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Friday, October 6, 2023

Double Asteroid Redirection Test

From Wikipedia, the free encyclopedia
Double Asteroid Redirection Test
Diagram of the DART spacecraft striking Dimorphos
NamesDART

Mission typePlanetary defense mission
OperatorNASA  / APL
COSPAR ID2021-110A
SATCAT no.49497
Website
Mission duration
10 months and 1 day

Spacecraft properties
Spacecraft
ManufacturerApplied Physics Laboratory
of Johns Hopkins University
Launch mass
  • DART: 610 kg (1,340 lb)
  • LICIACube: 14 kg (31 lb)
Dimensions
  • DART: 1.8 × 1.9 × 2.6 m (5 ft 11 in × 6 ft 3 in × 8 ft 6 in)
  • ROSA: 8.5 × 2.4 m (27.9 × 7.9 ft) (each)
Power6.6 kW

Start of mission
Launch date24 November 2021, 06:21:02 UTC
RocketFalcon 9 Block 5, B1063.3
Launch siteVandenberg, SLC-4E
ContractorSpaceX
Dimorphos impactor
Impact date26 September 2022, 23:14 UTC
Flyby of Didymos system
Spacecraft componentLICIACube (deployed from DART)
Closest approach26 September 2022, ~23:17 UTC
Distance56.7 km (35.2 mi)
Instruments
Didymos Reconnaissance and Asteroid Camera for Optical navigation (DRACO)

DART mission patch

Double Asteroid Redirection Test (DART) was a NASA space mission aimed at testing a method of planetary defense against near-Earth objects (NEOs). It was designed to assess how much a spacecraft impact deflects an asteroid through its transfer of momentum when hitting the asteroid head-on. The selected target asteroid, Dimorphos, is a minor-planet moon of the asteroid Didymos; neither asteroid poses an impact threat to Earth. Launched on 24 November 2021, the DART spacecraft successfully collided with Dimorphos on 26 September 2022 at 23:14 UTC about 11 million kilometers (6.8 million miles) from Earth. The collision shortened Dimorphos' orbit by 32 minutes, greatly in excess of the pre-defined success threshold of 73 seconds. DART's success in deflecting Dimorphos was due to the momentum transfer associated with the recoil of the ejected debris, which was substantially larger than that caused by the impact itself.

DART was a joint project between NASA and the Johns Hopkins Applied Physics Laboratory. The project was funded through NASA's Planetary Defense Coordination Office, managed by NASA's Planetary Missions Program Office at the Marshall Space Flight Center, and several NASA laboratories and offices provided technical support. The Italian Space Agency contributed LICIACube, a CubeSat which photographed the impact event, and other international partners, such as the European Space Agency (ESA), and Japan Aerospace Exploration Agency (JAXA), are contributing to related or subsequent projects.

Mission history

NASA and the European Space Agency (ESA) started with individual plans for missions to test asteroid deflection strategies, but by 2015, they struck a collaboration called AIDA (Asteroid Impact and Deflection Assessment) involving two separate spacecraft launches that would work in synergy. Under that proposal, the European Asteroid Impact Mission (AIM), would have launched in December 2020, and DART in July 2021. AIM would have orbited the larger asteroid to study its composition and that of its moon. DART would then kinetically impact the asteroid's moon on 26 September 2022, during a close approach to Earth.

The AIM orbiter was however canceled, then replaced by Hera which plans to start observing the asteroid four years after the DART impact. Live monitoring of the DART impact thus had to be obtained from ground-based telescopes and radar.

In June 2017, NASA approved a move from concept development to the preliminary design phase, and in August 2018 the start of the final design and assembly phase of the mission. On 11 April 2019, NASA announced that a SpaceX Falcon 9 would be used to launch DART.

Satellite impact on a small solar system body had already been implemented once, by NASA's 372 kg (820 lb) Deep Impact space probe's impactor spacecraft and for a completely different purpose (analysis of the structure and composition of a comet). On impact, Deep Impact released 19 gigajoules of energy (the equivalent of 4.8 tons of TNT), and excavated a crater up to 150 m (490 ft) wide.

Description

Spacecraft

The DART spacecraft was an impactor with a mass of 610 kg (1,340 lb) that hosted no scientific payload and had sensors only for navigation. The spacecraft cost US$330 million by the time it collided with Dimorphos in 2022.

Camera

DRACO camera

DART's navigation sensors included a sun sensor, a star tracker called SMART Nav software (Small-body Maneuvering Autonomous Real Time Navigation), and a 20 cm (7.9 in) aperture camera called Didymos Reconnaissance and Asteroid Camera for Optical navigation (DRACO). DRACO was based on the Long Range Reconnaissance Imager (LORRI) onboard New Horizons spacecraft, and supported autonomous navigation to impact the asteroid's moon at its center. The optical part of DRACO was a Ritchey-Chrétien telescope with a field of view of 0.29° and a focal length of 2.6208 m (f/12.60). The spatial resolution of the images taken immediately before the impact was around 20 centimeters per pixel. The instrument had a mass of 8.66 kg (19.1 lb).

The detector used in the camera was a CMOS image sensor measuring 2,560 × 2,160 pixels. The detector records the wavelength range from 0.4 to 1 micron (visible and near infrared). A commercial off-the-shelf CMOS detector was used instead of a custom charge-coupled device in LORRI. DRACO's detector performance actually met or exceeded that of LORRI because of the improvements in sensor technology in the decade separating the design of LORRI and DRACO. Fed into an onboard computer with software descended from anti-missile technology, the DRACO images helped DART autonomously guide itself to its crash.

