[{"data":1,"prerenderedAt":-1},["ShallowReactive",2],{"detail-sidebar-cat-0-en-105":3,"doc-seo-297589-105":59,"doc-detail-297589-en":131},{"code":4,"msg":5,"data":6},0,"success",[7,13,18,23,28,33,38,43,48,51,55],{"id":8,"doc_module":4,"doc_module_name":9,"category_name":10,"show_sort_weight":11,"slug":12},1,"Document","Story & Novel",90,"story-novel",{"id":14,"doc_module":4,"doc_module_name":9,"category_name":15,"show_sort_weight":16,"slug":17},2,"Literature",80,"literature",{"id":19,"doc_module":4,"doc_module_name":9,"category_name":20,"show_sort_weight":21,"slug":22},4,"Exam",70,"exam",{"id":24,"doc_module":4,"doc_module_name":9,"category_name":25,"show_sort_weight":26,"slug":27},5,"Comic",60,"comic",{"id":29,"doc_module":4,"doc_module_name":9,"category_name":30,"show_sort_weight":31,"slug":32},6,"Technology",50,"technology",{"id":34,"doc_module":4,"doc_module_name":9,"category_name":35,"show_sort_weight":36,"slug":37},7,"Healthcare",40,"healthcare",{"id":39,"doc_module":4,"doc_module_name":9,"category_name":40,"show_sort_weight":41,"slug":42},8,"Research & Report",30,"research-report",{"id":44,"doc_module":4,"doc_module_name":9,"category_name":45,"show_sort_weight":46,"slug":47},9,"Religion & Spirituality",20,"religion-spirituality",{"id":46,"doc_module":4,"doc_module_name":9,"category_name":49,"show_sort_weight":46,"slug":50},"World Cup","world-cup",{"id":52,"doc_module":4,"doc_module_name":9,"category_name":53,"show_sort_weight":52,"slug":54},10,"Lifestyle","lifestyle",{"id":56,"doc_module":4,"doc_module_name":9,"category_name":57,"show_sort_weight":24,"slug":58},19,"General","general",{"code":4,"msg":60,"data":61},"ok",{"site_id":62,"language":63,"slug":64,"title":65,"keywords":66,"description":67,"schema_data":68,"social_meta":124,"head_meta":126,"extra_data":128,"updated_unix":130},105,"en","corrosion-control-and-coatings-tsa-coatings-overcome-cui-problems","Corrosion control and coatings - TSA coatings overcome CUI problems","","Corrosion under insulation (CUI) is a widespread issue across refining, petrochemical, power, industrial, onshore and offshore sectors, especially where insulation hides corrosion until failure. CUI affects carbon steels and 300-series austenitic stainless steels, driving wall loss, pitting, and corrosion-induced stress corrosion cracking. Water ingress into insulation sustains damage, while operating temperatures around 93°C increase risk. Thermal sprayed aluminium (TSA) creates mechanically bonded barrier coatings after surface preparation, atomisation and particle impact, offering a simpler inspection-free prevention approach. Life-cycle savings evaluation supports TSA as a practical solution.",{"@graph":69,"@context":123},[70,84,106],{"@type":71,"itemListElement":72},"BreadcrumbList",[73,77,79,82],{"item":74,"name":75,"@type":76,"position":8},"https://docshare.wps.com","Home","ListItem",{"item":78,"name":9,"@type":76,"position":14},"https://docshare.wps.com/document/",{"item":80,"name":40,"@type":76,"position":81},"https://docshare.wps.com/document/research-report/",3,{"item":83,"name":65,"@type":76,"position":19},"https://docshare.wps.com/document/corrosion-control-and-coatings-tsa-coatings-overcome-cui-problems/297589/",{"url":83,"name":65,"@type":85,"image":86,"author":91,"headline":65,"publisher":94,"fileFormat":97,"inLanguage":63,"description":67,"dateModified":98,"datePublished":99,"encodingFormat":97,"isAccessibleForFree":100,"interactionStatistic":101},"DigitalDocument",{"url":87,"@type":88,"width":89,"height":90},"https://docshare.wps.com/thumbnails/corrosion-control-and-coatings-tsa-coatings-overcome-cui-problems/297589.png","ImageObject",300,407,{"name":92,"@type":93},"Chumphorn","Person",{"url":74,"name":95,"@type":96},"DocShare","Organization","application/pdf","2026-11-04","2026-09-18",true,{"@type":102,"interactionType":103,"userInteractionCount":105},"InteractionCounter",{"@type":104},"ViewAction",16,{"@type":107,"mainEntity":108},"FAQPage",[109,115,119],{"name":110,"@type":111,"acceptedAnswer":112},"Why is corrosion under insulation (CUI) difficult to find?","Question",{"text":113,"@type":114},"Insulation covers mask the corrosion problem until it is too late. This delays discovery and increases the likelihood of failure.","Answer",{"name":116,"@type":111,"acceptedAnswer":117},"What damage does CUI cause in carbon steels and stainless steels?",{"text":118,"@type":114},"In carbon steels, CUI can lead to generalized or localized wall loss. In stainless pipes, it often causes pitting and corrosion-induced stress corrosion cracking.",{"name":120,"@type":111,"acceptedAnswer":121},"How do TSA coatings help prevent CUI?",{"text":122,"@type":114},"Thermal sprayed aluminium forms a mechanically bonded barrier coating on properly prepared substrates. The process cleans and grit-blasts the surface, atomises aluminium, accelerates particles to the substrate, and then inspects coating quality.","https://schema.org",{"og:url":83,"og:type":125,"og:title":65,"og:site_name":95,"og:description":67},"article",{"robots":127,"canonical":83},"index,follow",{"doc_id":129,"site_id":62},297589,1790215429,{"code":4,"msg":5,"data":132},{"doc_id":129,"user_id":133,"nickname":92,"user_avatar":134,"doc_module":4,"category_id":39,"category_name":40,"doc_title":65,"doc_description":67,"doc_content":135,"file_id":136,"file_url":137,"file_type":138,"file_size":139,"view_count":105,"is_deleted":4,"is_public":8,"is_downloadable":8,"audit_status":8,"page_count":8,"language":140,"language_code":63,"site_id":62,"html_lang":63,"table_of_contents":141,"faqs":142,"seo_title":143,"seo_description":67,"update_tm":144,"read_time":81,"preview_page_count":4},2336475401981,"https://ap-avatar.wpscdn.com/avatar/22000c94efd8d5204d?x-image-process=image/resize,m_fixed,w_180,h_180&k=1786935347598174694","⎪ Corrosion control and coatings ⎪  \nTSA coatings overcome CUI problems  \nCorrosion under insulation, or CUI, is a common problem in many industries, including those in the petrochemical and power sectors. Evaluation of lifecycle savings has recently led to new, simple approaches to its prevention, such as the thermal sprayed aluminium (TSA) processes that form barrier coatings that are mechanically bonded to the substrate.  \nCorrosion under insulation (CUI)  \nis difficult to find because of the  \ninsulation cover that masks the  \ncorrosion problem until it is too late. This is a problem shared by the refining, petrochemical, power, industrial, onshore and offshore industries.  \nThe problem occurs on all carbon steelsas well as on 300 series austenitic stainless steels. On carbon steelsit manifestsas generalised or localised wall loss, while on stainless pipes it often causes pitting and corrosioninduced stress corrosion cracking.  \nThough failure can occur ina broadband of temperatures, corrosion becomes a significant concern in steel at temperatures between 0 and 149 °Cand is most severe at about 93 °C. Corrosion and corrosion-induced stress corrosion cracking rarely occur when operating temperatures are routinely above 149 °C.  \nCorrosion under insulation is caused by the ingress of water into the insulation, which traps the water like a sponge in contact with the metal surface. The water can come from rain water, leakage, deluge system water, wash water or sweating from temperature cycling or low temperature operations, such as refrigeration units.  \nIt is also widely known that the results of CUI are costly. CUI can account foras muchas 40 to 60% of a company’s piping maintenance costs; result in repairs in the millions; and it leads to significant downtime. Most studies on the topic involve all forms of corrosion and their associated costs, without breaking down the costs of CUI.  \nA study completed in 2001 by a research team of corrosion specialists in the USA reported the direct cost of corrosion under insulation to be $276-billion per year, with that number potentially doubling when indirect costs are also considered.  \nIn recent years, the CUI prevention philosophy of many large petrochemical companies has been an inspection-free, maintenancefree concept. Insulated systems, particularly piping systems, are expected to have a service life of 25 to 30 years.  \nEvaluation of life-cycle savings has led to the consideration of new, simple approaches to preventing CUI, such as the application of a thermal spray coating of aluminium onto the piping prior to insulating it.  \nThermal sprayed aluminium  \nAll thermal spraying processes rely on the same principle of heating a feedstock, accelerating it toa high velocity, and then allowing the particles to strike the substrate. The particles then deform and freeze onto the substrate. The coating is formed when millions of particles are deposited on top of one another. With thermal sprayed aluminium (TSA),  \nThermal sprayed aluminium (TSA) being applied to a footbridge using the flamespray process.  \nthese particles are bonded to the substrate mechanically.  \nThe first step of any coating process is surface preparation. This is done by cleaning and white metal grit blasting the surface to be coated. Masking techniques may be adopted for components that only need specific areas coated. The second step is to atomise the aluminium, which is done by introducing the feedstock material into the heat source.  \nThe heat source may be produced by either chemical reaction (combustion) or electrical power (twin-wire arc spray, for example) . Next, the particles are accelerated to the substrate by the gas stream and deform on impact to make a coating. Finally, the coatings are inspected and assessed for  \nquality by either mechanical or microstructural evaluation.  \nThe two common thermal spray techniques used to apply TSAto components are wire flame spray and twin-wire electric arc spray. Ad","cbCaic3Ho8dfESeN","https://ap.wps.com/l/cbCaic3Ho8dfESeN","pdf",527282,"English","# Corrosion under insulation (CUI)\n## Why CUI is hard to detect\n## Where CUI occurs and what it damages\n## Temperature and operational risk\n## Causes of CUI\n## Costs and industry prevention trends\n# TSA coatings as a prevention approach\n## Core thermal spray principle\n## Surface preparation and masking\n## Aluminium atomisation, acceleration and coating formation\n## Inspection and assessment\n## Common TSA application techniques","[{\"question\":\"Why is corrosion under insulation (CUI) difficult to find?\",\"answer\":\"Insulation covers mask the corrosion problem until it is too late. This delays discovery and increases the likelihood of failure.\"},{\"question\":\"What damage does CUI cause in carbon steels and stainless steels?\",\"answer\":\"In carbon steels, CUI can lead to generalized or localized wall loss. In stainless pipes, it often causes pitting and corrosion-induced stress corrosion cracking.\"},{\"question\":\"How do TSA coatings help prevent CUI?\",\"answer\":\"Thermal sprayed aluminium forms a mechanically bonded barrier coating on properly prepared substrates. The process cleans and grit-blasts the surface, atomises aluminium, accelerates particles to the substrate, and then inspects coating quality.\"}]","Corrosion control and coatings - TSA coatings overcome CUI problems | PDF",1789745986]