Thermal Spray Coatings THERMAL SPRAY COATINGS provide celfectve long-term corrosion protection oF ion land stool over a wide range of corrosive environ ments. Corrasion protection can be obtained For lip to 20 years without maintenance and up to 40 eae with minimal maintenance, Sach long-term protection has been documented for both aumo- pherie and immersion service in amerous i atic cell will got be created, which may. Be einimental to the performance of the coating system. Preheating of the substrate is often benet- cial: Prefcaing to 65 to 95°C (150 to 200°) wil eliminate surface condensation and will reduce Shrink itferentials between the eating and the fubsirate, 1 generally employed only with the fame spray processes, which Use their Mame as the heat source Tor warming the substrate Coating Selection for Atmospheric and Immorsion Environments Zine and aluminum and thee alloys: ure the metal most widely used for therinal spn) snticorrosion coatings. They are extensively used far the corrosion prtection of iron and steel ip ‘wide tange of environment and have heen shown fo provide very long-ierm protection (over 20 years) in both marine and industrial locations. ‘The Builsh Standards Insitute Cove of Prostice (ef 1 specifies tnt only these electrochemically sctive metals wll give protection of greater than 30 years for every type of environmen. consid xed and that nea of immersed seater Seawater splash zones, caly sealed sprayed zine ‘or aluninum wil give such protection. Corrosion tesls of thermal spray coated steel conducted by the American. Welding Society confer the ce imarkable effectiveness of sprayed zine and alu= thinum coatings ever long periods of lime ‘various nostle eaviroaments (Ret 2 ‘Under most conitians, vine and alominam sre more corrosion resistant than steel: therefore they form an effective burrier film between the Sleel substrate nd the atmosphere. Mote impor J+ Schamatic of he plese roy proce tant, because they are unolie Uy steel. they also Lact galvaniclly to protect the Ferrous sbbsirate from corrosion in electrolytic solutions. such st saline environments In effet the metallized cost ing serves as 2 sacrificial anode, This prevenis oreosion of the steel subsite even where the coating coverage incomplete or sulfers me hanical damage, Zine and aluminum coatings hoth provide & cellent protection in.a wide variety of mene snd industeil environments. In general, sluminurs orvodes fess rapidly than nen highly acc Conditions, but zine performs Better that amie ham ia alkaline comdivians, Aluminum is chosen for the protection of steel in chemical plants dein ther applications in hich the lemperitre Is Tikoly to exceed 120 °C (250 "F). Sprayed 2inc tings are used in cos mines because of the Possibility of impact spark generation between slumi¢um asd rusty sieel (Ret). Zine is orm Iy the preferred metal for the protection of steel in fresh cold waters luminim fused ia aquends Solutions above 6 °C (150 P), ‘Thermal spray zinc sr! alminuen coatings progressively supplanting both painting and hat Ap wulvanicing for reasons of effectiveness and {eonomics. Thermal spray Coutngs have a pre Sictible ie, require «ingle sopicaion, proxi ‘damaged arcas cathodically, have good abrasion Fesstance, and Uo tx require devin ‘The size or shupe of the structure 49 be pro- tected isnot iting factor. Components ear be ‘metal sprayed in-plant or on site. und automation 'S possible for Tong runs of Hlentcal werk. The thickness of the metal coating cat be controlled according to the depiee of protection reyute The lifeofthe metal coating is proportional te the coating weight per unit area. For a very long Service life or in highly corrosive conliions, tis possible to inereave the cating. thickness. ta {enhance corrosion protection. Sprayed zinc or aluminum coatings con be applied in thicknesses ranging from 50 10 500 ym {20 20 is) (Ret 4, Furthermore, parts tht se Dot 10 be canted can be masked durog sprsving find the coating. thicknesses can be Varied in ‘ferent reas of the same stnuciure. Areas of ‘coating discontinuity or istficient thickness can fewily be revtiied by additional spraying Both aluminum and zine coatings have good adhesion to grit-hlised stock, Spraying dacs not feause