Heat exchangers corrosion protection by using organic coatings

Corrosion phenomena in aluminium heat exchangers represent a problem in terms of durability and efficiency of thermal exchange. This work evaluates the barrier properties of two coatings that represent the state of the art for the protection in the heat, ventilating, air conditioning/refrigerating field (HVAC/R): electrophoretic coating (E-coating) using epoxy resin and spraying of polyurethane coating with addition of metallic pigments. The ability of the coatings to cover the surface of heat exchanger has been evaluated by means of optical microscopy in order to highlight critical zones of the system for the application of the coatings. The electrochemical behaviour of coated heat exchangers has been studied by means of electrochemical impedance spectroscopy in 3.5% NaCl solution. The local electrochemical behaviour of coating defects has been investigated using the electrochemical micro-cell, which enables to perform potentiodynamic polarization measurements on single defects. E-coatings evidenced difficulties to provide uniform thickness of the coating at the extremities of the fins. Spraying of the polyurethane coating containing pigments require particular care in order to fully cover zones of the heat exchanger with difficult accessibility. The electrochemical behaviour of coated heat exchangers is affected by the existence of defects in the coatings.