Solar arrays

The spacecraft's solar arrays used a Roll Out Solar Array (ROSA) design, that was tested on the International Space Station (ISS) in June 2017 as part of Expedition 52.

Using ROSA as the structure, a small portion of the DART solar array was configured to demonstrate Transformational Solar Array technology, which has very-high-efficiency SolAero Inverted Metamorphic (IMM) solar cells and reflective concentrators providing three times more power than current other solar array technology.

Antenna

The DART spacecraft was the first spacecraft to use a new type of high-gain communication antenna, a Spiral Radial Line Slot Array (RLSA). The circularly-polarized antenna operated at the X-band NASA Deep Space Network (NASA DSN) frequencies of 7.2 and 8.4 GHz, and had a gain of 29.8 dBi on downlink and 23.6 dBi on uplink. The fabricated antenna in a flat and compact shape exceeded the given requirements and was tested through environments resulting in a TRL-6 design.

NASA's Evolutionary Xenon Thruster (NEXT)

Ion thruster

DART demonstrated the NEXT gridded ion thruster, a type of solar electric propulsion. It was powered by 22 m2 (240 sq ft) solar arrays to generate the ~3.5 kW needed to power the NASA Evolutionary Xenon Thruster–Commercial (NEXT-C) engine. Early tests of the ion thruster revealed a reset mode that induced higher current (100 A) in the spacecraft structure than expected (25 A). It was decided not to use the ion thruster further as the mission could be accomplished without it, using conventional thrusters fueled by the 110 pounds of hydrazine onboard. However, the ion thrusters remained available if needed to deal with contingencies, and had DART missed its target, the ion system could have returned DART to Dimorphos two years later.

Secondary spacecraft

LICIACube CubeSat, a companion satellite of the DART spacecraft

The Italian Space Agency (ASI) contributed a secondary spacecraft called LICIACube (Light Italian CubeSat for Imaging of Asteroids), a small CubeSat that piggybacked with DART and separated on 11 September 2022, 15 days before impact. It acquired images of the impact and ejecta as it drifted past the asteroid. LICIACube communicated directly with Earth, sending back images of the ejecta after the Dimorphos flyby. LICIACube is equipped with two optical cameras, dubbed LUKE and LEIA.

Effect of the impact on Dimorphos and Didymos

The spacecraft hit Dimorphos in the direction opposite to the asteroid's motion. Following the impact, the instantaneous orbital speed of Dimorphos therefore dropped slightly, which reduced the radius of its orbit around Didymos. The trajectory of Didymos was also modified, but in inverse proportion to the ratio of its mass to the much lower mass of Dimorphos. The actual velocity change and orbital shift depended on the topography and composition of the surface, among other things. The contribution of the recoil momentum from the impact ejecta produces a poorly predictable "momentum enhancement" effect. Before the impact, the momentum transferred by DART to the largest remaining fragment of the asteroid was estimated as up to 3–5 times the incident momentum, depending on how much and how fast material would be ejected from the impact crater. Obtaining accurate measurements of that effect was one of the mission's main goals and will help refine models of future impacts on asteroids.

The DART impact excavated surface/subsurface materials of Dimorphos, leading to the formation of a crater and/or some magnitude of reshaping (i.e., shape change without significant mass loss). Some of the ejecta may eventually hit Didymos's surface. If the kinetic energy delivered to its surface was high enough, reshaping may have also occur in Didymos, given its near-rotational-breakup spin rate. Reshaping on either body would have modified their mutual gravitational field, leading to a reshaping-induced orbital period change, in addition to the impact-induced orbital period change. If left unaccounted for, this could later have led to an erroneous interpretation of the effect of the kinetic deflection technique.

Observations of the impact

Telescopes observing DART's impact
SOAR telescope shows the vast plume of dust and debris blasted from the surface of the asteroid Dimorphos

DART's companion LICIACube, the Hubble and James Webb space telescopes, and the Earth-based ATLAS observatory all detected the ejecta plume from the DART impact. On September 26, SOAR observed the visible impact trail to be over 10,000 km long. Initial estimates of the change in binary orbit period were expected within a week and with the data released by LICIACube. DART's mission science depends on careful Earth-based monitoring of the orbit of Dimorphos over the subsequent days and months. Dimorphos was too small and too close to Didymos for almost any observer to see directly, but its orbital geometry is such that it transits Didymos once each orbit and then passes behind it half an orbit later. Any observer that can detect the Didymos system therefore sees the system dim and brighten again as the two bodies cross. The impact was planned for a moment when the distance between Didymos and Earth is at a minimum, permitting many telescopes to make observations from many locations. The asteroid will be near opposition and visible high in the night sky into 2023. The change in Dimorphos's orbit around Didymos was detected by optical telescopes watching mutual eclipses of the two bodies through photometry on the Dimorphos-Didymos pair. In addition to radar observations, they confirmed that the impact shortened Dimorphos' orbital period by 32 minutes. Based on the shortened binary orbital period, the instantaneous reduction in Dimorphos' velocity component along its orbital track was determined, which indicated that substantially more momentum was transferred to Dimorphos from the escaping impact ejecta than from the impact itself. In this way, the DART kinetic impact was highly effective in deflecting Dimorphos.

