Mitigating Corrosion Under Insulation and Mechanical Degradation in High-Temperature Systems Using Novel Multifunctional Thermal Coatings (C2026-00384)

Farhad Raeisi

Industrial systems operating under high-temperature conditions, such as pipelines, pressure vessels, and process equipment, commonly employ thermal insulation to reduce energy losses. However, this insulation can also trap moisture and contaminants, creating conditions conducive to corrosion under insulation (CUI), thermally induced fatigue, and environmentally assisted cracking. These degradation mechanisms are exacerbated by repeated thermal cycling, mechanical stresses, and aggressive chemical exposure, leading to premature material failure, costly maintenance, and safety risks.
This study investigates the combined effects of corrosion, mechanical fatigue, and external stress cracking under thermally insulated conditions through controlled laboratory simulations. A novel multifunctional thermal coating developed by Detectica Inc. is evaluated for its ability to mitigate heat loss while resisting corrosion and mechanical degradation at temperatures exceeding 200 °C. The research employs thermal cycling chambers, salt fog environments, and electrochemical impedance spectroscopy to quantify coating durability, corrosion resistance, and crack initiation behavior under cyclic loading.
Initial results show that the coating significantly reduces heat flux and corrosion rates, maintaining adhesion and integrity after extended thermal cycling. These findings offer valuable guidance for optimizing protective coatings for high-temperature service and help set benchmarks for industrial use, supporting robust mitigation strategies in CUI-prone environments.