February 19, 2024

In the coatings industry, achieving optimal anticorrosion protection while being resource-efficient can be a challenge. Traditional approaches often rely on high loadings of corrosion inhibitors, which can lead to increased costs and environmental impact. However, with Hexigone's Intelli-ion technology, a paradigm shift is underway as its anticorrosion solution requires lower loadings compared to traditional products.

The term “loadings” refers to the amount of a particular ingredient, such as a corrosion inhibitor, added to a coating formulation. In the case of zinc phosphate, loadings of about three to 20 per cent are often necessary to achieve desired levels of corrosion protection. However, this approach comes with drawbacks such as increased material costs, reduced formulation flexibility, and environmental draw-backs due to the presence of heavy metals.

Unlike traditional inhibitors, Intelli-ion operates on a smart-release mechanism, wherein corrosion inhibitors are released precisely when and where they are needed most.

However, what is unique is that Intelli-ion has a lower specific gravity (1.35) compared to conventional inhibitors. This characteristic allows Intelli-ion to occupy more volume within the coating matrix, reducing the overall amount of inhibitor required for optimal performance. For example, the one per cent in weight of Intelli-ion will take-up three per cent volume in the dry film thickness. As a result, coatings formulated with Intelli-ion require 1/3 of the loading vs zinc phosphate (ZnP), leading to environmental benefits while maintaining anti-corrosion performance.

If you have previously formulated for three per cent of anti-corrosive pigment as part of your pigment volume concentration (PVC) in the dry film thickness, incorporating one per cent of AX1 into your formulation will seamlessly integrate without compromising the critical CPVC (Critical Pigment Volume Concentration) of the system. This allows for the effective enhancement of corrosion protection while maintaining the integrity and performance of your coating.

Salt Spray Testing: Unveiling the Efficacy of Low Loadings

The testing imagery below showcases panel results following 1000 hours salt-spray testing (ASTM-B117). A leading primer coating containing 5 per cent zinc phosphate was compared to formulations containing 0.5 percent and one per cent of Intelli-ion’s quick-release ion-exchange inhibitor—yielding excellent results. Significantly reducing the inhibitor loadings can offer coatings manufacturers lower costs, improved adhesion and differentiation in the coatings market.

Intelli-ion also works alongside zinc phosphate to allow manufacturers to take a ‘step-change’ in their coatings formulation rather than completely replacing their current inhibitor—as demonstrated by the 1,000 salt spray results below (ASTM-B117). Manufacturers are optimising their formulations to at least half the amount of ZnP to add 0.5 to two per cent of Intelli-ion to take advantage of synergistic protection mechanisms and reduced raw material costs.

By requiring lower loadings than traditional products like zinc phosphate, Intelli-ion can deliver cost savings, enhanced efficiency, and reduced environmental impact. With Intelli-ion, coatings manufacturers can truly do more for less, ushering in a new era of sustainable corrosion protection.