Follow-up mission

In a collaborating project, the European Space Agency is developing Hera, a spacecraft that will be launched to Didymos in 2024 and arrive in 2026. (5 years after DART's impact), to do a detailed reconnaissance and assessment. Hera would carry two CubeSats, Milani and Juventas.

AIDA mission architecture


Host spacecraft Secondary spacecraft Remarks
DART LICIACube
  • By the Italian Space Agency
  • 6U CubeSat
  • LUKE (LICIACube Unit Key Explorer) Camera and LEIA (LICIACube Explorer Imaging for Asteroid) Camera
Hera Juventas
  • By GomSpace and GMV
  • 6U CubeSat orbiter
  • Camera, JuRa monostatic low-frequency radar, accelerometers, and gravimeter
  • Will attempt to land on the asteroid surface
Milani
  • By Italy/Czech/Finnish consortium
  • 6U CubeSat orbiter
  • VIS/Near-IR spectrometer, volatile analyzer
  • Will characterize Didymos and Dimorphos surface composition and the dust environment around the system
  • Will perform technology demonstration experiments
SCI

Mission profile

Target asteroid

Pre-impact shape model of Didymos and its satellite Dimorphos, based on photometric light curve and radar data

The mission's target was Dimorphos in 65803 Didymos system, a binary asteroid system in which one asteroid is orbited by a smaller one. The primary asteroid (Didymos A) is about 780 m (2,560 ft) in diameter; the asteroid moon Dimorphos (Didymos B) is about 160 m (520 ft) in diameter in an orbit about 1 km (0.62 mi) from the primary. The mass of the Didymos system is estimated at 528 billion kg, with Dimorphos comprising 4.8 billion kg of that total. Choosing a binary asteroid system is advantageous because changes to Dimorphos's velocity can be measured by observing when Dimorphos subsequently passes in front of its companion, causing a dip in light that can be seen by Earth telescopes. Dimorphos was also chosen due to its appropriate size; it is in the size range of asteroids that one would want to deflect, were they on a collision course with Earth. In addition, the binary system was relatively close to the Earth in 2022, at about 11 million km (7 million mi). The Didymos system is not an Earth-crossing asteroid, and there is no possibility that the deflection experiment could create an impact hazard. On 4 October 2022, Didymos made an Earth approach of 10.6 million km (6.6 million mi).

Preflight preparations

DART being encapsulated in the Falcon 9 payload fairing on 16 November 2021

Launch preparations for DART began on 20 October 2021, as the spacecraft began fueling at Vandenberg Space Force Base (VSFB) in California. The spacecraft arrived at Vandenberg in early October 2021 after a cross-country drive. DART team members prepared the spacecraft for flight, testing the spacecraft's mechanisms and electrical system, wrapping the final parts in multilayer insulation blankets and practicing the launch sequence from both the launch site and the mission operations center at APL. DART headed to the SpaceX Payload Processing Facility on VSFB on 26 October 2021. Two days later, the team received the green light to fill DART's fuel tank with roughly 50 kg (110 lb) of hydrazine propellant for spacecraft maneuvers and attitude control. DART also carried about 60 kg (130 lb) of xenon for the NEXT-C ion engine. Engineers loaded the xenon before the spacecraft left APL in early October 2021.

Starting on 10 November 2021, engineers mated the spacecraft to the adapter that stacks on top of the SpaceX Falcon 9 launch vehicle. The Falcon 9 rocket without the payload fairing rolled for a static fire and later came back to the processing facility again where technicians with SpaceX installed the two halves of the fairing around the spacecraft over the course of two days, 16 and 17 November, inside the SpaceX Payload Processing Facility at Vandenberg Space Force Base and the ground teams completed a successful Flight Readiness Review later that week with the fairing then attached to the rocket.

A day before launch, the launch vehicle rolled out of the hangar and onto the launch pad at Vandenberg Space Launch Complex 4 (SLC-4E); from there, it lifted off to begin DART's journey to the Didymos system and it propelled the spacecraft into space.

Launch

Liftoff of Falcon 9 with DART.
 
DART separation from second stage

The DART spacecraft was launched on 24 November 2021, at 06:21:02 UTC.

Early planning suggested that DART was to be deployed into a high-altitude, high-eccentricity Earth orbit designed to avoid the Moon. In such a scenario, DART would use its low-thrust, high-efficiency NEXT ion engine to slowly escape from its high Earth orbit to a slightly inclined near-Earth solar orbit, from which it would maneuver onto a collision trajectory with its target. But because DART was launched as a dedicated Falcon 9 mission, the payload along with Falcon 9's second stage was placed directly on an Earth escape trajectory and into heliocentric orbit when the second stage reignited for a second engine startup or escape burn. Thus, although DART carries a first-of-its-kind electric thruster and plenty of xenon fuel, Falcon 9 did almost all of the work, leaving the spacecraft to perform only a few trajectory-correction burns with simple chemical thrusters as it homed in on Didymos's moon Dimorphos.

Transit

Animation of DART's trajectory
  DART ·   65803 Didymos ·   Earth ·   Sun ·   2001 CB21 ·   3361 Orpheus

The transit phase before impact lasted about 9 months. During its interplanetary travel, the DART spacecraft made a distant flyby of the 578-meter-diameter near-Earth asteroid (138971) 2001 CB21 in March 2022. DART passed 0.117 AU (17.5 million km; 10.9 million mi) from 2001 CB21 in its closest approach on 2 March 2022.

