in g

R u s t w id t h o f c r e e p a g e

P u ll- o ff t e s t

B lis t e r ( g e n e r a l)

4 .6 M p a n o b lis te r

3 r d S / P + E p o x y p a in t

n o c h a n g e n o p e e l n o r u s t 4 .3 M p a n o b lis te r E p o x y p a in t o n ly n o c h a n g e

3rd S/P + Epoxy paint Epoxy paint only

* Paint system: 3rd S/P (15μm) + Epoxy paint (300μm), 2.3mm-thick test panel * Failure area of pull-off test: all test panels have cohesion break of Epoxy paint (100%).

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◇ Resistance to 3% NaCl aq immersion at 40oC (JIS K 5600-6-1) Test Item Appearance Knife cutting Rust width of

creepage

Pull-off test

Blister (general)

Epoxy paint only no change

no peel

sometimes rust

3rd S/P + Epoxy paint no change

no peel no rust 4.3Mpa no blister 4.5Mpa no blister

3rd S/P + Epoxy paint Epoxy paint only Over coatability of 3rd generation. (2 months) Over coatability of 3rd generation. (2 months)

3% NaCl aq Immersion at 40 3% NaCl aq Immersion at 40℃ ℃

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◇ Resistance to 3% N aCl aq im m ersion w ith cathodic protection at 40 oC Test Item Appearance Knife cutting

R ust w idth of creepage

Pull-off test

Blister (general)

4.0M pa no blister no rust no rust 3.9M pa no blister Epoxy paint only no change no peel

3rd S/P + Epoxy paint

no change no peel

* Paint system: 3rd S/P (15μm) + Epoxy paint (300μm), 2.3mm-thick test panel * Failure area of pull-off test: all test panels have cohesion break of Epoxy paint (100%). * Cathodic protection: Zn (Φ=15mm/test panel×4)

3rd S/P + Epoxy paint Epoxy paint only Over coatability of 3rd generation. (2 months) Over coatability of 3rd generation. (2 months)

3% NaCl aq Immersion with Cathodes at 40 3% NaCl aq Immersion with Cathodes at 40℃ ℃

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n o p e e l

• ◇ R e s is ta n c e to c o n tin u o u s c o n d e n s a tio n a t 5 0 oC ( > 9 5 % R H )

(J I S K 5 6 0 0 -7 -2 ) T e s t I te m A p p e a ra n c e

K n ife c u ttin g

R u s t w id th o f c re e p a g e

P u ll-o ff te s t

B lis te r (g e n e ra l)

4 .0 M P a n o b lis te r

3 rd S / P + E p o x y p a in t

n o c h a n g e n o p e e l

• 3 .5 M p a

n o b lis te r E p o x y p a in t o n ly n o c h a n g e * Paint system: 3rd S/P (15μm) + Epoxy paint (300μm), 2.3mm-thick test panel * Failure area of pull-off test: all test panels have cohesion break of Epoxy paint (100%).

Epoxy paint only 3rd S/P + Epoxy paint Over coatability of 3rd generation. (2 months) Over coatability of 3rd generation. (2 months)

Condensation at 50 Condensation at 50℃ ℃

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Balance of Performance Balance of Performance

1st and 2nd generation Anti-White rust property Heat resistance Weldability Overcoatability Cutting Property Anti-corrosive property

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Balance of Performance Balance of Performance

3rd generation Anti-corrosive property Heat resistance Weldability Cutting Property Anti-White rust property Overcoatability

1st and 2nd generation

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Conclusion Conclusion

The 3 The 3rd

rd generation shop primer

generation shop primer… … ◇ ◇ is easy to keep intact surface. is easy to keep intact surface. ◇ ◇ contribute to high productivity. contribute to high productivity. ◇ ◇ act with enough performance of act with enough performance of Epoxy main coat. Epoxy main coat. ◇ ◇ will be able to comply with PSPC will be able to comply with PSPC requirements. requirements.

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The end The end

thank you thank you

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