Chapter 4.

4
Thermal-Spray (Metallized) Coatings for Steel
Robert A. Sulit

Introduction and deposited to form a laminar TSC on a prepared

Thermal-spray coatings (TSCs) are used substrate (Figure 1a).
extensively for the corrosion protection of steel and
iron in a wide range of environments. The corrosion
tests carried out by the American Welding Society and
the 34 and 44 year marine-atmosphere performance
reports of the LaQue Center for Corrosion Technology
confirm the effectiveness of flame-sprayed aluminum
and zinc coatings over long periods of time in a wide
range of hostile environments.1, 2, 3 The British Stan-
dards Institution code of practice for the corrosion
protection of steel specifies that only TSCs give
Figure 1a. Thermal spraying.
protection greater than 20 years to first maintenance
for the 19 industrial and marine environments consid-
ered and that only sealed, sprayed aluminum or zinc
gives such protection in sea water immersion or splash
zones.4
In Federal Highway Administration laboratory
and field trials of low VOC coatings for the protection
of steel bridges, 85/15 Zn/Al, 99.9 Zn, and 99.9 Al
TSCs demonstrated the best corrosion performance
among 34 coating systems. Metallized coatings have
zero VOC. Conclusions are based on 6.5-yr. panel
testing in a severe marine exposure site and 5-yr
panel testing on three bridges in different but severe
corrosion environments.5 The 85/15 Zn/Al over SSPC
10/NACE 2 near-white metal blast is estimated to
reach 5-15% degradation in a severe marine environ-
ment in 30 years.
The current industry standard for the applica-
tion of TSCs is SSPC CS 23.00, Specification for the
Application of Thermal Spray Coatings (Metallizing) of
Fig. 1b. Arc spraying 85/15 on the interior of a 7 ft. diam.
Aluminum, Zinc and Their Alloys and Composites for
pipe over the Missouri River in Montana. Courtesy
the Corrosion Protection of Steel.6 The qualifications
Montana Dept. of Natural Resources and Conservation
for metallizing contractors are specified in the SSPC-
QP series of qualification procedures for coating
The material used may be in the form of a powder or
contractors.7
wire. The thermal spray gun generates the necessary
heat by using combustible gases or an electric arc. As
Thermal Spraying
the materials are heated, they are changed to a plastic
Thermal spraying is a group of processes in
or molten state, atomized, confined, and accelerated
which the thermal-spray feedstock material is heated,
by a compressed gas stream to the substrate. The
atomized, and propelled by a conveying gas stream
 Figure 2. Typical arc-spray installation.
particles strike the substrate, flatten, and form thin
platelets (splats) that conform and adhere to the
irregularities of the prepared substrate and to each
other.
Electric Arc Spraying
TSCs of zinc, aluminum, or their alloys, are
used infrastructure corrosion-control applications,
primarily applied by the electric arc thermal-spray
process. Arc spraying production rates are 3 to 5 times
faster than flame spraying concomitant with less
energy cost.
In the arc-wire process, two consumable wire
electrodes that are insulated from each other automati-
cally advance to meet at a point in an atomizing gas
stream. A potential difference of 18 to 40 volts applied
across the wires starts an arc that melts the tips of the
wire electrodes. An atomizing gas stream, usually
compressed air, is directed the arc zone, shearing off
molten droplets that form the atomized spray.
The arc spray system is shown in Figure 2.
Wire electrodes are fed through wire guides and into
the contact tips. The atomizing nozzle conducts the
compressed air and directs it across the arc zone.
Insulated power cables connect the gun to the DC
power source. Arc guns also include mechanisms for
feeding the wire at a controlled rate. Contact tips are
sized for a particular wire diameter. A trigger switch on
the gun controls the wire feed, compressed air supply,
and electric power. During the melting cycle, the feed
wire is super heated to the point where some volatil-
236
ization may occur. The high particle temperatures
produce metallurgical interactions and/or diffusion
zones after impact with the substrate. These localized
reactions form minute weld spots with good cohesive
and adhesive strengths.
Safety
Potential thermal-spraying hazards include
exposure to vapors, metal dust, fumes, gases, noise,
and arc ultraviolet (UV) radiation. Uncontrolled metal
dust is an explosion and inhalation hazard. Improperly
used thermal-spray equipment can create potential fire
and explosion hazards from the fuel gases and a
potential electrical shock hazard from the electrical
and electronic equipment and charged wire spools.