DART's DRACO camera opened its aperture door and took its first light image of some stars on 7 December 2021, when it was 3 million km (2 million mi) away from Earth. The stars in DRACO's first light image were used as calibration for the camera's pointing before it could be used to image other targets. On 10 December 2021, DRACO imaged the open cluster Messier 38 for further optical and photometric calibration.

On 27 May 2022, DART observed the bright star Vega with DRACO to test the camera's optics with scattered light. On 1 July and 2 August 2022, DART's DRACO imager observed Jupiter and its moon Europa emerging from behind the planet, as a performance test for the SMART Nav tracking system to prepare for the Dimorphos impact.

Course of the impact

Animation of DART around Didymos - Impact on Dimorphos
  DART ·   Didymos ·   Dimorphos

Two months before the impact, on 27 July 2022, the DRACO camera detected the Didymos system from approximately 32 million km (20 million mi) away and started refining its trajectory. The LICIACube nanosatellite was released on 11 September 2022, 15 days before the impact. Four hours before impact, some 90,000 km (56,000 mi) away, DART began to operate in complete autonomy under control of its SMART Nav guidance system. Three hours before impact, DART performed an inventory of objects near the target. Ninety minutes before the collision, when DART was 38,000 km (24,000 mi) away from Dimorphos, the final trajectory was established. When DART was 24,000 km (15,000 mi) away Dimorphos became discernible (1.4 pixels) through the DRACO camera which then continued to capture images of the asteroid's surface and transmit them in real-time.

DRACO was the only instrument able to provide a detailed view of Dimorphos' surface. The use of DART's thrusters caused vibrations throughout the spacecraft and solar panels, resulting in blurred images. To ensure sharp images, the last trajectory correction was executed 4 minutes before impact and the thrusters were deactivated afterwards.

The last full image, transmitted two seconds before impact, has a spatial resolution of about 3 centimeters per pixel. The impact took place on 26 September 2022, at 23:14 UTC.

The head-on impact of the 500 kg (1,100 lb) DART spacecraft at 6.6 km/s (4.1 mi/s) likely imparted an energy of about 11 gigajoules, the equivalent of about three tonnes of TNT, and was expected to reduce the orbital velocity of Dimorphos between 1.75 cm/s and 2.54 cm/s, depending on numerous factors such as material porosity. The reduction in Dimorphos's orbital velocity brings it closer to Didymos, resulting in the moon experiencing greater gravitational acceleration and thus a shorter orbital period. The orbital period reduction from the head-on impact serves to facilitate ground-based observations of Dimorphos. An impact to the asteroid's trailing side would instead increase its orbital period towards 12 hours and make it coincide with Earth's day and night cycle, which would limit any single ground-based telescope from observing all orbital phases of Dimorphos nightly.

DART impact and its corresponding plume as seen by using the Mookodi instrument on the SAAO's 1-m Lesedi telescope

The measured momentum enhancement factor (called beta) of DART's impact of Dimorphos was 3.6, which means that the impact transferred roughly 3.6 times greater momentum than if the asteroid had simply absorbed the spacecraft and produced no ejecta at all – indicating the ejecta contributed more to moving the asteroid than the spacecraft did. This means one could use either a smaller impactor or shorter lead times for the same deflection. The value of beta depends on various factors, composition, density, porosity, etc. The goal is to use these results and modeling to infer what beta could be for another asteroid by observing its surface and possibly measuring its bulk density. Scientists estimate that DART’s impact displaced over 1,000,000 kg (2,200,000 lb) of dusty ejecta into space – enough to fill six or seven rail cars. The tail of ejecta from Dimorphos created by the DART impact is at least 30,000 km (19,000 mi) long with a mass of at least 1,000 t (980 long tons; 1,100 short tons), and possibly up to 10 times that much.

Footprint of DART spacecraft over the spot where it impacted asteroid Dimorphos

The DART impact on the center of Dimorphos decreased the orbital period, previously 11.92 hours, by 33±1 minutes. This large change indicates the recoil from material excavated from the asteroid and ejected into space by the impact (known as ejecta) contributed significant momentum change to the asteroid, beyond that of the DART spacecraft itself. Researchers found the impact caused an instantaneous slowing in Dimorphos' speed along its orbit of about 2.7 millimeters per second — again indicating the recoil from ejecta played a major role in amplifying the momentum change directly imparted to the asteroid by the spacecraft. That momentum change was amplified by a factor of 2.2 to 4.9 (depending on the mass of Dimorphos), indicating the momentum change transferred because of ejecta production significantly exceeded the momentum change from the DART spacecraft alone. While the orbital change was small, the change is in the velocity and over the course of years will accumulate to a large change in position. For a hypothetical Earth-threatening body, even such a tiny change could be sufficient to mitigate or prevent an impact, if applied early enough. As the diameter of Earth is around 13,000 kilometers, a hypothetical asteroid impact could be avoided with as little of a shift as half of that (6,500 kilometers). A 2 cm/s velocity change accumulates to that distance in approximately 10 years.

By smashing into the asteroid DART made Dimorphos an active asteroid. Scientists had proposed that some active asteroids are the result of impact events, but no one had ever observed the activation of an asteroid. The DART mission activated Dimorphos under precisely known and carefully observed impact conditions, enabling the detailed study of the formation of an active asteroid for the first time. Observations show that Dimorphos lost approximately 1 million kilograms of mass as a result of the collision.