excessive heating of the substrate: there {ore there is no distortion or effect on the me chanical properties of the steel. AM) grades of lec! cn he sprayed ‘A limited ammount of porosity usally = 187) is ui inherent feature of thermal spray costings. In the case of active metal coatings, such as zine slominum, porosity nol deficiency, Pores will fot result im sudstiate attack, because of the protection afforded hy galvanic aehon. In ficTable 1 Thermal spray coatings for atmospheric and immersion service ite of entire or Hae apres e——— Atmospheric Inbiod Nonpotlted) noel wt {alan ate i 8D Coasts iNonpaledh 3D ‘Cont Pea mw Immersion Seasons zone © m6 Seunatermerion 0 ik the afr face prosiy provides an exelle: hase for scales or topeouts wher thee te ese for decorative purpose ort extend the ifeurthe coun Over the yeahs sine and slminun thermal spniye tidings hive etn toe n= rad ‘tv of eoraon protection prosrams Ih Tope: where metal apayng for Eortowin protec ton eos hed far moe val tan in the Unied Sts thee are numerous cane torts ‘uote Sprayed sires, mn song S40 year agn ta have bees Leptin good Condo wih enna maumonance tt 5 “The selection ef zine aluminum coating system depend on ie sce environment ad ike Seured te. Tale | nts sach coun fr simosphenic and inmerion sari, bu fended to ive only 8 pide tn chosing» ‘Zine-Aluminum Alloys. Corvosion protec tion ein algo be provide by te tse of ne sluninuraloy, sca 2-134), Thealoy docs to nwo the frformence ror of gue a Slumumu bu stotes i Europe and Japan so tore recely, nthe ried Stes sees alloys conic the advantages of ne and sinned ray ovperform thts crala Cintronmente Ut! 6) The Zarate nom Sine ee wt power or: sla tosis comparble to eber puree ol less steels, aluminum bronze, nickelnase alloys, And MCFAIY. among omer materials. are 280 thermal sprayed 16 combot corrosion in certain applications. Selection of specific alloy depends ‘onthe particular environment. When using these flloys, I must be understood that these coatings will not galvanically provect the underlying sleet ‘This ean he a particular problem dc to. the porosity of thera spray coatings. Great cate must be taken to ensure that these coatings are propesly scaled in onder to prevent penetration of the corrosive mediam to the uoderlying stee] und subsequent corrosion af the coatingsubstate in Coating Selection for High-Temperature Environmonts ‘Thermal spray coatings are extensively used by indusiry to protect stecl components snd structures from heat oxidation at surface temper tures {9.195 °C (2000 “Fy. By ensuing lon {erm protection, thermal spray coatings show real economic advantages during the sesvice Ives of suc items, Coatings are particulary ellective in protecting lowalloy and cuthon steels. Table > lists thermal spray coatings for use in high-tem: perature applications. ‘Aluminum fis been widely ased to protect such sels in 8 number of applications involving high surtace temperatures. Nickel-chromium a: Joys and some of the MCEALY alloys have also provided protection in severe environments. ‘Coatings for Temperatures to 550 °C (1020 °F). Sprayed aluminum coatings provide ‘excellent dxidation resistance and ealbese pes lection against corrosion Gy industri mo. spheres, hot gases, and condensation prot at temperatures to 550 °C (1020). Sealing ofthe Sprayed aluminum costings, although not essen Til, may be desired for decorative purposes or to maintain a clean appearance. A highsemperatine $huminuan-pigmented scone pnt (= generally recommend Nickel chromium alloys provide good protec lion over this temperature range i the presence fof sulfurous gases. To achieve adequate protec lion, nickel-chromium alloys shoud have 4 chro miuin content of at Teast a0" (Ref 8). The ads Hon "of smal amount ei tianinny also advantageous for increasing corrosion resistance Toble 2 Thermal spray coatings for elevated-temperature service Sco neat ig ely Tye acum aes pt $409 IDO) a te Presence of silos pases Niteern ns is sso 1 tet6e) ‘Alumni or wluinussron a 3 Sota SC 11-180 ‘Nisha stroma or MCFATY MS 6 a ty auninon “ Thermal Spray Coatings / 461 fan strengthening the coating-to-substrate bond (Rot Coatings for Temperatures From 550 900 °C (1020 to 1650 °F). For service ten peratures in