Zinc Metallizing
Systems Engineering
Training Manager
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Information
Some examples of where are these coatings are used and how they
have performed
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Substrate
Material Feedstock
Heat Source
Accelerated
Droplet
Or
Coating
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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
1.
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
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Thermal spray, especially with soft metals sprayed with the combustion
wire equipment, is a relatively cold process. Substrate temperatures
seldom reach >200F/95C.
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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.
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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.
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Petrochemical applications
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Petrochemical applications
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Petrochemical applications
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Navy corrosion
applications
The Navy has many documented uses for thermal spray coatings of all
types, including corrosion coatings
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Hot-Dip Galvanizing
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Hot-Dip Galvanizing
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Hot-Dip Galvanizing
Galvanized Coating
Thermal
Spray
Coating
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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.
The acids, fumes, contaminated rinse water, and other byproducts of the
galvanizing process are considered hazardous. Thermal spray waste is
generally metal dust, which when applied in a shop environment, is
collected by specially designed dust collectors that remove up to 99.99%
of the generated dust, down to .12 microns, and may be recycled. Metal
dust generated while spraying onsite may be ignored, swept up, or
collected with grit blasting containment and collection systems
depending on local requirements and conditions.
Most paint and powder coating applicators can easily upgrade to thermal
spray coatings. It is difficult, or impossible to upgrade to a galvanizing
line, therefore fabricated parts must be shipped to approved galvanizers
and then shipped back to approved painters/powder coaters.
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While galvanized coatings are difficult to top coat and may require
special surface preparations (acid etching, phosphating, etc.) to allow
topcoats to adhere to them, thermal spray coatings 5-15% porosity make
them a perfect surface for paints and powder coats. The coating soaks
up topcoats like a sponge, creating a tremendous bond between the
metal coating and the top coat.
Field repairs to galvanizing can only be done with paint, which does not
last nearly as long as the galvanized coating. Typical thermal spray
equipment is portable and easily used onsite in the field. An added
benefit to this equipment is its low cost, less than $12,000 for a
complete portable system.
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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.
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