Protective coatings and methods of forming same

Abstract

A multi-layer protective coating for a substrate arranged in or on a vessel and method of forming multi-layer protective coating on a substrate arranged in or on a vessel. Multi-layer protective coating includes a thermal sprayed bonding layer formed on and in contact with a first face of the substrate prepared in a manner to allow the bonding layer to adhere, the bonding layer having a substrate face and a non-substrate face, a resistance layer made of a material resistant to impact forces and corrosion caused by a corrosive environment in a vicinity of the substrate arranged in or on the vessel, the resistance layer formed on and in contact with the non-substrate face of the bonding layer, the resistance layer having a bond face and a non-bond face, and a sealant layer formed on and in contact with the non-bond face of the resistance layer.

What is claimed: 
     
         1 . A multi-layer protective coating for a substrate arranged in or on a vessel, comprising:
 a thermal sprayed bonding layer formed on and in contact with a first face of the substrate prepared in a manner to allow the bonding layer to adhere, the bonding layer having a substrate face and a non-substrate face;   a resistance layer made of a material resistant to impact forces and corrosion caused by a corrosive environment in a vicinity of the substrate arranged in or on the vessel, the resistance layer formed on and in contact with the non-substrate face of the bonding layer, the resistance layer having a bond face and a non-bond face; and   a sealant layer formed on and in contact with the non-bond face of the resistance layer.   
     
     
         2 . The coating of  claim 1 , wherein the vessel is at least one of a ship, an aircraft, a spacecraft, a rail-transport vehicle, and a land-based vehicle. 
     
     
         3 . The coating of  claim 1 , wherein the bonding layer comprises at least one of a metal and metal alloy, the resistance layer comprises at least one of a metal and metal alloy, and the sealant layer comprises at least one of a urethane-based sealant and an epoxy. 
     
     
         4 . The coating of  claim 1 , wherein the sealant layer comprises at least one of a urethane-based sealant and an epoxy. 
     
     
         5 . The coating of  claim 1 , wherein the sealant layer seals pores of the resistance layer. 
     
     
         6 . The coating of  claim 1 , wherein the resistance layer comprises at least one of a nickel-based alloy and an iron-based alloy. 
     
     
         7 . The coating of  claim 6 , wherein the iron-based alloy comprises a Fe 13Cr 0.5Si 0.5Ni 0.5Mn 0.35C composition. 
     
     
         8 . The coating of  claim 1 , wherein the resistance layer has a thickness range of about 0.1 mm to about 2 mm. 
     
     
         9 . The coating of  claim 1 , wherein the bonding layer comprises a nickel-based alloy. 
     
     
         10 . The coating of  claim 9 , wherein the nickel-based alloy has a composition selected from the group consisting of Ni 5Al composition, a Ni 20Al composition, a Ni 20Al 20Fe 4Cr composition, and combinations thereof. 
     
     
         11 . The coating of  claim 1 , wherein the bonding layer has a thickness ranging from about 0.02 mm to about 0.3 mm. 
     
     
         12 . The coating of  claim 1 , wherein the substrate is a cargo hold plate of an oceangoing vessel. 
     
     
         13 . The coating of  claim 1 , wherein the resistance layer comprises a Ni 16Mo 15.5Cr 5Fe 3.7W composition. 
     
     
         14 . A substrate arranged in or on a vessel having a multi-layer protective coating resistant to impact forces and corrosion, comprising:
 a thermal sprayed bonding layer that bonds to the substrate, wherein the bonding layer is formed on and in contact with a first side of a substrate from which contamination has been removed;   a resistance layer formed directly on and in contact with the bonding layer, wherein the resistance layer is structured to be resistant to the impact forces and corrosion caused by a corrosive environment in a vicinity of the substrate arranged in or on the vessel; and   a sealant layer formed directly on and in contact with the resistance layer for sealing pores of the resistance layer.   
     
     
         15 . The substrate of  claim 14 , wherein the resistance layer comprises at least one of a nickel-based alloy and an iron-based alloy. 
     
     
         16 . The substrate of  claim 14 , wherein the resistance layer comprises a Ni 16Mo 15.5Cr 5Fe 3.7W composition. 
     
     
         17 . A method of forming a multi-layer protective coating on a substrate arranged in or on a vessel, comprising the steps of:
 preparing a first substrate surface of the substrate by removing corroded surface material from the first substrate surface and roughening the first substrate surface;   thermal spraying a bonding layer on and in contact with the first substrate surface;   forming a resistance layer on and in contact with the bonding layer, the resistance layer being resistant to impact forces and corrosion caused by a corrosive environment in a vicinity of the substrate arranged in or one the vessel and comprising at least one of an iron-based alloy and a nickel-based alloy; and   forming a sealant layer on and in contact with the resistance layer, wherein the sealant layer penetrates pores of the resistance layer.   
     
     
         18 . The method of  claim 17 , wherein the substrate is a steel plate of a cargo hold of the vessel. 
     
     
         19 . The method of  claim 18 , wherein the vessel is at least one of a ship, an aircraft, a spacecraft, a rail-transport vehicle, and a land-based vehicle. 
     
     
         20 . The method of  claim 17 , wherein the forming of the resistance layer comprises forming the resistance layer with a thermal spray coating. 
     
     
         21 . The method of  claim 20 , wherein the thermal spray coating is formed with an electric wire arc spray system and the resistance layer comprises at least one of a nickel-based alloy and an iron-based alloy. 
     
     
         22 . The substrate of  claim 14 , wherein the substrate is a steel plate arranged in a cargo hold of the vessel. 
     
     
         23 . The substrate of  claim 14 , wherein the substrate is arranged in or on a vessel comprising least one of a ship, an aircraft, a spacecraft, a rail-transport vehicle, and a land-based vehicle. 
     
     
         24 . The coating of  claim 1 , wherein the resistance layer has a thickness range of about 0.5 mm to about 2 mm. 
     
     
         25 . The coating of  claim 1 , wherein the resistance layer has a thickness range of about 0.7 mm to about 1.1 mm.