this cage, sprayed aluatinum oF Alumirum alloy coatings #80 1p 200 um (to & mls) thick have proven to be elfective. At hess lemperatures, spayed aluminum diTuses into the sleel surface. These aluminized coatings are onporous. consisting esseotally of at a hngntizon alloy containing about 15% Al. Dusing Prolonget service at $9010 900 °C (1020 0 1680 Fle the aluminuiniron dision process conti ues, resulting inthe depletion of aluminum tthe slecl surface: therefore, oxidation resistance & Drogressively impaired ‘The aluminuan sprayed stel is often heat treat ced before being put into service in order to bring bout the required dilusion, If high-bondina Thermal spray process, such as eletric are spray ing is used. the heat-tscating step is not always necessary. Eleotric are sprayed steel can be put directly into service and can be heat tested dling operation, Coatings for Temperatures From 900 to 1000 °C (1650 to 1830 °F). Nickel-chromium alloy coatings 375 jn (1S mails) thick ea be Used for protection ot emperatures in this ange In the abseace of sulfurous gases, the alloys poner ally range in composition from NeISCr23Fe 10 Ni20Cr. For environments containing sultrots gies, # tickel-chromium alloy. followed by a Supplementary protective coating of 10) jm (4 rls} of sprayed aluminum, hus shown to'be an effective system. During heat treatment oF ser Vice the aluminum difuses ina the nickel-cheo- ‘mums alloy. forming an aluminum-rich lave that is highly resistant co sulfurous gas attack (Ref 7) Work "with superalloys has shown thet FeCrAlY alloys, when thermally sprayed ie an inert atmosphere. ofera stable system with good dluciliy and oxidation resistance at these high temperatures (Ret 10). Specially. inert electric are sprayed FeCTAlY is applied to tungsten alloy Fibers to produce w very strong corrosion css tant herteinforced superalloy for use in earbine blades at very high temperatures Scaling of Thermal Sprayed Coatings Sealers. oF tapeaals are commonly vsed to extend the life of thermal spray coatings and for Slecorative purposes. They are generally ppied ‘minimum of two eos: the fist coat 1 thinned to illow proper penetration into the cate ing pores. Common sealers inckide Vinyls, cP foxes, phenolics, amd polyurethanes. Such mate- nals re discussed in detail the article "Organi (Caatingy and Linings” in this Value, Sealers are not always necessary for zine or tluminurn coats, because ofthe galvanic pro fection afforded. However, they are commonly Used in mus envizvoments {0 seal the pores of the coating and 10 extend surface life. A sealed ‘ating ls generally gives & more easing sp- pearance Sealers are essential for most immersion of hemical corrosion applications. In tterials other thn eine or aluini ich do ‘ot galvanically protect the steel, must be sealed {eo prevent evatng Failure due to the porosity of the coatingInspection and quality contro! procedures for thermal sprayed coatings are similar 10: Those used Tor other types of coatings y of Surface Preparation. The ab sives use for surface preparation should be Inspected to ensure that they meet specifications fo grit size. type. and cleanliness. ARter Ihe blasting operation, the surface should be Visually inspected to ensure that the sustrate i clean. Praflometer can be used to inspect Tor adequate Surface roughness. Standard coupons or photo- sraphs may also be used as visual standards 10 ensure proper surface. preparation. These are readily available from the SSPC. oF they can be ‘in advance by the applicator ing Quality. Generally. certiieation of the coating material canbe ready obtained fom. the material supplier This eetifes that the mar terial meets proper specificatioas tor such qual lies as chemieal componition and physical char fcterstics. ‘The spray equipment should. be ‘operated und maintained aeconding t0 the st ‘sof the manuactorer ‘The installed coating can be visually inspected for surface finish and defects. Coating thickness can be verified by destructive testing. which consists of removing the coating with & knife or chisel. More commonly. the thickness of zine oF lunynumnceatings is verified by using a magnetic ‘ry lm thickness age ‘Typical Applications Thermal spray coatings, primarily sine and sluminom, have