Sequence of operations for impact

Date
(before impact)
Distance from
Dimorphos
Raw image Events
27 July 2022
(T-60 days)
38,000,000 km (24,000,000 mi)
The DRACO camera detects the Didymos system.
11 September 2022
23:14 UTC
(T-15 days)
8,000,000 km (5,000,000 mi)
Ejection of LICIACube, which maneuvers to avoid crashing into the asteroid.
26 September 2022
19:14 UTC
(T-4 hours)
89,000 km (55,000 mi)
Terminal phase—start of autonomous navigation with SMART Nav. DRACO locks onto Didymos since Dimorphos is not visible yet.
22:14 UTC
(T-60 minutes)
22,000 km (14,000 mi)
The DRACO camera detects Dimorphos.
22:54 UTC
(T-20 minutes)
7,500 km (4,700 mi)
SMART Nav enters precision lock onto Dimorphos and DART begins thrusting toward Dimorphos.
23:10 UTC
(T-4 minutes)
1,500 km (930 mi)
Start of final course correction
23:11 UTC
(T-2 minutes 30 seconds)
920 km (570 mi)
Last image with both Didymos (lower-left) and Dimorphos entirely in frame is taken
23:12 UTC
(T-2 minutes)
740 km (460 mi)
End of final course correction
23:14 UTC
(T-20 seconds)
130 km (81 mi)
The photos taken reach the expected spatial resolution.
23:14 UTC
(T-11 seconds)
68 km (42 mi)
Last image showing all of Dimorphos by DART
23:14 UTC
(T-3 seconds)
18 km (11 mi)

23:14 UTC
(T-2 seconds)
12 km (7.5 mi)
Final complete image of Dimorphos transmitted. Resolution roughly 3 cm per pixel (~ 30m across).
23:14 UTC
(T-1 second)
6 km (3.7 mi)
Last partial image taken by DART before impact, transmission of the image was interrupted by the destruction of the spacecraft and all of its transmitting hardware. Resolution per pixel to be determined at a later date by analysis of image and timing.
23:14 UTC
(T-0)
0 km (0 mi)
Impact Dimorphos (estimated impact velocity 6 kilometers/second)
23:17 UTC
(T+2 min 45 s)
56.7 km (35.2 mi)
Closest approach to Dimorphos by LICIACube.

Gallery

Coating

From Wikipedia, the free encyclopedia

A coating is a covering that is applied to the surface of an object, usually referred to as the substrate. The purpose of applying the coating may be decorative, functional, or both. Coatings may be applied as liquids, gases or solids e.g. Powder coatings.

Paints and lacquers are coatings that mostly have dual uses of protecting the substrate and being decorative, although some artists paints are only for decoration, and the paint on large industrial pipes is for preventing corrosion and identification e.g. blue for process water, red for fire-fighting control. Functional coatings may be applied to change the surface properties of the substrate, such as adhesion, wettability, corrosion resistance, or wear resistance. In other cases, e.g. semiconductor device fabrication (where the substrate is a wafer), the coating adds a completely new property, such as a magnetic response or electrical conductivity, and forms an essential part of the finished product.

A major consideration for most coating processes is that the coating is to be applied at a controlled thickness, and a number of different processes are in use to achieve this control, ranging from a simple brush for painting a wall, to some very expensive machinery applying coatings in the electronics industry. A further consideration for 'non-all-over' coatings is that control is needed as to where the coating is to be applied. A number of these non-all-over coating processes are printing processes. Many industrial coating processes involve the application of a thin film of functional material to a substrate, such as paper, fabric, film, foil, or sheet stock. If the substrate starts and ends the process wound up in a roll, the process may be termed "roll-to-roll" or "web-based" coating. A roll of substrate, when wound through the coating machine, is typically called a web.

Applications

Coating applications are diverse and serve many purposes. Coatings can be both decorative and have other functions. A pipe carrying water for a fire suppression system can be coated with a red (for identification) anticorrosion paint. Most coatings to some extent protect the substrate, such as maintenance coatings for metals and concrete. A decorative coating can offer a particular reflective property, such as high gloss, satin, or a flat or matte appearance.

A major coating application is to protect metal from corrosion. This use includes preserving machinery, equipment, and structures. Most automobiles are made of metal. The body and underbody are typically coated with underbody coating. Anticorrosion coatings may use graphene in combination with water-based epoxies.

Coatings are used to seal the surface of concrete, such as seamless polymer/resin flooring, bund wall/containment lining, waterproofing and damp proofing concrete walls, and bridge decks.

Roof coatings are designed primarily for waterproofing and sun reflection to reduce heating. They tend to be elastomeric to allow for movement of the roof without cracking the coating membrane.

The coating, sealing, and waterproofing of wood have been going on since biblical times, with God commanding Noah to build an ark and then coat it. Wood has been a key material in construction since ancient times, so its preservation by coating has received much attention. Efforts to improve the performance of wood coatings continue.

Automotive coatings are used to enhance the appearance and durability of vehicles. These coatings include primers, basecoats, and clearcoats, and they are applied using various techniques, including electrostatic and spray gun applications.

