In the workshop of a ship parts factory in Qingdao, quality inspector Xiao Li is frowning at the galvanized bolts that have just completed the 2,000-hour salt spray test - the surface of the samples treated by the traditional process is already covered with red rust, while Wuhan Bright Chemical Co., Ltd. The same batch of products of the new electroplating chemicals only showed sporadic white spots at the edges. This batch of goods is to be sent to a deep-sea drilling platform in Norway, and the other party requires that it must pass a 2,500-hour test. The factory director wiped his sweat and said. Three months later, when the test report showed "no red rust for 2,136 hours", the entire workshop was in an uproar - this was the first time the factory had broken through the 2,000-hour mark, and it also made Wuhan Bright's electroplating chemicals famous in the field of Marine engineering.
From the "72-hour passing line" to the "2,000-hour moat
The corrosion of metal fasteners in the Marine environment can be described as an "extreme test". High salt content, humidity, and large temperature differences. Traditional galvanized coatings usually turn red after less than 72 hours in salt spray tests. The R&D team of Wuhan Bright spent five years overcoming this difficult problem: its core composite corrosion inhibitor forms a dense protective film on the metal surface through a dual mechanism of "physical shielding + chemical passivation" - nitrogen and sulfur heterocycles in the molecular chain adsorb at the metal defects, blocking the erosion path of chloride ions. Meanwhile, nano-scale silica particles fill the pores, reducing the contact area with corrosive media by over 90%.
This technological breakthrough is directly reflected in the customer data. After a certain wind power equipment enterprise in Zhejiang used the galvanized intermediate of Wuhan Bright, the maintenance cycle of the offshore wind turbine bolts was extended from annual replacement to inspection every five years. After three years of service in the Bohai Bay, the corrosion rate of the steering shaft treated with its nickel-plated intermediate by Dalian Shipyard was only 1/8 of the industry average. "Previously, customers always said, 'How long can your products last?' Now they ask, 'Can they last a little longer?'" " Mr. Wang, the technical director of Wuhan Bright, said with a smile.
The "Marine adaptation Technique" of the three core intermediates
In response to the anti-corrosion requirements of different metal substrates, Wuhan Bright has launched three dedicated electroplating intermediates, all of which have been certified by Det Norske Veritas (DNV).
Electroplating Intermediates For Nickel Plating are specially designed for high-strength stainless steel fasteners. The organic phosphonate it contains can inhibit the grain boundary corrosion of the nickel layer. Combined with a special brightener, the coating can pass the 1500-hour salt spray test at a thickness of 0.05mm. After a nuclear power plant in Fujian adopted this product to treat valve bolts, it successfully solved the problem of coating peeling on nuclear-grade equipment.
Electroplating Intermediates For Zinc Plating focus on low-cost and highly efficient protection. By introducing rare earth elements for modification, a "micro-battery passivation zone" is formed in the ordinary galvanized layer, which enhances the anti-corrosion performance by three times. After being put into use by a certain container factory in Guangdong, the cost of galvanizing per container was reduced by 12%, but the salt spray test time was extended from 480 hours to 1800 hours.
Electroplating Intermediates For Copper Plating focus on the Marine adaptability of electronic components. The thiol compounds added to it can remove the oxide film on the surface of the copper layer. Combined with the carbon nanotube dispersion technology, the conductivity of the coating is increased by 20%, and the salt spray resistance time exceeds 1000 hours - which is crucial for the copper bar connection components in offshore wind power converters.
We even modified our customers' electroplating tanks. Engineer Wang recalled, "A certain client treated the offshore platform support with ordinary galvanizing solution, but the tests always failed to meet the standards." We adjusted the intermediate formula, reducing the chloride ion concentration in the tank opener from 120ppm to 30ppm. As a result, the salt spray time jumped directly from 800 hours to 2000 hours.
The ambition to shift from "selling medicine" to "selling solutions"
In the laboratory of Wuhan Bright, engineers are looking further into the future. Nowadays, what customers want is not just "no rust", but "knowing when it will rust". Engineer Wang pointed at the electroplating layer life prediction model on the computer and said. The company is developing smart electroplating chemicals. By embedding traceable fluorescent labels in the intermediates and combining them with big data analysis, it can accurately predict the corrosion rate of the coating in specific environments - "For instance, inform customers that the corrosion depth of this batch of bolts will reach 0.02mm after three years of service in the South China Sea, and it is recommended to replace them in advance."
This concept of "preventive preservation" has received a market response. Last year, Wuhan Bright signed a strategic cooperation agreement with China State Shipbuilding Corporation to provide full life-cycle electroplating chemical management services for its newly-built 100,000-ton cruise ships. "Previously, we sold 'medicine', but now we sell 'anti-corrosion insurance'." " General Manager Li of the company said, "When customers find out that using our products can keep the equipment running at sea for two more years, it is more effective than any advertisement."
At present, the electroplating chemicals of Wuhan Bright have been applied in more than 300 Marine engineering projects worldwide, serving international giants such as Siemens Gamesa and Samsung Heavy Industries. Its galvanized intermediates have a market share of 28% in Southeast Asia, while its nickel plating intermediates hold a 35% share in the European offshore wind power sector.
Our ultimate goal is to make metals "immortal" in the ocean. Looking at the slogan "Zero Tolerance for Corrosion" on the laboratory wall, Mr. Li said, "Perhaps one day, people will forget the word 'rust prevention' - because metals themselves do not rust."
