Abstract
High-strength bolt attachment parts of steel bridges are prone to corrosion at an early stage, and blast nozzles and power tools cannot be inserted due to the structural shape during repairs, and there are many cases where rust remains partially. To solve such a problem, the Cold Spray technology, which uses a powder that mixes zinc and alumina, exhibits corrosion resistance by depositing a film even if rust remains. In this paper, first the anticorrosion mechanism on the residual rust was examined by focusing on the permeation prevention of the corrosion factor of the Cold Spray anticorrosion film and the adhesion of the residual rust boundary. Findings indicate that the Cold Spray anticorrosion film exhibits a porosity approximately one-tenth that of films engendered via the thermal spraying method, thereby constituting a denser film with heightened environmental barrier attributes. The firm adherence of the Cold Spray anticorrosion film to the residual rust interface is explained by differences in hardness between Cold Spray, residual rust, and zinc. Furthermore, the physical characteristics of zinc undergo modifications influenced by the temperature environment during construction, imparting a plasticity to zinc on uneven rust surfaces.
Similar content being viewed by others
References
Ahn, J. H., Lee, J. M., Cheung, J. H., & Kim, I. T. (2016). Clamping force loss of high-strength bolts as a result of bolt head corrosion damage: Experimental research A. Engineering Failure Analysis, 59, 509–525. https://doi.org/10.1016/j.engfailanal.2015.08.037
Assadi, H., Kreye, H., Gärtner, F., & Klassen, T. (2016). Cold spraying—A materials perspective. Acta Materialia, 116, 382–407. https://doi.org/10.1016/j.actamat.2016.06.034
Bala, N., Singh, H., Karthikeyan, J., & Prakash, S. (2014). Cold spray coating process for corrosion protection: A review. Surface Engineering, 30, 414–421. https://doi.org/10.1179/1743294413Y.0000000148
Champagne, V. K. (Ed.). (2007). The cold spray materials deposition process. Woodhead Publishing Ltd.
Champagne, V. K. (2008). The repair of magnesium rotorcraft components by cold spray. Journal of Failure Analysis and Prevention, 8, 164–175. https://doi.org/10.1007/s11668-008-9116-y
Chavan, N. M., Kiran, B., Jyothirmayi, A., Phani, P. S., & Sundararajan, G. (2013). The corrosion behavior of cold sprayed zinc coatings on mild steel substrate. Journal of Thermal Spray Technology, 22, 463–470. https://doi.org/10.1007/s11666-013-9893-z
da Silva, F. S., Bedoya, J., Dosta, S., Cinca, N., Cano, I. G., Guilemany, J. M., & Benedetti, A. V. (2017). Corrosion characteristics of cold gas spray coatings of reinforced aluminum deposited onto carbon steel. Corrosion Science, 114, 57–71. https://doi.org/10.1016/j.corsci.2016.10.019
East Nippon Expressway Co., Ltd., Central Nippon Expressway Co., Ltd., West Nippon Expressway Co., Ltd. (2020). Design Guidelines Vol. 2 Bridge Maintenance (in Japanese).
Hanshin Expressway Co., Ltd. (2017). Road structure repair procedure Part 3 Pavement, expansion joints, painting (in Japanese).
Hassani-Gangaraj, S. M., Moridi, A., & Guagliano, M. (2015). Critical review of corrosion protection by cold spray coatings. Surface Engineering, 31, 803–815.
Hiwa, Y., Shimozato, T., Kato, Y., Ono, S., Kimura, M., & Nakano, M. (2020). Verification test of Cold Spray corrosion protection technology for corroded steel bridge girder ends. Journal of Structural Engineering, 66A, 388–399. https://doi.org/10.11532/structcivil.66A.388. in Japanese.
Ichikawa, Y., & Shinoda, K. (2021). Current status and challenges for unified understanding of bonding mechanism in solid particle deposition process. Materials Transactions, 62, 691–702.
JSCE. (2006). Recommendations on design, construction and maintenance for friction type of high strength bolted connections (in Japanese).
JSCE. (2014). Design methods and examples for repair and rehabilitation of corrosion-damaged steel structures (in Japanese).
JSCE. (2019). Issues and countermeasures for recovering anticorrosion performance of steel structures in atmospheric environment (in Japanese).
Kato, Y., Shimozato, T., Tai, M., Oshikawa, W., & Hiwa, Y. (2019). Electrochemical property of Cold Sprayed Coating with mixed particles of zinc and alumina for corroded steel substrate. Steel Construction Engineering, 26(102), 33–41. https://doi.org/10.11273/jssc.26.102_33. in Japanese.
Kawaguchi, Y., Miyazaki, F., Yamasaki, M., Yamagata, Y., Kobayashi, N., & Muraoka, K. (2017). Influence of temperature and velocity of thermal spray droplet on Al-5Mg coating qualities. Journal of Japan Thermal Spraying Society, 54(1), 1–7. https://doi.org/10.11330/jtss.54.1. in Japanese.