Coatings are used to alter tribological properties and wear characteristics. Other functions of coatings include:

Analysis and characterization

Numerous destructive and non-destructive evaluation (NDE) methods exist for characterizing coatings. The most common destructive method is microscopy of a mounted cross-section of the coating and its substrate. The most common non-destructive techniques include ultrasonic thickness measurement, X-ray fluorescence (XRF), X-Ray diffraction (XRD) and micro hardness indentation. X-ray photoelectron spectroscopy (XPS) is also a classical characterization method to investigate the chemical composition of the nanometer thick surface layer of a material. Scanning electron microscopy coupled with energy dispersive X-ray spectrometry (SEM-EDX, or SEM-EDS) allows to visualize the surface texture and to probe its elementary chemical composition. Other characterization methods include transmission electron microscopy (TEM), atomic force microscopy (AFM), scanning tunneling microscope (STM), and Rutherford backscattering spectrometry (RBS). Various methods of Chromatography are also used, as well as thermogravimetric analysis.

Formulation

The formulation of a coating depends primarily on the function required of the coating and also on aesthetics required such as color and gloss. The four primary ingredients are the resin (or binder), solvent which maybe water (or solventless), pigment(s) and additives. Research is ongoing to remove heavy metals from coating formulations completely.

Processes

Coating processes may be classified as follows:

Vapor deposition

Chemical vapor deposition

Physical vapor deposition

Chemical and electrochemical techniques

Spraying

Roll-to-roll coating processes

Common roll-to-roll coating processes include:

  • Air knife coating
  • Anilox coater
  • Flexo coater
  • Gap Coating
    • Knife-over-roll coating
  • Gravure coating
  • Hot melt coating- when the necessary coating viscosity is achieved by temperature rather than solution of the polymers etc. This method commonly implies slot-die coating above room temperature, but it also is possible to have hot-melt roller coating; hot-melt metering-rod coating, etc.
  • Immersion dip coating
  • Kiss coating
  • Metering rod (Meyer bar) coating
  • Roller coating
  • Silk Screen coater
    • Rotary screen
  • Slot Die coating - Slot die coating was originally developed in the 1950s. Slot die coating has a low operational cost and is an easily scaled processing technique for depositing thin and uniform films rapidly, while minimizing material waste. Slot die coating technology is used to deposit a variety of liquid chemistries onto substrates of various materials such as glass, metal, and polymers by precisely metering the process fluid and dispensing it at a controlled rate while the coating die is precisely moved relative to the substrate. The complex inner geometry of conventional slot dies require machining or can be accomplished with 3-D printing.
  • Extrusion coating - generally high pressure, often high temperature, and with the web travelling much faster than the speed of the extruded polymer
    • Curtain coating- low viscosity, with the slot vertically above the web and a gap between slot-die and web.
    • Slide coating- bead coating with an angled slide between the slot-die and the bead. Commonly used for multilayer coating in the photographic industry.
    • Slot die bead coating- typically with the web backed by a roller and a very small gap between slot-die and web.
    • Tensioned-web slot-die coating- with no backing for the web.
  • Inkjet printing
  • Lithography
  • Flexography

Physical

Rust

From Wikipedia, the free encyclopedia
Colors and porous surface texture of rust

Rust is an iron oxide, a usually reddish-brown oxide formed by the reaction of iron and oxygen in the catalytic presence of water or air moisture. Rust consists of hydrous iron(III) oxides (Fe2O3·nH2O) and iron(III) oxide-hydroxide (FeO(OH), Fe(OH)3), and is typically associated with the corrosion of refined iron.

Given sufficient time, any iron mass, in the presence of water and oxygen, could eventually convert entirely to rust. Surface rust is commonly flaky and friable, and provides no passivational protection to the underlying iron, unlike the formation of patina on copper surfaces. Rusting is the common term for corrosion of elemental iron and its alloys such as steel. Many other metals undergo similar corrosion, but the resulting oxides are not commonly called "rust".

Several forms of rust are distinguishable both visually and by spectroscopy, and form under different circumstances. Other forms of rust include the result of reactions between iron and chloride in an environment deprived of oxygen. Rebar used in underwater concrete pillars, which generates green rust, is an example. Although rusting is generally a negative aspect of iron, a particular form of rusting, known as stable rust, causes the object to have a thin coating of rust over the top. If kept in low relative humidity, it makes the "stable" layer protective to the iron below, but not to the extent of other oxides such as aluminium oxide on aluminium.

Chemical reactions

Heavy rust on the links of a chain near the Golden Gate Bridge in San Francisco; it was continuously exposed to moisture and salt spray, causing surface breakdown, cracking, and flaking of the metal
Rust scale forming and flaking off from a steel bar heated to its forging temperature of 1200°C. Rapid oxidation occurs when heated steel is exposed to air

Rust is a general name for a complex of oxides and hydroxides of iron, which occur when iron or some alloys that contain iron are exposed to oxygen and moisture for a long period of time. Over time, the oxygen combines with the metal, forming new compounds collectively called rust, in a process called rusting. Rusting is an oxidation reaction specifically occurring with iron. Other metals also corrode via similar oxidation, but such corrosion is not called rusting.

The main catalyst for the rusting process is water. Iron or steel structures might appear to be solid, but water molecules can penetrate the microscopic pits and cracks in any exposed metal. The hydrogen atoms present in water molecules can combine with other elements to form acids, which will eventually cause more metal to be exposed. If chloride ions are present, as is the case with saltwater, the corrosion is likely to occur more quickly. Meanwhile, the oxygen atoms combine with metallic atoms to form the destructive oxide compound. These iron compounds are brittle and crumbly and replace strong metallic iron, reducing the strength of the object.