Follow proper safety precautions to minimize hazards.
Operators must comply with the procedures in the
safety references, the manufacturer’s technical
information, and Material Safety Data Sheets. A
summary of thermal-spray safety information may be
found in SSPC CS 23.00A, Part B: Guide 8.
Thermal-Spray Coatings (TSCs) for the
Corrosion Protection of Steel
Aluminum, zinc, and their alloys provide both
barrier and galvanic protection; barrier protection when
applied in non-through-porosity thickness, galvanic
protection when applied in a through-porosity thick-
ness. Zinc’s greater chemical activity provides greater
galvanic protection than aluminum. Aluminum’s lower
Table 1. Estimated Service Life of Aluminum TSCs.

Table 2. Estimated Service Life of Zinc and 85/15 Zn/Al-Alloy TSCs.

237
Table 3a. Predicted Service Life for Selected Thermal Spray Applications(A).
chemical activity, adherent oxide film, and higher wear
and temperature resistance as compared to zinc,
provides longer term protection along with high-
temperature and abrasion/wear resistance.
When zinc is alloyed with aluminum, the zinc-
rich spray material forms an effective corrosion-
resistant coating, having the attributes of both elemen-
tal components. 85/15 Zn/Al alloy and pseudo Al-Zn
alloy, produced by arc spraying Al and Zn wires, can
be used to maximize their alloy performance over their
individual performance. In this case, the corrosion
resistance of zinc is combined with the severe-
environment and high-temperature resistance of
aluminum. When cut to expose the substrate steel, or
when applied in a through-porosity thickness, these
TSCs will retard corrosion through cathodic protection.
Selecting TSCs
The selection of TSCs should be based on the
service environment and the desired service life: Table
1 illustrates the service life for aluminum TSCs and
Table 2 the service life for zinc and zinc/aluminum
alloys.9
U.S. Army Corps of Engineers (USACE) has
experience with 85-15 zinc-aluminum alloy coating
(0.016 in. [400 mm]) providing 10 years of service in
very turbulent ice- and debris-laden water.10 Table 3a
shows typical service lives of paint coatings and
238
predicted service life of TSCs for selected USACE
applications.
Sealing and Topcoating TSCs
TSCs of aluminum, zinc, and their alloys have
porosity ranging up to 15%. Interconnected porosity
will extend from the surface to the substrate when the
TSC is applied at less than a non-through porosity
thickness. Sealing fills the porosity extending the
service life of the TSC. Sealing is accomplished by
applying thin sealer coatings that will penetrate into
and are absorbed into the pores of the TSC or natu-
rally by the oxidation of the sprayed aluminum or zinc
filling the pores with a tightly adherent oxide layer. The
seal coat must be applied before significant natural
oxidation occurs to be effective. The pigment particle
size for colored sealers must be small enough to flow
easily into the pores of the TSC, nominally a 5-
fineness grind per ASTM D 1210.11
For service temperatures > 250oF [120oC], a
high-temperature resistant coating such as an alumi-
num pigmented silicone sealer is required.
Sealed TSCs are preferable to topcoated
TSCs. Sealed TSCs should be topcoated only when:
(1) the environment is very acidic or very alkaline, i.e.,
when pH is outside the range of 5 to 12 for zinc and
zinc alloy TSCs or 4 to 9 for aluminum and 90/10 MMC
TSCs; (2) the metal is subject to direct attack by
specific chemicals; (3) the required decorative finish
can be obtained only with a topcoat; and (4) when
additional abrasion resistance is required. Topcoat
materials must be compatible with the TSC material,
sealer, and the intended service environment. Never
topcoat an unsealed TSC.
Examples
There is a history of aluminum and zinc TSC
corrosion protection for structural steel work: buildings,
bridges, towers, radio and TV antenna masts, steel
gantry structures, high-power search radar aerials,
overhead walkways, railroad overhead line support
columns, electrification masts, tower cranes, traffic
island posts, and street and bridge railings.
Zinc TSCs complement hot-dip galvanizing
and should be considered when fabrications are
excessively large or otherwise cannot be hot-dip
galvanized. Zinc TSC should also be considered for
repairing galvanized coating damaged during the
fabrication process (e.g., welding, cutting and joining
areas) and for maintenance recoating. Here, a zinc
TSC is particularly advantageous because it ensures
the uniformity and reproducibility of the galvanized
coating thickness.