Kiyokawa, S., Inokuchi, S., Kimura, M., & Shimozato, T. (2015). Mechanical properties and corrosion performance of high-strength bolts covered with metal coating generated by Cold Spray Technique. Steel Construction Engineering, 22(85), 133–141. https://doi.org/10.11273/jssc.22.85_133. in Japanese.
Koivuluoto, H., & Vuoristo, P. (2014). Structure and corrosion properties of cold sprayed coatings: A review. Surface Engineering, 30, 404–413. https://doi.org/10.1179/1743294413Y.0000000201
Lapushkina, E., Ying, S., Mary, N., Ogawa, K., & Normand, B. (2019). Elaboration of sacrificial Zinc coating on carbon steel via High pressure cold spray technique. In International thermal spray conference and exposition (pp. 259–264).
Metropolitan Expressway Co., Ltd. (2021). Steel bridge painting design and construction procedure (in Japanese).
Moridi, A., Hassani-Gangaraj, S. M., Guagliano, M., & Dao, M. (2014). Cold spray coating: Review of material systems and future perspectives. Surface Engineering. https://doi.org/10.1179/1743294414Y.0000000270
Natori, T., Nishikawa, K., Murakoshi, J., & Ohno, T. (2001) Study on characteristics of corrosion damages in steel bridge members. In Proceedings of JSCE, No.668/I-54 (pp. 299–311) (in Japanese). https://doi.org/10.2208/jscej.2001.668_299
Papyrin, A. (2001). Cold spray technology. Advanced Materials & Processes, 159(9), 49–51.
Japan Road Association. (2012). Road bridge repair and reinforcement case studies (in Japanese).
Japan Road Association. (2014). Steel Road Bridge Anticorrosion Handbook (in Japanese).
Sakaki, K., Nagata, K., Takata, K., Yuto, D., & Shimizu, Y. (2009). Effect of metal powder and base material combination on cold spray particle adhesion status. Nihonyousyakyoukai Zenkokukouentaikai Ronbunshu (pp. 19–20) (in Japanese).
Sakaki, K. (2010). Promising field in new thermal spray technology “cold spray.” Journal of Japan Thermal Spraying Society, 47(3), 113–119. in Japanese.
Shimozato, T., Hiwa, Y., Arizumi, Y., & Yamashiro, K. (2017). An experimental study of formation ability of corrosion protection coating on rust steel plate surfaces by applying Cold Spray Technique. Steel Construction Engineering, 24(93), 65–72. https://doi.org/10.11273/jssc.24.93_65. in Japanese.
Supervised by Okinawa General Bureau Development and Construction Department, Okinawa Prefecture Civil Engineering Department. (2019) Okinawa area steel bridge anticorrosion manual (in Japanese).
Tai, M., Shimozato, T., Nagamine, Y., Arizumi, Y., & Yabuki, T. (2018). Dependence of residual axial force on thickness and shape in corroded high-strength bolts. Journal of Structural Engineering. https://doi.org/10.1061/(ASCE)ST.1943-541X.0002078
Tanaka, H. (1982). Metallic Resources Series –Zinc. Tetsu to Hagane, 68(8), 923–929. https://doi.org/10.2355/tetsutohagane1955.68.8_923. in Japanese.
Tao, Y., Xiong, T., Sun, C., Jinn, H., Du, H., & Li, T. (2009). Effect of α-Al2O3 on the properties of cold sprayed Al/α-Al2O3 composite coatings on AZ91D magnesium alloy. Applied Surface Science, 256, 261–266. https://doi.org/10.1016/j.apsusc.2009.08.012
Tapphorn, R., & Ulmer, D. (2004). Application of oxidation/corrosion resistant coatings to rocket engine combustion chamber liners, AeroMat2004, Seattle.
Yin, S., Wang, X., Li, W., & Jie, H. (2011). Effect of substrate hardness on the deformation behavior of subsequentlyincident particles in cold spraying. Applied Surface Science, 257, 7560–7565. https://doi.org/10.1016/j.apsusc.2011.03.126
Yin, S., Wang, X., Li, W., Liao, H., & Jie, H. (2012). Deformation behavior of the oxide film on the surface of cold sprayed powder particle. Applied Surface Science, 259, 294–300. https://doi.org/10.1016/j.apsusc.2012.07.036
Zhao, Z., Tang, J., ul Haq Tariq, N., Wang, J., Cui, X., & Xiong, T. (2020). Microstructure and corrosion behavior of cold-sprayed Zn-Al composite coating. Coatings, 10, 931. https://doi.org/10.3390/coatings10100931
Author information
Authors and Affiliations
Contributions
YH: Conceptualization, Methodology, Investigation, Writing—original draft, Writing—review& editing. TS: Conceptualization, Writing—review & editing, Supervision, Formal analysis. YT: Writing—review & editing, Validation.
Corresponding author
Ethics declarations
Conflict of interest
The authors have no relevant financial or non-financial interests to disclose.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Hiwa, Y., Shimozato, T. & Tamaki, Y. Denseness and Adhesion of Low-Pressure Cold Spray Coating to Corroded Steel Bridges. Int J Steel Struct 24, 109–117 (2024). https://doi.org/10.1007/s13296-023-00803-6
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s13296-023-00803-6