Thermal spraying, also commonly referred to as metal spraying, is a coating process where a wide range of metals or ceramics can be sprayed onto the surface of another material. There are untold uses because of this – here’s 10 applications for starters…
1. Wind Turbines
Atmospheric corrosion causes harm to wind turbines. It’s because of this many manufacturers specify thermal sprayed zinc or zinc/aluminium alloys as a way of corrosion protection. Thermal sprayed coatings – utilising the arc spray process – offer a resilient finish, that will be less susceptible to damage than many paint coatings.
2. Oil Industry – Pipes, Risers and Structures
Oil industry pipes, risers and structures in many cases are subjected to harsh elements and oil and gas platform structures benefit from the application of thermal sprayed aluminium (TSA). This is performed utilising the arc or flame spray process, industrial spray coating where in fact the molten material is atomised with a cone of compressed air and propelled towards the pipes. This spray solidifies when it hits the surface to create a dense coating, which protects against corrosion for in excess of 20 years in the harshest of environments.
There’s usually heavy footfall or traffic over bridges so metal spraying them is ideal, as not just does it protects from corrosion – in addition it helps extend a bridge’s life. The flame spray process, where in fact the wire is fed with a driven roller system through the centre of an oxygen-fuel gas flame and is melted, is ideal for protecting bridges. This really is which may be the best protection from corrosion and provides protection for 20 years to first maintenance.
4. Petro-chemical Plants
In the petro-chemical industry, Corrosion Under Insulation (CUI) – where accelerated corrosion can occur under wet insulation – consumes a substantial percentage of maintenance budgets. By protecting against CUI, companies can move towards inspection-free and maintenance-free piping systems and significantly reduce maintenance costs. The spraying metal process is the ideal solution for the protection of refinery and process plant vessels, tanks and steel fabrications, as it’s proven to be always a very robust coating solution for protecting against CUI.
5. Structural Steelwork
The Burj Al Arab hotel in Dubai is one of the most famous steel structures that’s been metal sprayed. Altogether, 10,000 m2 of steel work was arc sprayed, including the heli deck frame work, roof mounted mast and 6 diagonal support braces. The aluminium coating should protect the Burj Al Arab from corrosion for about 15 to 20 years, even yet in the harsh, coastal environment by which it’s situated.
6. Seam Spraying Of ERW Tubes
Tubes are produced on a tube forming mill by Electrical Resistance Welding (ERW) the longitudinal seam. Throughout the welding process, the heat generated destroys the external coating around the weld area. Unless the ERW seam is protected, this area will corrode. The perfect way to guard it’s to spray the seam with a material that has similar corrosion resistant properties. This corrosion resistant tube has numerous uses, including domestic and garden furniture, car seat frames, parking barriers, balustrades and even car exhaust pipes.
7. LPG Cylinders
Metal spraying can be used to guard LPG, propane gas or butane gas bottles against corrosion. Gas cylinders in many cases are refurbished and, within that process, the surface of the bottles is grit blasted to prepare it just before spraying with zinc. LPG cylinders are generally sprayed utilising the arc spray process.
8. Architectural Coatings
There are numerous creative architectural coating solutions for things like balcony parts, such as for example support columns, balcony decks and curved railings, and decorative window and door frames. If used externally, they’ll be put through the corrosive aftereffects of the weather so have to be protected. Metal spraying is ideal for this, like a cold process there is no threat of distortion or fettling, unlike with hot dip galvanising. There’s also the opportunity to make use of different coatings, such as for example bronze or copper, to fit with the general design scheme.
9. Metal Spraying Versus Galvanising
Metal Spraying has many advantages for plenty of industries, along with being fully a great option to hot dip galvanising, that may cause distortion to the structures being dipped. Galvanising is a hot process whereas metal spraying is a cool process. The advantages of metal spraying include: no distortion due to heat, allowing sealed hollow fabrications to be treated without the danger of explosion; no size limit; carried on site; when equipment’s not used it may be turned off – saving money.
10. Film Industry Sets And Artistic Coatings
Polystyrene props are popular on film industry stage sets, as they’re simple to manage. To produce them better quality, the polystyrene is metal sprayed with zinc and steel. This makes the props stronger and less prone to dents when being moved around the set and reduces artwork time. Arc spraying is ideal for using on polystyrene, because the molten particles created during the method only hold a small amount of heat energy. This heat dissipates rapidly when it comes into experience of the large surface of the polystyrene.