Oxidation of iron

When iron is in contact with water and oxygen, it rusts.[5] If salt is present, for example in seawater or salt spray, the iron tends to rust more quickly, as a result of chemical reactions. Iron metal is relatively unaffected by pure water or by dry oxygen. As with other metals, like aluminium, a tightly adhering oxide coating, a passivation layer, protects the bulk iron from further oxidation. The conversion of the passivating ferrous oxide layer to rust results from the combined action of two agents, usually oxygen and water.

Other degrading solutions are sulfur dioxide in water and carbon dioxide in water. Under these corrosive conditions, iron hydroxide species are formed. Unlike ferrous oxides, the hydroxides do not adhere to the bulk metal. As they form and flake off from the surface, fresh iron is exposed, and the corrosion process continues until either all of the iron is consumed or all of the oxygen, water, carbon dioxide or sulfur dioxide in the system are removed or consumed.

When iron rusts, the oxides take up more volume than the original metal; this expansion can generate enormous forces, damaging structures made with iron. See economic effect for more details.

Associated reactions

The rusting of iron is an electrochemical process that begins with the transfer of electrons from iron to oxygen. The iron is the reducing agent (gives up electrons) while the oxygen is the oxidizing agent (gains electrons). The rate of corrosion is affected by water and accelerated by electrolytes, as illustrated by the effects of road salt on the corrosion of automobiles. The key reaction is the reduction of oxygen:

O2 + 4 e + 2 H2O → 4 OH

Because it forms hydroxide ions, this process is strongly affected by the presence of acid. Likewise, the corrosion of most metals by oxygen is accelerated at low pH. Providing the electrons for the above reaction is the oxidation of iron that may be described as follows:

Fe → Fe2+ + 2 e

The following redox reaction also occurs in the presence of water and is crucial to the formation of rust:

4 Fe2+ + O2 → 4 Fe3+ + 2 O2−

In addition, the following multistep acid–base reactions affect the course of rust formation:

Fe2+ + 2  H2O ⇌ Fe(OH)2 + 2 H+
Fe3+ + 3  H2O ⇌ Fe(OH)3 + 3 H+

as do the following dehydration equilibria:

Fe(OH)2 ⇌ FeO + H2O
Fe(OH)3 ⇌ FeO(OH) + H2O
2 FeO(OH) ⇌ Fe2O3 + H2O

From the above equations, it is also seen that the corrosion products are dictated by the availability of water and oxygen. With limited dissolved oxygen, iron(II)-containing materials are favoured, including FeO and black lodestone or magnetite (Fe3O4). High oxygen concentrations favour ferric materials with the nominal formulae Fe(OH)3−xOx2. The nature of rust changes with time, reflecting the slow rates of the reactions of solids.

Furthermore, these complex processes are affected by the presence of other ions, such as Ca2+, which serve as electrolytes which accelerate rust formation, or combine with the hydroxides and oxides of iron to precipitate a variety of Ca, Fe, O, OH species.

The onset of rusting can also be detected in the laboratory with the use of ferroxyl indicator solution. The solution detects both Fe2+ ions and hydroxyl ions. Formation of Fe2+ ions and hydroxyl ions are indicated by blue and pink patches respectively.

Prevention

Cor-Ten is a group of steel alloys which were developed to eliminate the need for painting, and form a stable rust-like appearance after several years' exposure to weather.

Because of the widespread use and importance of iron and steel products, the prevention or slowing of rust is the basis of major economic activities in a number of specialized technologies. A brief overview of methods is presented here; for detailed coverage, see the cross-referenced articles.

Rust is permeable to air and water, therefore the interior metallic iron beneath a rust layer continues to corrode. Rust prevention thus requires coatings that preclude rust formation.

Rust-resistant alloys

Stainless steel forms a passivation layer of chromium(III) oxide. Similar passivation behavior occurs with magnesium, titanium, zinc, zinc oxides, aluminium, polyaniline, and other electroactive conductive polymers.

Cor-Ten sheet with rust coating

Special "weathering steel" alloys such as Cor-Ten rust at a much slower rate than normal, because the rust adheres to the surface of the metal in a protective layer. Designs using this material must include measures that avoid worst-case exposures since the material still continues to rust slowly even under near-ideal conditions.

Galvanization

Interior rust in old galvanized iron water pipes can result in brown and black water

Galvanization consists of an application on the object to be protected of a layer of metallic zinc by either hot-dip galvanizing or electroplating. Zinc is traditionally used because it is cheap, adheres well to steel, and provides cathodic protection to the steel surface in case of damage of the zinc layer. In more corrosive environments (such as salt water), cadmium plating is preferred. Galvanization often fails at seams, holes, and joints where there are gaps in the coating. In these cases, the coating still provides some partial cathodic protection to iron, by acting as a galvanic anode and corroding itself instead of the underlying protected metal. The protective zinc layer is consumed by this action, and thus galvanization provides protection only for a limited period of time.

More modern coatings add aluminium to the coating as zinc-alume; aluminium will migrate to cover scratches and thus provide protection for a longer period. These approaches rely on the aluminium and zinc oxides protecting a once-scratched surface, rather than oxidizing as a sacrificial anode as in traditional galvanized coatings. In some cases, such as very aggressive environments or long design life, both zinc and a coating are applied to provide enhanced corrosion protection.