Wellhead valve assemblies, for offshore use,
have been thermal-spray coated for salt atmosphere
protection since the 1950s. Aluminum TSCs are used
for high-temperature corrosion protection of flare
stacks. Aluminum and zinc TSCs have been used for
external protection of oil and propane gas storage
tanks. TSCs have been used to protect pipelines
against many environments. Pile couplings, valves,
sewer covers, industrial gas bottles, and other small
industrial items are candidates for TSCs.
The interior of steel hopper rail cars for hauling coal
have been sprayed with aluminum for sulfuric-acid
corrosion protection and with aluminum composite for
both corrosion and abrasion protection. Steel car
exteriors have been sprayed with zinc for atmospheric-
corrosion protection.
Zinc TSCs are used to protect potable water
pipelines and storage tanks as specified in ANSI/
AWWA D-102-78, American Water Works Association
Standard for Painting Water-Storage Tanks.12 Alumi-
num and zinc TSCs are used on sluice gates in
irrigation systems and canal lock gates in shipping
canals.
Sealed aluminum and zinc TSCs improve the
corrosion resistance of steel bridgework and railings
239
subjected to marine and de-icing salts. Reinforcing
steel in concrete can be zinc sprayed to retard corro-
sion. Reinforced concrete bridges and highways,
especially in those in marine and freezing environ-
ments where de-icing salts are used, commonly suffer
from chloride intrusion into the concrete followed by
reinforcing steel corrosion and concrete spalling. Zinc
TSCs are used for reinforcing steel protection prior to
pouring the concrete. Zinc TSCs are sprayed directly
on bridge concrete substructures to provide a sacrifi-
cial protection coating or to be a secondary anode
when electrically connected to an impressed current
cathodic protection system.
In marine applications, ship structural areas
and components are preserved with aluminum and
zinc TSCs. The U.S. Navy uses aluminum TSCs in
new ship construction and in the overhaul, repair, and
maintenance of ship structures and for a wide range of
shipboard components, especially those in topside and
wet spaces.13 The British, Australian, and New
Zealand Navies use a duplex zinc (base) and alumi-
num (top) TSC system. Commercial shipping and
barges have used TSCs to preserve ship superstruc-
tures and a range of topside and interior components.
TSC Cost
This section contrasts paint and TSCs based
on cost and expected service life.10 Both paint and
TSCs may be used to provide corrosion protection.
The use of TSCs is preferred on the basis of fitness-
for-purpose for a few specific applications including
corrosion protection in very turbulent ice- and debris-
laden water, high-temperature applications, and zebra-
mussel resistance. TSCs may also be selected
because of restrictive air pollution regulations that do
not allow the use of some paint with excessive VOC
emissions. For all other applications the choice
between thermal spray and paint coatings should be
based on cost.
Whenever possible, coating selection should
be based on life cycle cost. Because of their some-
what higher first cost, TSCs are often overlooked. To
calculate life cycle costs the installed cost of the
coating system and its expected service life must
be known. Life-cycle costs for coating systems are
readily compared by calculating the average equiva-
lent annual cost (AEAC) for each system under
consideration.
The basic installed cost of a TSC system is
Table 3b. Stepwise Procedure.
calculated by adding the costs for surface preparation,
materials, consumables, and thermal spray applica-
tion. The cost of surface preparation is well known.
The cost of time, materials, and consumables may be
calculated using the “stepwise” procedure shown in
Table 3b.
Table 4. Deposit Efficiency of Thermal Spray
Processes.
Other factors that increase the cost of thermal-
spray and other coating jobs include the costs of
containment, inspection, rigging, mobilization, waste
storage, and worker health and safety.
