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Some examples of where are these coatings are used and how they
have performed
Substrate
Or
Coating
What is Thermal Spray?
These coatings are typically mechanically bonded to a grit blasted
surface
Metals that feed into the thermal spray gun are the actual coatings.
There are no solvents or VOC's.
The coatings are similar to the metals being sprayed, however there
are some important differences
2. Metal particles in the coating create a layered effect within the coating
structure
3. Due to the rapid cooling of the metal particles as they adhere to the
substrates, thermal sprayed coatings have unique crystalline structures
not normally found in wrought metals
Almost any material can be thermal sprayed onto almost any substrate
What is Thermal Spray?
Thermal spray, especially with soft metals sprayed with the combustion
wire equipment, is a relatively cold process. Substrate temperatures
seldom reach >200F/95C.
How thermally sprayed coatings of
Zn and Al, combat corrosion
For atmospheric, buried, and marine environment corrosion protection, Zn (TSZ), Al
(TSA), and their alloys have proven that they provide long term corrosion protection
and outperform most all other methods.
Anodic (TSZ/TSA) metal coatings applied to steel cathodes (more noble than Zn or
Al), are referred to as cathodic or sacrificial protection coating systems.
These thermal spray coatings provide corrosion protection by excluding the
environment (or electrolyte) and acting as a barrier coating (like paints, polymers,
and epoxies), but unlike typical barrier coatings they also provide sacrificial anodic
protection.
Typical thermal spray
applications or Zn, Al, and their alloys
Hundreds of bridges have been thermal sprayed (metallized) over the past 100 years. There are
many document cases of >50 years of corrosion protection provided by thermal spray coatings.
Zinc and zinc alloys are also sprayed directly onto concrete to protect the steel rebar within.
Typical thermal spray applications
for Zn, Al, and their alloys
Typical thermal spray applications
for Zn, Al, and their alloys
Carbon steel equipment (petrochemical facilities, power generation, Naval ships, etc.) are coated with TSA, TSZ, and 85/15.
Petrochemical users expect TSA coatings to provide >20 years with no maintenance or corrosion inspections.
A TSA coating has been operating in severe petrochemical vessel operating conditions. One coating in particular has protecting carbon steel equipment operating in cyclic service of ambient to 350F/175C, in contact with wet insulation, for >50 years with
no visible corrosion .
TSA coatings are also specified as a solution to stress corrosion cracking (SCC) of austenitic stainless steel.
Offshore oil rigs operating in severe conditions rely on thermal spray aluminum for corrosion protection. >20 service life with no maintenance has been documented.
These coating systems meet specifications from organizations such as NACE, SSPC, AWS, US Navy, US Army Corps of Engineers, and many others.
Petrochemical applications
Petrochemical applications
Petrochemical applications
Navy corrosion
applications
The Navy has many documented uses for thermal spray coatings of all
types, including corrosion coatings
Galvanized Coating
Thermal
Spray
Coating
Galvanizing VS. Thermal Spray
Pure aluminum (>99%), zinc (>99.9%), and zinc-aluminum alloys may
be sprayed, whereas galvanizing is never pure zinc, it is Zn/Fe matrix.
Also, the molten zinc bath is often contaminated with pickup from
materials that are dipped into it.
Aluminum and the 85/15 zinc-aluminum alloy coatings are not available
by hot dip galvanizing.
Aluminum and Zn/Al coatings protect steel better than pure zinc in
marine and industrial environments.
This paper reviews the use of wire arc spray zinc vs. galvanizing on ski
lifts. The authors discuss a case study in which painted lifts required
repainting every 3 years, hot dipped lifts showed signs of corrosion in
fewer than 5 years and thermal sprayed ski lifts exhibited no corrosion
after 5 years. It was estimated that the wire arc-spray zinc coating,
depending upon the thickness, would have a life expectancy of 20 years
with minimal maintenance. The authors concluded that thermal spray
coatings were more resistant to abrasion and wear than thin galvanized
coatings.
Combustion Wire System
Combustion Wire System
Combustion Wire System
Combustion Wire System
Combustion Wire System
Combustion Wire System
Combustion Wire System
Twin Wire Arc System
Twin Wire Arc System
Twin Wire Arc System
Twin Wire Arc System
Twin Wire Arc System
Twin Wire Arc System
Twin Wire Arc System
Twin Wire Arc System