Typical galvanization of steel products that are to be subjected to normal day-to-day weathering in an outside environment consists of a hot-dipped 85 µm zinc coating. Under normal weather conditions, this will deteriorate at a rate of 1 µm per year, giving approximately 85 years of protection.

Cathodic protection

Cathodic protection is a technique used to inhibit corrosion on buried or immersed structures by supplying an electrical charge that suppresses the electrochemical reaction. If correctly applied, corrosion can be stopped completely. In its simplest form, it is achieved by attaching a sacrificial anode, thereby making the iron or steel the cathode in the cell formed. The sacrificial anode must be made from something with a more negative electrode potential than the iron or steel, commonly zinc, aluminium, or magnesium. The sacrificial anode will eventually corrode away, ceasing its protective action unless it is replaced in a timely manner.

Cathodic protection can also be provided by using an applied electrical current. This would then be known as ICCP Impressed Current Cathodic Protection.

Coatings and painting

Flaking paint, exposing a patch of surface rust on sheet metal

Rust formation can be controlled with coatings, such as paint, lacquer, varnish, or wax tapes that isolate the iron from the environment. Large structures with enclosed box sections, such as ships and modern automobiles, often have a wax-based product (technically a "slushing oil") injected into these sections. Such treatments usually also contain rust inhibitors. Covering steel with concrete can provide some protection to steel because of the alkaline pH environment at the steel–concrete interface. However, rusting of steel in concrete can still be a problem, as expanding rust can fracture concrete from within.

As a closely related example, iron clamps were used to join marble blocks during a restoration attempt of the Parthenon in Athens, Greece, in 1898, but caused extensive damage to the marble by the rusting and swelling of unprotected iron. The ancient Greek builders had used a similar fastening system for the marble blocks during construction, however, they also poured molten lead over the iron joints for protection from seismic shocks as well as from corrosion. This method was successful for the 2500-year-old structure, but in less than a century the crude repairs were in imminent danger of collapse.

Rust and dirt on the surface of a sheet pan.

When only temporary protection is needed for storage or transport, a thin layer of oil, grease or a special mixture such as Cosmoline can be applied to an iron surface. Such treatments are extensively used when "mothballing" a steel ship, automobile, or other equipment for long-term storage.

Special anti-seize lubricant mixtures are available and are applied to metallic threads and other precision machined surfaces to protect them from rust. These compounds usually contain grease mixed with copper, zinc, or aluminium powder, and other proprietary ingredients.

Bluing

Bluing is a technique that can provide limited resistance to rusting for small steel items, such as firearms; for it to be successful, a water-displacing oil is rubbed onto the blued steel and other steel.

Inhibitors

Corrosion inhibitors, such as gas-phase or volatile inhibitors, can be used to prevent corrosion inside sealed systems. They are not effective when air circulation disperses them, and brings in fresh oxygen and moisture.

Humidity control

Rust can be avoided by controlling the moisture in the atmosphere. An example of this is the use of silica gel packets to control humidity in equipment shipped by sea.

Treatment

Rust removal from small iron or steel objects by electrolysis can be done in a home workshop using simple materials such as a plastic bucket filled with an electrolyte consisting of washing soda dissolved in tap water, a length of rebar suspended vertically in the solution to act as an anode, another laid across the top of the bucket to act as a support for suspending the object, baling wire to suspend the object in the solution from the horizontal rebar, and a battery charger as a power source in which the positive terminal is clamped to the anode and the negative terminal is clamped to the object to be treated which becomes the cathode.

Rust may be treated with commercial products known as rust converter which contain tannic acid or phosphoric acid which combines with rust; removed with organic acids like citric acid and vinegar or the stronger hydrochloric acid; or removed with chelating agents as in some commercial formulations or even a solution of molasses.

Economic effect

Outdoor Rust Wedge at the Exploratorium showing the expansion of rusting iron

Rust is associated with the degradation of iron-based tools and structures. As rust has a much higher volume than the originating mass of iron, its buildup can also cause failure by forcing apart adjacent parts — a phenomenon sometimes known as "rust packing". It was the cause of the collapse of the Mianus river bridge in 1983, when the bearings rusted internally and pushed one corner of the road slab off its support.

Rust was an important factor in the Silver Bridge disaster of 1967 in West Virginia, when a steel suspension bridge collapsed in less than a minute, killing 46 drivers and passengers on the bridge at the time. The Kinzua Bridge in Pennsylvania was blown down by a tornado in 2003, largely because the central base bolts holding the structure to the ground had rusted away, leaving the bridge anchored by gravity alone.

Reinforced concrete is also vulnerable to rust damage. Internal pressure caused by expanding corrosion of concrete-covered steel and iron can cause the concrete to spall, creating severe structural problems. It is one of the most common failure modes of reinforced concrete bridges and buildings.

Cultural symbolism

Rust is a commonly used metaphor for slow decay due to neglect, since it gradually converts robust iron and steel metal into a soft crumbling powder. A wide section of the industrialized American Midwest and American Northeast, once dominated by steel foundries, the automotive industry, and other manufacturers, has experienced harsh economic cutbacks that have caused the region to be dubbed the "Rust Belt".

In music, literature, and art, rust is associated with images of faded glory, neglect, decay, and ruin.

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