Design Guidance and Process Standards
Design Guidance
Applying TSCs for the protection of steel
structures and components requires comparable
design considerations as that for high-performance
paint-coating systems, i.e., material selection, geom-
240
etry and surface considerations in the structural design
and during fabrication/assembly, accessibility for
surface preparation, coating application, and in-service
maintenance and repair. Design guidance documents
suitable for thermal-spray systems are listed in the
reference section.4, 10, 14, 15
Process Standards
There are two thermal-spray process stan-
dards for the corrosion protection of steel in the U.S.
and one ISO standard. These are also listed in the
reference section.6, 13, 16
Inspecting Thermal-Spray Coatings
Inspection Requirements
The requirements and methods for inspection
of thermal-spray coatings should be considered during
the initial design and implemented/updated during the
fabrication and assembly of steel structures and their
components. The TSC system requirements for initial
application and in-service performance should be
established to parallel to other inspection require-
ments. Inspection should be based on inspecting and
documenting the major planning, production, and
maintenance and repair actions for the life-cycle
support of the structural and components of the TSC
system. The flow chart (Figure 3) shows the key
thermal-spray inspection events for a project. The
construction and initial application phase includes the
Figure 3. Flow chart of the key inspection TSC events for a project.

241
Table 5. Inspection Requirements.
application process and quality-control checkpoints
detailed in SSPC CS 23.00.6
It is important to note that the TSC procure-
ment contract or the job order must specify the inspec-
tion requirements, i.e., the acceptable parameters and
measurement methods per Table 1 of SSPC CS 23.00.
If inspection requirements and methods are not
specified, the inspection and corrective action for
deficiencies cannot be contractually binding on the
applicator.
Design Phase
Establish TSC system requirements and
inspection acceptance tests comparable to Table 6 in
SSPC CS 23.00. The design engineer, in the contract,
should define the TSC specifications, application
process, and inspection and acceptance requirements.
The contract specifications should be based and
balanced (traded off) with the project engineering
requirements, and construction schedule on a life-
cycle basis. The design should specify the key (man-
datory) inspection items, acceptance values, and their
sequence in the construction, overhaul, or repair
schedule. The thermal-spray inspection actions should
also be integrated into the overall project inspection
schedule.
Construction Phase
During the construction phase, the key inspection
events include surface preparation, thermal-spray
equipment setup, TSC application, and sealing or
sealing and topcoating. The in-process QC check-
points are those cited in SSPC CS 23.00.6
In-Service
Establish the TSC in-service inspection
actions and schedule to conform to the anticipated
wear and degradation for the service environments
and wear/abrasion duty cycles. The TSC inspection
242
should be harmonized with other project inspection
requirements to minimize inspection time and re-
sources. Refer to SSPC-PA Guide No. 5, Guide to
Maintenance Painting Programs, for additional infor-
mation.17 Repair TSCs per ANSI/AWS C2.18, Guide for
the Protection of Steel with Thermal Sprayed Coatings
of Aluminum and Zinc and Their Alloys and Compos-
ites.8
TSC System Requirements and Applica-
tion Process
Proper surface preparation is mandatory to the
successful application of a TSC. Accordingly, if sepa-
rate contractors perform the surface preparation and
thermal spraying, the suitability of the surface prepara-
tion should be approved by the TSC applicator. The
procurement contract should account for this interac-
tion among the owner’s inspector and the surface-
preparation and thermal-spraying contractors.
The major production and QC activities shown in
Figure 4 are taken from SSPC CS 23.00.6 The
applicable Section and Quality Control Checkpoint
(QCCP) numbers are noted in the lower right-hand
corner of each process action. A summary of the key
production step follows.
Surface Preparation
The steel substrate should be prepared to (1)
white metal finish, SSPC-SP 5/NACE 1, for marine
and immersion service, or (2) the minimum of near-
white metal finish, SSPC-SP 10/NACE 2, for other
service applications.
The steel substrate shall have, at a minimum,
an angular profile depth ≥ 63 mm (2.5 mils) with a
sharp angular shape. There is currently no standard
method for measuring the angularity of the blast
profile. However, a “metallographic examination of a
successful bend coupon” can be used to evaluate the
angularity suitability of the blast.
The profile depth shall be measured according
Table 6. TSC System Requirements and Acceptance Tests.

243
Figure 4. Key production and quality control checkpoints (QCCPs) for applying thermal-spray coatings.

to ASTM D 4417, Method C (replica tape, x-coarse, 38 10 cm2 (1.6 in.2). The spot measurement may not
to 113 mm [1.5 to 4.5 mils]), or Method B (profile depth measure the peaks and valleys of the TSC.
gauge), or both.18
Use clean dry angular blasting media. Mineral
and slag abrasives shall be selected and evaluated
according to SSPC-AB 1, steel grit to SSPC AB-3.19, 20
Table 7 lists the blasting media and mesh size found
suitable for TSCs on steel substrates.

