Ship Production Panel Meeting Tampa, Fl, January 2006

Digital image processing for rust assessment

Muehlhan Equipment Services GmbH Hamburg, Germany

Rust degrees in standardisation

Muehlhan

Rust degree on coated surfaces (ISO 4628-3)

Flash rust degree after surface preparation (ISO/FDIS 8501-4)

Rust degrees in standardization

Rust degrees at initial condition (before surface preparation) (ISO 8501-1)

Rust degrees on coated surfaces (ISO 4628-3) (SSPC-VIS 2)

Flash rust degree after surface preparation (ISO/FDIS 8501-4) (SSPC- VIS 4 NACE VIS 7)

ISO

Muehlhan

Muehlhan

A, B, C, D

Ri 0 bis Ri 5

L, M, H

Flash rusting after surface preparation

Jet Edge, Inc.

UHP-waterjetting

Muehlhan

Muehlhan

Wet blast cleaning

Flash rust degrees - SSPC-VIS 4 / NACE VIS 7

Flash rust degree light L FR-1 Description A surface which, when viewed without magnifications, exhibits small quantities of a yellow/brown rust layer through which the steel substrate may be observed. The rust or discoleration may be evenly distributed or present in patches, but will be tightly adherent and not easily removed by light wiping with a cloth. A surface which, when viewed without magnification, exhibits a layer of yellow/brown rust that obscures the original steel surface. The rust layer can be evenly distributed or present in patches, but it will be reasonably well adherent and lightly marks a cloth that is lightly wiped over the surface. A surface which, when viewed without magnification, exhibits a layer of heavy red/brown rust that hides the initial surface condition completely. The rust may be evenly distributed or present in patches, but the rust is loosely adherent, easily comes off, and leaves significant marks on a cloth that is lightly wiped over the surface.

moderate

FR-2

heavy

FR-3

Effects on flash rusting

Parameter Salt contamination Relative humidity Wetting regime Temperature Preparation quality Effect on flash rusting + + + (> 60 %) + - -

Flash rust is the result of atmospheric (oxygen) corrosion.

Chlorides and flash rusting

120

Begin of flash rusting in h

90

60

Limit according to IMO DE 48/12, 2004

30

20 0.5

0 0 5 10 15 20 25 30 35

Chloride level in g/cm

Reference: Dept. of Transport and Urban Planning, Adelaide, Australia

Wetting regime and flash rusting

Muehlhan

Muehlhan

Wet blasting at high relative humidity (70%)

UHP-jetting with rotating nozzle carrier

Flash rust morphology

Muehlhan Muehlhan

Muehlhan

Muehlhan

Goethite-crystals (-FeOOH)

Lepidocrocite-csystals (-FeOOH)

Phase composition of rust

Lepidocrocite

Condition: a b c d e f g h after blast cleaning after blast cleaning after blast cleaning old rust, St 33 old rust, St 50 old rust, St 37 old rust, Brcke Industry rust, scale

b c

d f

Goethite

Magnetite

Measurements from: Keller (1967), Hiller (1966) crystalline phases only.

Kinetics of flash rusting

no flash rust

light flash rust

moderate flash rust

Reference: CorrPro, Washington

Kinetics of rusting

Reinhard & Irmscher, 1983

Karaivanov & Gawrilov, 1973

Loss in reflectance due to rusting

Diffraction intensity Lepidocrocite

Kinetics of flash rusting

16 Fe2+ concentration in g/m

12

Sa 2

heavy (7.0 g/m)

light (2.5 g/m)

0 0 2 4 6 8 10 12

Duration in days
Reference: SNCF, Paris

Kinetics of flash rusting

Steel condition Fe2+-concentration in g/m No visible flash rust Sa 2 Rust Degree C Deteriorated Shop Primer 0-2 1.5 - 4 0-3 Light / Moderate 2-7 4-8 3-6
Reference: SNCF, Paris

Heavy (powdery) >7 >8 >6

Flash rust degree Thickness in m

No visible flash rust 0.5

Light 2.4

Moderate 18.2

Reference: CorrPro, Washington

How harmful is flash rust

Coating Epoxy, solvent-free K 0 0 0 0 S 1 3 1 1 A Y B Y B Epoxy, with glass flakes K 0 0 0 0 S 1 2 1 1 A Y Y B B Epoxy, with gf, low cure temperature K 0 0 0 0 S 2 2 1 1 A Y Y Y Y Epoxy, modified K 0 0 0 0 S 0 2 1 0 A B B B B Tar-coal epoxy K 0 0 0 0 S 1 2 1 2 A B B Y Y Epoxy, tank lining K 1 0 0 1 S 1 1 2 1 A Y Y Y Y

Test Dw2 Dw2 + FR Dw3 Dw3 + FR

Dry film thickness: 2 x 150 m Tests: K = cross cut (numbers in mm) S = impact test (0 no damage, 1 very slight debonding, 2 slight debonding) A = pull-off test (Y failure in glue; A/B adhesive failure; B failure in coating) Dw2 / Dw3 = UHP jetting according to STG 2222 FR = Flash rust (L/M) Test duration: 36 months Reference: Morris (2000)

12

Epoxy (solvent-free)
Y 8,3 A/B 5,17 A/B 2,75 Y 8,6

10,7

B 11

Y 10,3

Pull-off strength in MPa

0 Brush Needle gun Dw2 Dw2+FR Method Dw3 Dw3+FR Dry blast

Certain coating systems tolerate flash rusting

Many coating systems do not tolerate flash rusting

Certain coating systems do tolerate flash rust

Euronavy

Muehlhan

When better not overcoat flashrust?

