Results from our Partners
Hexigone can offer four key benefits for coatings manufacturers:
C5 Corrosion Protection - Waterborne Epoxy primer with PU topcoat
Test: ASTM B117
Duration: 1440 hours
Film thickness: Primer layer - 120 µm and the topcoat was applied at approx. 60 µm
Both images: Formulated with 2% AX1 % 2% ATP co-blend
Comments: The panels used for testing were shot-blasted to Sa2.5 as per C5 specification. After 1440 hours of salt spray testing (SST) to ASTM B117, our WB Epoxy system with AX1 displayed zero blistering. Half of the system was removed to reveal minimal corrosion at the scribe, demonstrating Intelli-ion®'s excellent performance.
Benefits to the customer: Exceptional protection and a transition to sustainability: reaching 1440 hours allows existing manufacturers of C5 standards of paint to switch to more sustainable inhibitors whilst maintaining performance.
C5 Corrosion Protection - Solventborne Epoxy primer with PU topcoat
Test: ASTM B117
Duration: 1440 hours
Film thickness: Primer layer - 120 µm and the topcoat was applied at approx. 60 µm
Both images: Formulated with 5% AX1 % only
Comments: The panels used for testing were shot-blasted to Sa2.5 as per C5 specification. After 1440 hours of salt spray testing (SST) to ASTM B117, our SB Epoxy displayed zero signs of blistering in the coating system. The SB Epoxy system meets specifications with no blistering, minimum cross scribe corrosion, and no undercoat corrosion present on the full substrate.
Benefits to the customer: High level of protection and a transition to sustainability are achieved through the use of low VOC solvent-borne coatings, offering environmentally friendly alternatives for customers.
Marine / Protective co-blend
Company: Teamac (Teal & Mackrill)
Test: ASTM B117
Duration: 750 hours
Film thickness: 100µm
Comments: Following the 750 hours of salt spray, the right-hand side panel showed comparatively little red rust, with minimal creep from the scribe and no corrosion product. This demonstrates excellent adhesion and superior corrosion protection. It is important to note that this panel was double scribed on one diagonal cut. The left-hand side panel showed comparatively extensive corrosion damage, with visible creep from the scribe and corrosion product at the scribe.
Benefits to the customer: Performance increased. Removal of warning label. Cost savings on raw materials.
Industrial co-blend
Company: Tier 1 Industrial Coatings Manufacturer
Test: ASTM B117
Duration: 1,000 hours
Film thickness: 200µm
Comments: Intell-ion® containing primers protect on shot blasted steel significantly better than the inhibitor which has been used for the last 25 years.
Benefits to customer: Step change in performance, sustainability credentials, differentiated product, increased customer confidence leading to increased sales.
Infrastructure co-blend
Company: Tier 1 Coating Supplier
Test: ASTM B117
Duration: 500 hours
Film thickness: Left – 110µm, right - 130µm
Comments: These results show that Intelli-ion® delivers higher corrosion protection as an addition to a phosphate- based inhibitor – demonstrating synergistic effects.
Benefits to customer: Step change in performance, sustainability credentials, differentiated product, decreased raw materials costs.
Aerospace Chrome-free Coatings
Company: Indestructible Paint Ltd.
Test: ASTM B117
Duration: 1060 hours
Film thickness: 80µm
Comments: On mild steel untreated, Intelli-ion® delivers a higher performance at the scribe and panel body coating. These results show that Intelli-ion® delivers higher corrosion protection as a single replacement AND as an addition to a phosphate based inhibitor – demonstrating synergistic effects.
Benefits to the customer: Increased performance for their customers and decreased raw material costs.
General Industrial coatings - complete replacement
Company: Tier 1 Coating Supplier
Test: ASTM B117
Duration: 1000 hours
Film thickness: Left – 175µm, right - 210µm
Comments: Alkyd primer with topcoat on mild steel. This demonstrates excellent adhesion and better corrosion protection.
Benefits to the customer: Increased performance and significant decrease in raw material costs.
Automotive/General Industrial coatings - Waterborne
Company: Tier 1 Coating Supplier
Test: ASTM B117
Duration: 1000 hours
Comments: Following 1000 hours in the saltspray, the left-hand side panel showed comparatively extensive corrosion damage, while right-hand side panel showed less blistering and better adhesion.
Benefits to the customer: Both panels have been coated with the same topcoat. Comparable or higher performance with decreased raw material costs.
Coil Coatings - Solvent Borne
Company: Tier 1 Coil Coating Supplier
Test: ASTM B117
Film Thickness: 5-7µm Primer, 20µm Topcoat
Comments: Cut edge failure is the customer’s most common guarantee claim. Intelli-ion® demonstrated 10x the performance on the cut edge than the current chrome free technology with no reformulation.
Benefits for customer: Increased confidence in performance, new to market product
Images: Naturally-exposed panels at Muriwai beach; A) P1, B) P2 and C) P3 coating systems after ten months of unwashed exposure
Coil Coatings - Waterborne
Company: Tier 1 Coil Coating Supplier
Test: Novel Rapid Scanning Vibrating Electrode Technique (SVET) and Natural Weathering on Muriwai Beach, New Zeleand.
Film Thickness: 5-7µm Primer, 20µm Topcoat
Comments: With reformulation, the Intelli-ion® technology was incorporated by a Tier 1 company, into a waterborne coil coating. Testing demonstrated the correlation of the superior performance over the current chrome free technology in both the rapid (SVET) and natural weathering testing
Benefits to customer: Protection performance increased by 250% by substituting in the Intelli-ion® technology, new to market product.
Adhesion test results (post ASTM B117 testing)
Company: “Off-the-shelf" standard 2K epoxy primer
Test: Pull off test after 1000 hours of ASTM B117 testing
Duration: 1000 hours
Film thickness: 110µm
Result: Intelli-ion AX1 not only provides superior corrosion protection but also enhances adhesion performance, resulting in longer-lasting protection for metal assets.
Standard 2k epoxy primer (left):
100% adhesion failure between the primer and metal (AB)
5% drop in of AX1 (right):
10% glue failure
90% cohesive (C) failure within the topcoat
Adhesion test results
Test: Pull off test
Film thickness: Base coat 37µm and top coat 40-50µm
Result: The addition of AX1 improves intercoat adhesion between the primer layer and the topcoat. When increasing AX1 from 0.5% to 2.4%, adhesion doubles from 1.4MPa to 3.3MPa.
2.5% AX1 (right):
40% adhesion failure between primer and topcoat (BC)
55% cohesive (C) failure within the topcoat
5% glue failure
0.5% AX1 (left):
85% adhesion failure between the primer and topcoat (BC)
10% cohesive (C) failure within the topcoat
5% glue failure
Method
Samples were scribed using an Elcometer 1638 DIN scratching tool fitted with a 1 mm cutter. The scribes were carried out in a cross shape across the samples in a horizontal orientation. The scribe perforated the coating in order to expose the substrate steel.
Following scribing, the samples were placed in a salt spray chamber in racks at an angle of 45° from the normal. The chamber was run in accordance with ASTM B117 continuous salt spray fog testing. This consisted of creating a fog of 5% w/v NaCl in distilled water at pH 7.0 at 35°C consistently for a set number of hours.
Following exposure to the salt spray testing, samples were rinsed using distilled water and dried using lint free cloth before being analysed.
References:
Journal of the Oil & Colour Chemists’ Association - Surface Coatings International, SCI.(2020) ‘Inspiring Colourful Futures’, September - October. Volume 103.5