Corrosion Protection Technology

International shipping, powered by heavy fuel oil and marine diesel, generates significant CO₂ and pollutant emissions. This makes the transition to hydrogen-based fuels such as methanol and, in the future, ammonia, essential. However, uncertainties remain regarding the corrosion resistance of materials used throughout the fuel supply chain. This project investigates the corrosion behavior under methanol and ammonia exposure, evaluates suitable manufacturing and coating technologies, and develops new testing methods. The goal is to provide reliable, corrosion-resistant system components for the safe and economical use of these alternative marine fuels.

This project examines the long-term effectiveness of thermally sprayed aluminum (TSA) corrosion protection for an offshore wind farm in the Baltic Sea. Various steel samples coated with TSA were deployed on specialized racks in the sediment and water zones of the wind farm and will be analyzed in the laboratory after several years. The challenge for this novel corrosion protection concept in the Baltic Sea lies in its unique conditions, such as brackish water, fluctuating oxygen availability, and low winter temperatures. The solution involves combining realistic field exposure with detailed analytics. The benefits include reliable data, increased operational safety, and early detection of potential weaknesses.

Biofouling on ship hulls leads to significantly increased fuel consumption and the introduction of invasive species into alien aquatic habitats. Stricter environmental and safety regulations combined with economic factors make the regular mechanised underwater cleaning of hulls attractive. The aim of this project is to investigate the feasibility of an ROV-based cleaning solution including downstream wastewater treatment according to the highest ecological standards. For this purpose, versatile technical challenges for a development are identified and illuminated. The project work shows that with the implementation, a possibility for the greening of shipping can be created and a new market for maritime service providers will emerge.

Coatings provide maritime structures with effective protection against corrosion. Damage to the anti-corrosion coating can already occur during transport and installation of the equipment, but also in the course of its long service life. In the Underwater Maintenance research project, Fraunhofer IGP is therefore developing a smart solution for repairing coating damage to maritime structures as part of the Smart Ocean Technologies research group. What is currently implemented by the use of divers is to be mechanised in the future by underwater vehicles (ROV). The technology is based on a coating process for underwater application that has been qualified in laboratory tests. The subsequent connection of the developed application technology to corresponding vehicles will make repair work more efficient and safer.

Extreme atmospheric and high mechanical loads characterise the requirements for coating systems in the offshore sector. Steel structures used there are particularly susceptible to corrosion damage in the area of the edges and weld seams due to the edge alignment that occurs. In order to protect the steel structure, an additional layer is currently applied by hand (pre-laying process). This pre-laying process is very time-consuming and cost-intensive, which means that a high savings potential can be derived from the possibility of automation. Furthermore, the implementation of an optical inline layer thickness measurement for quality assurance is being investigated. Within the scope of the research project, the automation potentials will be worked out and implemented in real trials on mock-up structures.

Offshore wind turbines are constantly exposed to wind, water and salt. The protection of the steel structures is ensured by high-performance coating systems. The application of these liquid coating materials is associated with enormous effort due to environmental conditions and quality monitoring in the coating process. With the development of a film coating system, the requirements for the technical hall equipment can be significantly reduced. For example, a ventilation system and explosion-proof areas can be dispensed with. The development of an automated application system is planned. In combination with the film coating system, the need for quality monitoring is significantly reduced. In addition, fewer employees are working in the hazardous areas.