1. If the flash rust is only loosely adherent (designation H), or, respectively, if the flash rust layer is rather thick.

Muehlhan

Muehlhan

2. If the flash rust is not clean (e.g. salt contaminated).

clean rust

chloride contaminated rust

Visual flash rusting references

Standard / Reference Method Light (slight) ISO 8501-4 SSPC-VIS 5 SSPC-VIS 4 NFT 35 520 International International Hempel Jotun Water washing WAB cleaning Waterjetting Cleaning Slurryblasting Hydroblasting Waterjetting L L L OF1 L L FR-1 JG-2 Flash rust degree Moderate (medium) M M M M M FR-2 JG-3 Heavy (considerable) H H H OF2 H H FR-3 JG-4

Reference images for flash rust

Hempel Jotun SSPC / International ISO

Visual flash rust assessment

Muehlhan

Muehlhan

Moderate (FR-2 = M) - Hempel

Light (L) International / SSPC / NACE

Visual flash rust assessment (?)

IP

Hempel

C HB2.5 M

C WJ2-FR2

Adhesion test for flash rust assessment

Degree L M H Adhesion (SSPC-VIS 4 / NACE VIS 7) tightly adherent reasonably well adherent loosely adherent

loosely adherent = H

Muehlhan

Easily comes off = H

Muehlhan

Assessment with Hempels Tape-Test

Muehlhan

FR-1 (L)
Muehlhan

FR-2 (M)

Tape-Test after WAB cleaning

FR-3 (H)

Assessment scheme acc. to Hempel

Image processing
Muehlhan Dr. J. Ppplau

Muehlhan

Dr. J. Ppplau

Rust designation in a colour space

Hue Saturation Saturation

Value

Value

unsaturated Steel Colour correlation

Colour as a rating criterion

Muehlhan Muehlhan Muehlhan

Shot blasting, Sa 2
7000 7000

WAB cleaning + flash rust

7000

Coating with underrustings

Muehlhan
6000 5000 Pixel numberl 4000 3000 2000 1000

Muehlhan
6000 Pixel number 5000 4000 3000 2000 1000

Muehlhan
6000 5000 4000 3000 2000 1000

Pixel number

0
1 47 70 24 93 116 185 208 231 139 162 254 0 155 243 111 133 177 199 221 23 45 67 89 1 0 177 111 133 155 199 221 243 23 45 67 89 1

Dimension

Dimension

Dimension

Colours of iron(hydr)oxides

Torrent & Barron, 2002

VCH, Weinheim

Occupation level - image processing

SSPC/NACE-Definitions: light flash rust (6%) Layer through which the steel surface may be observed. Layer that obscures the original steel surface.

IP

Dr. J. Ppplau

IP

Dr. J. Ppplau

moderate flash rust (30%)

IP

Dr. J. Ppplau

heavy flash rust (60%)

Layer that hides the initial surface condition completely.

Calculation programme: Rustfinder, Dr. Jens Ppplau, Hamburg

Colour parameters - Image processing

Initial image

Low intensity (Rustfinder)

High intensity (Rustfinder)

Muehlhan

Dr. J. Ppplau

Dr. J. Ppplau

Calculation programme: Rustfinder, Dr. Jens Ppplau, Hamburg

Classification of rust intensities

Results of non-calibrated measurements
CorrPro
Dr. J. Ppplau

Initial image

After image processing

Calculation programme: Rustfinder, Dr. Jens Ppplau, Hamburg

Next steps
Calibration of flash rusting degrees based on coating manufacturers specifications. Installation of a test version of the software. Transition from macro images (cm-range) to longshot images (range of tenth of m). Use of standard imaging technique, e.g. cellular phone cameras. Standardization of the procedure and its implementation into a Surface Quality Monitoring System (SQMS).

How to avoid flash rusting?

Use of very clean water; e.g. water from reverse osmosis processes, distilled water. Use of mobile water cleaning / desalination devices. Muehlhan: -water = two-step reverse osmosis plant.

Muehlhan

Muehlhan

How to avoid flah rusting?

Immediate drying after blast cleaning / washing / jetting Muehlhan: -switch + -select: Control switch for the selection of: - Dry blast cleaning; Wet blast cleaning; Washing; Drying

Muehlhan

UHPAB-nozzle mit -switch + -select

No drying

Drying

How to avoid flash rusting?

Addition of inhibitors, etc. Flash rust formation can be avoided over a longer period even in areas with high humidity. Acceptance? Coating manufacturers must be consulted, and they should approve the product.

Muehlhan

Muehlhan

after 24 h

after 48 h

Many Thanks.
momber@muehlhan.com poepplau@muehlhan.com madonna@muehlhan.com