There are a multitude of industries that utilize corrosion inhibitors for a variety of industrial applications Without these important inhibitors, these industries would not be able to perform the various tasks that ensure their success. And so, they would fall into disarray. However, in order to understand how to prevent this, in this blog we will explain everything you need to know about these inhibitors.
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Before we understand what corrosion inhibitors are and what they do, let us define a few terms. Corrosion is a chemical process that occurs when a metallic surface is oxidized – meaning it encounters oxygen and loses one or more electrons. This may seem insignificant, but it can be extremely dangerous if left unchecked. Any structure or surface with metal that is exposed to air or chemicals can corrode, leaving behind unstable and unsafe buildings, pipelines, bridges, and more. Having measures in place to prevent such corrosion will not only extend the lifetime of your equipment but can also save you money in the long run.
There are several ways to prevent corrosion from occurring, such as keeping the metal clean and dry, using a coating, or using non-corrosive metals like aluminum and stainless steel. One of the most common ways is to use a chemical that inhibits – or prevents – corrosion, hence the name. These chemicals work to substantially decrease the rate of corrosion by acting as a barrier between the corrosive element (typically oxygen) and the metal surface. There are several types of corrosion inhibitors, with the most common being anodic (chemicals that prevent metal from being oxidized), cathodic (chemicals that block oxygen from being reduced), and mixed (inhibitors that perform both functions).
Different inhibitors will be effective on different metals and alloys (mixtures of metals and/or non-metals) and against different corrosive agents. Here is a brief list of corrosion inhibitors that are commonly used:
Known to contribute substantial material waste, corrosion causes practical and quality control issues in metalworking. Metal is susceptible to environmental degradation throughout every phase of production — as raw workpieces in transit from supplier to manufacturer, during storage, and even as finished parts ready for end-users. Once signs of corrosion appear, the material’s days may be numbered, if not already expired — and mitigation or replacement is expensive.
According to NACE International, the total cost of corrosion damage across the globe adds up to an estimated $2.5 trillion every year. That’s why preventing rust and corrosion are some of the most effective ways to reduce operating costs.
Corrosion inhibiting fluids have long played a critical role in most manufacturing operations, protecting workpieces through the trials of transit and storage. Traditional corrosion inhibitors, however, focus only on this one purpose, with formulas designed for short-term, long-term, and specific environmental conditions.
Newer generations of corrosion inhibitors go far beyond transit and storage: They can also help streamline operations, increase throughput, and provide even longer-lasting protection. In fact, the WEDOLiT™ catalog of corrosion inhibitors has pioneered many of these advances.
Here are some of the qualities to expect from next-generation rust prevention:
Traditional corrosion inhibitor fluids can be toxic for the environment and people, largely because of the high quantities of volatile organic compounds (VOCs) they release into the atmosphere. High VOC formulations contribute to increased air pollution and unpleasant shop environments.
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Next-generation corrosion inhibitors, such as those in the WEDOLiT line, are low- or VOC-free, in accordance with European regulations. In addition to improving air quality, the environmentally friendly formulations have higher flashpoints, which promotes a safer shop environment and reduces the release of organic compounds into the atmosphere.
Many next-generation corrosion inhibitors feature higher hydrophobic characteristics, which reduce dewatering times. For example, WEDOLiT AS , designed for short-term corrosion prevention, includes surface-active substances that displace water and emulsions faster than competing specialized dewatering formulas. In one case study, a customer cut dewatering time in half, even on parts with complex geometries where water could potentially collect. AS also extended corrosion protection to several weeks longer than the customer’s previous dewatering rust preventative.
In addition to improving dewatering speed, many next-generation corrosion inhibitors are formulated to replace and consolidate various products into a single solution. For example, many WEDOLiT corrosion inhibitors offer long-term corrosion protection and include enough lubricity to effectively serve as forming fluids. Then there are prelubes like WEDOLiT N 22-3, which is a forming fluid and coolant that offers substantial corrosion protection and can significantly slash production costs.
Other products, including WEDOLiT AW , combine parts cleaning with corrosion protection, washing dirt and contaminants off of finished parts while also creating a protective film to prevent rust.
These advanced, multi-purpose formulations improve productivity by reducing the number of products and steps needed in an operation. Consolidating needs into one product also saves money by reducing labor utilization and consuming less fluid.
Many multi-purpose formulations are optimized for specific manufacturing processes. Typically, corrosion inhibitors that combine different specialty fluids and production steps into one product are often a response to the needs of a specific industry — especially automotive and other stamped part manufacturers.
These fluids can also help manufacturers innovate and streamline the way they produce parts. When enough industry leaders achieve a higher level of productivity, it creates new industry standards, setting the stage for greater innovations.
Many next-generation corrosion inhibitors perform better than traditional formulas and other corrosion prevention methods. For example, vapor corrosion inhibitor (VCI) packaging is a type of packaging that protects metals from corrosion with a thin, invisible seal over the surface. In one case study with an automotive manufacturer, WEDOLiT product was shown to outperform VCI packaging. While the VCI packaging left parts prone to rusting during overseas transit, one WEDOLiT corrosion inhibitor coated the parts so effectively, that it reduced customer complaint rates to less than 10 percent.
As workpieces become more expensive and production schedules become more demanding, next-generation corrosion inhibitors can help job shops control operating costs and remain as efficient as possible. These advanced formulas do far more than just prevent corrosion — they streamline manufacturing processes and help operations redefine their standards of speed and excellence.
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