TSC Requirements
Feedstock and TSC Thickness. The TSC feedstock
material and thickness should be selected according to
intended service environment and service life. The
minimum and maximum TSC thickness shall be
measured in accordance with SSPC-PA 2.21
Figure 5. Line and spot measurement procedures.
(1) For flat surfaces a measurement line shall be
used. The average value of five readings taken in Portable TSC Tensile Bond Instrument and Measure-
line at 1.0-in. (2.5-cm) intervals shall be deter- ment. The TSC tensile bond shall be measured
mined. The line measurement measures the peaks according to ASTM D 4541 using a self-aligning
and valleys of the TSC. portable adhesion test instrument or equivalent. The
(2) For complex geometries and geometry transitions minimum TSC tensile bond value may be specified
a measurement spot shall be used. The measure- according to Table 8. Higher values may be specified.
ment spot should have an area of approximately One portable tensile-bond measurement shall

244
Table 7. Blasting Media and Mesh Size Found Suitable for TSCs on Steel Substrates.
be made about every 500 ft2 (50 m2). If the tensile
bond is less than the contract specification, the
degraded TSC shall be removed and reapplied.
For nondestructive measurement, tensile force
shall be measured to the contract-specified tensile.
The tensile force shall then be reduced and the tensile
fixture removed without damaging the TSC.
Bend Test. The bend test (180o bend on a mandrel) is
used as a qualitative “system test” for the proper
surface preparation, equipment setup, and spray
parameters. The bend test puts the TSC in tension.
The mandrel diameter for the threshold of cracking
depends on substrate thickness, coating thickness,
and mandrel diameter.
Table 8. Minimum Tensile-Bond Requirements (per
ASTM D 4514 using a self-aligning portable test
instrument).
Bend-Test Procedure for TSC Thickness Range 7-
12 mils [175-350 mm].
(1) Spray five corrosion-control bend coupons and
pass the following bend test:
(a) Use a carbon steel coupons of approximate
dimensions 2 x 4 to 8 x 0.05 in. [50 x 100 to
200 x 1.25 mm].
245
(b) Surface preparation per contract specification.
(c) Spray 7-12 mils [200-250 mm] thick TSC. The
TSC should be sprayed in crossing passes
laying down approximately 3-4 mils [75-100
mm] per pass.
(d) Bend coupons 180˚around a 0.5-in. [13-mm]
diameter mandrel.
(2) Bend test passes if, on the bend-radius (see
Figure 6), there is (a) no cracking or spalling or (b)
only minor cracking that cannot be lifted from the
substrate with a knife blade.
(3) Bend test fails if the coating cracks with lifting from
the substrate.
Table 9. Bend-Test Cracking Threshold: Mandrel Diam-
eter vs. Zn TSC Thickness.
TSC Cut Test. The TSC cut test should consist of a
single cut 1.5-in [40-mm] long through the TSC to the
substrate without severely cutting into the substrate.
All cuts should be made with sharp edge tools. The
chisel cut should be made at a shallow angle. The
bond should be considered unsatisfactory if any part of
the TSC along the cut lifts from the substrate.
TSC Finish. The deposited TSC shall be uniform
without blisters, cracks, loose particles, or exposed
steel as examined with a 10x loupe.
TSC Porosity. If required by the purchaser, the
maximum allowable porosity and the metallographic
measurement method to be used for the evaluation
shall be specified. Note: Porosity measurements are
not used for in-process quality control in metallizing for
corrosion protection of steel. However, porosity
measurements may be used to qualify thermal-spray
application processes and spray parameters.
Figure 6. TSC bend test: pass and fail examples.
TSC QC Measurement Procedures and Instruments.
The suitability of the TSC thickness, portable tensile
bond, bend test, and cut-test measurement proce-
dures and instruments shall be validated during the
contract pre-award validation.
Job Reference Standard (JRS). The JRS is a job site
pass/fail reference standard representative of the
whole job or major sections of the job. The JRS is
should be prepared by the TSCA at the pre-award job
conference to demonstrate and validate the TSCA’s
surface-preparation and thermal-spray application
processes. The JRS should be used as a “comparator”
to evaluate the suitability of the application process.
