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Thermal Spray Coating Adds an Extra Layer of Protection

Metalizing or metal spraying, also known as Thermal Spray Coating, deposits molten material on a workpiece to form a protective coating. Four types of thermal spray coating processes commonly used are flame, electric arc, detonation and plasma spraying.

Metalizing applications include:

  • Corrosion protection for all types of steel structures and equipment
  • Extending tube wall life of coal fired utility and chemical recovery boilers
  • Condenser tube sheets and waterbox corrosion protection
  • Anti-skid coatings
  • Corrosion and erosion protection of carbon steel in wet steam environments
  • Corrosion protection for off-shore platform supports and sheet piles

Common metal spray coating materials include:

  • Aluminum
  • Bronze alloys
  • Carbon steel
  • Chrome steel
  • Hastalloy
  • Monel
  • Nickel
  • Nickel chrome
  • Stainless
  • Zinc

Advantages of spray applied metal coatings:

  • Range of temperatures – Thermal sprayed coatings can be applied at temperature ranges from 0 to 100 F.
  • Consistency – Sprayed metal is consistent in quality and purity and requires no curing time.
  • Withstand rough usage – Thermal sprayed coatings applied to grit blasted steel enables the structure to withstand rough usage, without sacrificing the protection.
  • Prevents corroding – The sacrificial action, particularly of Zinc, prevents steel from corroding at the edges and discontinuities may occur if the coatings are mechanically applied.
  • Flexibility in size and shape of work pieces – Unlike the hot dip galvanizing process, metal spraying can be applied to workpieces of any shape or size.
  • Use as base or top coat – Thermal sprayed metal coatings are slightly porous which makes them an excellent base for a sealer or paint topcoat, extending the overall life of the protective coating system and provides the desired aesthetics while maintaining the plant’s color coding scheme
  • Long life span – Thermal sprayed metal coatings can last up to 40 years without degradation or required maintenance, longer than polymer-based paint systems.