been successflly sed to con bt corrosion in a wide range of pplieations Steel structures nd companents that have been Zine or aluminum sprayed include TV towers fatennae, radar, bridges, light poles. girders sk lifts. and countess other simlar structure. In adion. thermal spray coatings, primarily al rum. offer years of protection in marine applica- ions. suchas Budys and pslons, Aluminum Sspenying hasbeen used in eshore oil gs for well head assemblies, flare stacks, wks, nd ‘other sructiral sleet components Shipboard components. both above snd bela eck, commonly se skamuniin spraying. The United States Navy-in particular. ses aluminum spraying extensively 10 combat corrosion (Ret 11) There are countess approved applications for sprayed metal coatings aboard Navy’ ships (Ret 12), ‘Numerous immersion appications have also loved zine oF aluminum spraying. for exam le. dams and shui gates. TRe Interiors of pot be water storage tanks ae also sprayed with ne to provide corrosion protection at the stee with ‘out the thea of contaminating the Water with Solvent that may be preseat it an epoxy coating system, ‘Aluminum bas abo heen used to ganteol chem ieal corrosion in such applications as storage tanks for fuels or other iguids. The interiors oF railroad hopper ears afc often sprayed to protect them against sulfuric acid (1S0,) corrosion ‘when hauling eal ‘Stainless steels, Hastelloy alloys, and other alloys can also be effective against chemical corrosion for storage vessels rolls, pumps. and ‘other structures. The coatings must be properly sealed when using these alloys. Common applications involving bigh-tempera ture corrosion include couling exhaust sacks, chimney Mies, rotary hlns and dryers, eatalytic ‘ruckers. and furnace parts. These genenlly in Solve use of an allminuin or miekel-ehronin alloy coating such as those previously described. (ne specific hightemperature corrosion app ‘cation that has met with great success in recent Years is the coating of boilers in paper alls, power plants. and chemical plants. Water svall Tuber in these applications suffer severe corr sion because of the high sulfur content of the furning fuel the high operating pressures. and abrasion (Ref 13). A.27S:pm (1S.mil) coating of NistiCr-2Tt alloy offers extremely good protec tion against this very severe corrosion at temper atures up to 550°C 11020°F) (er 8), REFERENCES 1 "Cade of Prictice for Protective Coating of Iron snd. Steel Structures Aguinst_ Corre son." BS 5498:1977, Batish Standards ln: ‘Corrosion Tests of Flame-Spraved Co Steel: 19-Yeur Report.” C2.18-74, Ame Welding Society. 1974 ILC. Bailey. Altminim Costed Stoel: Spark ing and the Fires Hazard. Met. Mater. Oct 1978, p 2627 Selection of Sprayed Zine sow Alumieurn ‘Coatings for the Protection of Iron and Ste Against Corrosion. Techical Bulletin BAILS TAPA, Inc 1983 J.C. Bailey. “U.K. Experience in Protecting Tange Stractares by Metal Spraying.” Paper presented at dhe Eighth Intermationsl Ther mal Spravinu Conference. Miami Beach, PL American Welling Society. 1976 M- Leclerey und R. Bensimon, New Zic- Based Alloy for Metlizing.” Paper presen ced at the Eighth Interaational Metal Spray Conference, Miami Beach, FL, American Welding Society. 1976 “Sprayed Metal Coatings to Combat High Temperature Covtasion, Information 3, Association of Metal Sprayers RUD Unger and F-B. Easterly, “A. New Coating for Corrosioa Protection i Boilers.” Paper presented at the TAPPL Engineering Conference, Seattle, WA. Technical Assoc ation of the Pulp and Paper lodustry. 1988 FP. Sadowshisind P.C. Shab, "Nicke/Chro rmiuan Filler Metal.” U.S. Patent 4025.34, tor D. Petrasek, D. MeDanels, L. West, and 1. Stephens, Fiber Reinforced Superalioys, Mater. Prog. Aug 1986, p27 Metal Sprayed Couting Svatems for Com son Protection Aboard Naval Ships,” DOD. STD.2138(SH), United States Department of Defense, Nov 1981 ALR. Parks, "Metal Sprayed Coating Sy tems on Board U:S. Navy Ships.” Paper presented al the Second National Conference fon Thermal Spray. Long Beach, CA, Amer feun Society for Metals, 11, A. Plombley and W, Koczaiak, “Recovery Unit Waterwall Protection.” Paper preseat ed at the British Column Black. Laguor Recovery Baler Advisory Commitice Mest Vancouver, BC, 1974