Figure 7 illustrates the configuration of a JRS.
The JRS shall be made on a steel plate approxi-
mately 18 x 18 x 0.25 in. (46 x 46 x 0.60 cm). Note:
For structural steel, the reference standard does not
need to be more than 0.25 in. (0.60 cm) thick because
steel does not thermally distort when TSC is applied.
When the actual work is less than 0.25 in. (0.60 cm)
thick, the JRS should be made from material of a
thickness representative of the job.
(1) The JRS shall be made with the actual field
equipment and the process parameters and
procedures (surface preparation; thermal spraying;
sealing or sealing and topcoating; and the in-
process QC checkpoints) that shall be used for the
246
contracted work.
(2) The JRS shall be made in representative environ-
mental conditions spraying with or without enclo-
sure as appropriate.
(3) Thickness and tensile-bond measurements shall
be made according to Figure 8. The JRS is
unsatisfactory if any measurements are less than
the contract-specified value.
(4) The JRS is used as a pass/fail reference for the
applicator’s in-process QC and the purchaser’s
inspector.
(5) The preparation and the use of the JRS for in-
process QC and the inspector’s pass/fail reference
standard should be agreeable to both the pur-
chaser and TSCA.
Figure 7. Job reference standard configuration (JRS).
Job Control Record (JCR). SSPC CS 23.00A, Part A:
Specification, presents a JCR that covers the essential
job information. The JCR lists information on the TSCA,
the purchaser, TSC requirements, safety precautions,
surface preparation and abrasive blasting media require-
ments, flame- and arc-spray equipment and spraying
procedures and parameters. The JCR also lists the 11
production steps and their check-offs. The check-off list
may be used as part of the inspection procedure.
Thermal-Spray Coating Applicator (TSCA)
Qualification
There is one published and one standard in
preparation for the qualification of TSCA:
(1) ASTM D 4228-95, Standard Practice for Qualifica-
tion of Coating Application of Coatings for Steel
Surfaces provides a standard qualifying method
for coating applicators to verify their proficiency
and ability to attain the required quality for
Figure 8. Thickness and tensile-bond measurements for JRS qualification.

247
Table 10. Recommended Personnel Qualification Requirements & Minimum Required Experience per SSPC-QP 6.
application of specified coatings to steel surfaces
including those in a safety-related area in a
nuclear facility.
(2) SSPC-QP 6, Standard Procedure for Evaluating
Qualifications of Thermal-Spray (Metallizing)
Applicators, (in preparation) describes a method
for evaluating the qualification of thermal-spray
(metallizing) applicators (or firms) to apply ther-
mal-spray coatings in accordance with SSPC CS
23.00. Requirements and auditing criteria are
included for the surface preparation, thermal
spraying, and sealing or sealing and topcoating of
components/assemblies in the shop and complex
structures in the field. This procedure is applicable
to a fabricating shop, shipyard, or other entity that
applies coatings in the shop, even though provid-
ing coating application services is not the primary
function. TSCA must have equipment, materials,
and application and in-process QC procedures to
meet SSPC CS 23.00. Table 10 lists the personnel
qualification requirements and minimum required
experience.
TSC Inspector Qualification
The TSC inspector is a person who is knowledge-
able about the concepts and principles of TSC and
skilled in observing and measuring conformance to
SSPC CS 23. The TSC inspector, at a minimum,
should:
(1) Meet the knowledge requirements of a qualified
thermal-spray operator.
(2) Be skilled in observing and evaluating conform-
ance of the application process to the contract
248
specifications.
(3) Be knowledgeable of and skilled in using inspec-
tion equipment to measure and validate the
TSCA’s conformance to the purchasing contract.
(4) Submit timely oral and written reports to the
purchaser.
More information is also found in SSPC’s The
Inspection of Coatings and Linings: Handbook of Basic
Practices for Inspectors, Owners, and Specifiers.22
Summary
Thermal-spray coatings are used for the
corrosion protection of steel and iron in a wide range
of environments. TSCs of zinc, aluminum, or their
alloys are used for infrastructure corrosion-control
applications and are primarily applied by the electric
arc thermal-spray process. The current industry
standard for the application of TSCs is SSPC CS
23.00.6 The qualifications for metallizing contractors
are specified in the SSPC-QP series of qualification
procedures for coating contractors.7
References
1. Corrosion Tests of Flame-Sprayed Coated Steel:19-
Year Report; American Welding Society: Miami, FL.
