Novel calcium silicate-based anti-corrosive pigments for superior anti-corrosion performance
Benefits at a Glance
- Versatile anti-corrosion pigments for waterborne, solvent borne and powder coating products
- Superior anti-corrosion performance
- The spherical shape could enhance film hardness and abrasion resistance
- Easier to formulate at higher loading levels (as needed) because of its spherical nature
- Label-free product
SPHERILEX® AC 45 and SPHERILEX® AC 45 HS are calcium silicate-based anti-corrosive pigments, developed to meet the demand of superior anti-corrosion performance. These pigments consist primarily of silica (94%) and calcium oxide (6%). Their spherical morphology not only facilitates easier and more even dispersion compared to angular alternatives but also minimizes aggregation, enhancing dispersion stability. This characteristic ensuring consistent protection across the substrate.
The anti-corrosive pigments showed exceptional performance in various formulations from waterborne, to solvent borne and powder coating formulations. When used in water-borne 2K epoxy primers SPHERILEX® AC 45 and SPHERILEX® AC 45 HS demonstrated significant corrosion resistance, as evidenced by salt spray tests according to ASTM D1654 conducted over 1500 hours.
| Control | Ion-exchanged silica | SPHERILEX® AC 45 | SPHERILEX® AC 45 HS | |
|---|---|---|---|---|
| Average Creep (mm) | 13.4 | 4.3 | 2.8 | 2.9 |
| Average Delamination (mm) | 77.5 | 20.1 | 19.6 | 17.7 |
One of the standout features of SPHERILEX® AC 45 and SPHERILEX® AC 45 HS is their ability to perform at half the dosage level of traditional pigments. This not only reduces the material cost but also the environmental impact, aligning with the growing demand for sustainable industrial practices. The test results of salt spray testing according to DIN EN ISO 12944 after 1500 hours in a solvent borne 2K epoxy formulation showed reduced corrosion creep and rust grades compared to traditional zinc phosphate formulations.
| Control | Zinc phosphate | SPHERILEX® AC 45 | SPHERILEX® AC 45 HS | |
|---|---|---|---|---|
| Dosage [wt-%] | - | 8.5 | 4.2 | 4.2 |
| Corrosion Creep | 11 | 9 | 6 | 6 |
| Rust Grade | 1 | 0 | 0 | 0 |
In abrasion resistance tests, SPHERILEX® AC 45 and SPHERILEX® AC 45 HS showed significantly lower mass loss compared to blank samples, indicating enhanced film hardness and durability. This is particularly beneficial for applications where mechanical wear is a concern.
| Sample | % Mass loss after 500 cycles |
|---|---|
| Blank | 50.7 |
| SPHERILEX® AC 45 | 17.4 |
| SPHERILEX® AC 45 HS | 21.0 |
One of the most compelling features of SPHERILEX® AC 45 and SPHERILEX® AC 45 HS is its improved environmental footprint compared to traditional anti-corrosion pigments. Unlike chromate-based pigments, which are known for their carcinogenic potential, or phosphate-based pigments, which pose environmental concerns due to their impact on aquatic life, calcium silicate pigments offer a safer alternative. The formulation of SPHERILEX® AC 45 and SPHERILEX® AC 45 HS does not impact hazardous labeling, making it a preferable choice for industries aiming to reduce their ecological impact while maintaining high performance standards. SPHERILEX® AC 45 and SPHERILEX® AC 45 HS are globally applicable as they are registered across multiple international inventories.
SPHERILEX® AC 45 and SPHERILEX® AC 45 HS represent a significant advancement in anti-corrosion technology. Their innovative composition and morphology offer a compelling alternative to traditional pigments, providing enhanced performance, reduced environmental impact, and cost-effectiveness. As industries continue to seek solutions that balance performance with sustainability, these calcium silicate-based pigments are poised to become a preferred choice for anti-corrosion applications across various sectors.