2. Kain, R.M.; Baker, E.A. ASTM STP 947. Marine
Atmospheric Corrosion Museum Report on the Perfor-
mance of Thermal-Spray Coatings on Steel; ASTM:
West Conshohocken, PA.
3. Pikul, S.J. Appearance of Thermal-Sprayed Coat-
ings After 44 Years Marine Atmospheric Exposure at
Kure Beach, North Carolina; LaQue Center for Corro-
sion Technology, Inc., February 1966. Maintenance Painting Programs; SSPC: Pittsburgh.
4. B.S. 5493. British Standard Code of Practice for 18. ASTM D 4417. Standard Test Methods for Field
Protective Coatings of Iron and Steel Structures Measurement of Surface Profile of Blast Cleaned
Against Corrosion; British Standards Institution/ASTM: Steel; ASTM: West Conshohocken, PA.
New York, 1977. 19. SSPC-AB 1. Mineral and Slag Abrasives; SSPC:
5. Kogler, R.A; Ault, J.F.; Farachon, C.L. FHWA-RD- Pittsburgh.
09-058. Environmentally Acceptable Materials for the 20. SSPC-AB 3. Newly Manufactured or Re-Manufac-
Corrosion Protection of Steel Bridges; Federal High- tured Steel Abrasives; SSPC: Pittsburgh.
way Administration: Washington, D.C., 1997.
22. The Inspection of Coatings and Linings; Bernard
6. SSPC CS 23.00. Specification for the Application of R. Appleman, ed.; SSPC: Pittsburgh, 1997.
Thermal Spray Coatings (Metallizing) of Aluminum,
Zinc, and Their Alloys and Composites for the Corro-
About the Author
sion Protection of Steel; SSPC: Pittsburgh.
7. Qualification Procedures. In Steel Structures
Painting Manual: Volume 2—Systems and Specifica- Robert A. Sulit
tions; SSPC: Pittsburgh. Robert A. Sulit has been involved with thermal-spray
technology since 1977 in the areas of shipboard
8. AWS C2-18A, NACE RPX-2002, and SSPC CS
corrosion control, naval machinery repair, and the
23.00A. Application of Thermal-Spray Coatings
design/installation/operation of mobile/fixed corrosion
(Metallizing) of Aluminum, Zinc, and Their Alloys and
control shops. Chair of SSPC’s thermal-spray
Composites for the Corrosion Protection of Steel—Part
committee and the AWS/SSPC/NACE committee for
B: Guide, Draft #2, 2001-10-19.
corrosion protection of steel, he has authored or
9. ANSI/AWS C2.18. Guide for the Protection of Steel coauthored more than 110 technical papers and
with Thermal Sprayed Coatings of Aluminum and Zinc reports and one book, Principles of Radiation and
and Their Alloys and Composites; ANSI: New York. Contamination Control. Mr. Sulit is a former recipient of
10. U.S. Army Corps of Engineers (USACE) Engineer- the SSPC Technical Achievement Award (2000) and
ing Manual EM 1110-2-3401 Engineering and Design. several other industry honors.
Thermal Spraying: New Construction and Mainte-
nance; 29 January 1999.
11. ASTM D 1210. Test Method for Fineness of
Dispersion of Pigment-Vehicle Systems; ASTM: West
Conshohocken, PA.
12. ANSI/AWWA D-102-78. American Water Works
Association Standard for Painting Water-Storage
Tanks. AWWA/ANSI: New York.
13. MIL-STD-2138A(SH). Metal Sprayed Coatings for
Corrosion Protection Aboard Naval Ships.
14. Steel Structures Painting Manual: Volume 1—
Good Painting Practice; SSPC: Pittsburgh, 2002.
15. NACE Standard RP0187-89. Standard Recom-
mended Practice—Fabrication Details, Surface Finish
Requirements, and Proper Design Considerations for
Tank and Vessels to be Lined for Immersion Service;
NACE: Houston.
16. ISO 2063:1999. Metallic and Other Organic
Coatings—Thermal Spraying: Zinc, Aluminum, and
Their Alloys.
17. SSPC-PA Paint Application Guide No. 5. Guide to

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