General notes on metalizing application

What Is the Metallizing Process?

"What is metallizing?"
" That’s a question our customers often ask us here at Surtech Industries. Metallization is a general term that refe
surface. Depending on the desired result, the coating can consist of metals such

The metallization process can protect the workpiece from damaging external forces (corrosion, wear, weathering, etc.), im
enhance the finished product’s functionality. Industries that use metallization in their manufacturing processes include

What Are the Benefits of the Metallizing Process

Examples of the numerous benefits provided by the metallization

Enhanced corrosion protection — Rust is a common issue when working with most metals and especially with steel. Metall
and/or white rust, increasing the product’s lifespan by as much as
Increased durability — Most metallized coatings are known for their ability to adhere to the surface of the underlying workpi
types of finishes, which increases the substrate’s dura
Providing electrical conductivity — An issue when working with plastic materials is that they do not conduct electricity. Meta
vital manufacturing step in the electronics industr
Greater weather resistance — The steel on outdoor structures is vulnerable to the impact of snow, rain, wind and sun over tim
the underlying structure and the elements, which can lengthen the structure’s life
Reduced maintenance costs — Painted surfaces will need repainting periodically to preserve the finish. A metallized surface
Like paint, metallized coatings are available in a wide assortment of attractive colo

In general, the metallization process entails preparing the surface via abrasive blasting to remove imperfections and defec
sprayed onto the surface. Contact with the surface causes the particles to flatten out and freeze, which create

Zinc spraying — Zinc is a versatile, cost-effective material that acts as a sacrificial barrier, which can prevent corrosion from
coating that is less dense than hot-dip galvanizing. Zinc spray can be applied to any type of steel, although
Thermal spraying — This process involves the spraying of heated or melted metals onto the substrate surface. The metal is fe
sprayed as micro-sized particles. Thermal spraying enables the application of thick coa

Metal Flame Spray Coating From York, PA’s Surtech Ind

The flame spray powder coating process involves spraying melted, heated or warmed materials onto a surface. There are man
or helping to increase or extend the life cycle of the coated

In Surtech Industries’ 66,000 sq. ft. facility, located in York, PA, thermal spray metal coating can be applied on a wide range o
zinc/aluminum alloys applied for corrosion protection. This process has exhibited superior corrosion characteristic over galva
copper, bronze, brass, tin, stainless steel, high profile aluminum, and anti-skid stainless steel textures. Specific environmenta
proper coating to be applied.
Oxy-Fuel and Arc Gun P
In our York thermal spray coating facility, specialized application equipment is used to deliver the sprayed consumable to t
complexity of the part, the consistency of the coating thickness, and the quan
The flame spray powder coating process involves spraying melted, heated or warmed materials onto a surface. There are man
or helping to increase or extend the life cycle of the coated

In Surtech Industries’ 66,000 sq. ft. facility, located in York, PA, thermal spray metal coating can be applied on a wide range o
zinc/aluminum alloys applied for corrosion protection. This process has exhibited superior corrosion characteristic over galva
copper, bronze, brass, tin, stainless steel, high profile aluminum, and anti-skid stainless steel textures. Specific environmenta
proper coating to be applied.
Oxy-Fuel and Arc Gun P
In our York thermal spray coating facility, specialized application equipment is used to deliver the sprayed consumable to t
complexity of the part, the consistency of the coating thickness, and the quan

Product size constraints are 96 inches wide by 96 inches high by

Maximum weight is 4000 pounds.
Post surface application finishing can be offered to polish, buff, texture, or provide other surface smoothing
etalizing application

allizing Process?

a general term that refers to the application of a metal coating to another metallic or non-metallic
n consist of metals such as zinc, gold, aluminum or silver.

ar, weathering, etc.), improve the appearance of the object (giving it a shiny look, for example), or
turing processes include aerospace, automotive, oil & gas, defense, electrical and many others.

the Metallizing Process?

ded by the metallization process include:

ecially with steel. Metallization can create a protective coating that inhibits the development of red
s lifespan by as much as 20 years or more.
of the underlying workpiece or substrate. They are less likely to peel, blister, crack or flake than other
ases the substrate’s durability.
onduct electricity. Metallizing a plastic surface will enable it to transfer an electric current, which is a
n the electronics industry.
in, wind and sun over time. Metallization provides a protective coating that creates a barrier between
gthen the structure’s lifespan and preserve its appearance.
sh. A metallized surface will not require repainting or upkeep, resulting in lower maintenance costs.
tment of attractive colors to meet aesthetic requirements.

mperfections and defects, followed by the application of heat to produce molten particles that are
nd freeze, which creates adhesion to the surface and between the individual particles.

prevent corrosion from reaching the surface of the substrate. Zinc spray produces a slightly porous
ny type of steel, although it may not consistently reach recessed areas or crevices.
surface. The metal is fed in either powder or wire form, heated to a molten or semi-molten state and
application of thick coatings and a high metal deposition rate.

m York, PA’s Surtech Industries

a surface. There are many benefits of flame spray coating including increasing the component's "life",
e life cycle of the coated equipment.

pplied on a wide range of metallic and non-metallic substrates. Typically ferrous metals have zinc or
characteristic over galvanizing processes. Alloys that have been sprayed include zinc, zinc/aluminum,
. Specific environmental and application performance criteria need to be evaluated to determine the

Oxy-Fuel and Arc Gun Process

sprayed consumable to the substrate. This process can be manual or automated depending on the
g thickness, and the quantity of the production order.
Metallization
The process of metallization could be described as coating the surface of products with a metal layer to
obtain coatings that are corrosion-resistant, abrasion-resistant and decorative. Metal spraying
The metal-spraying, also known as “flame coating”, “flame spray metallizing” or simply “metallizing”, is a process of
spraying the molten metal onto a surface in order to repair wear or to provide a protective coating. During the
process a material in form of wire or powder is melted in an oxy-acetylene flame and atomized using compressed air
to form a fine spray. When the spray contacts the prepared surface of a substrate material, the fine molten droplets
rapidly solidify forming a solid metal coating.

It is crucial to note that the work piece remains at very low temperatures during spraying (up to 150°C), which means
that the metallizing is essentially a “cold” build-up process. Therefore, there is no damage, metallurgical changes or
distortion of the work piece during or after the completion of the process. This gives metal spraying a tremendous
advantage over other repair technologies such as brazing, welding, powder spraying etc. where working
temperatures are near melting point of the base metal.

The other major advantage is its versatility. Any combination of ferrous and non-ferrous combinations of base and
sprayed metals can be achieved. For example phosphorus bronze or copper can be sprayed on a mild steel base,
stainless steel can be sprayed on aluminum base, ceramics can be sprayed on stainless steel base and so on.

Due to its versatility and a huge number of available materials the list of specific applications is virtually endless. Here
are just a few situations where metal spraying process is frequently used:

Reclaimation of worn bearings and seals on all types of shafts

Reclaimation of bearing seat areas on various casings, motor covers, pumps etc
Repair of oil seal, mechanical seal drive, gland sections on shafts
Protection of seal areas on stainless steel shafts sleeves with ceramic coating
Repair of rotors, spindles, stirrer and other shafts
Reclamation of worn crankshaft journals on engines or compressors
Reclamation of worn-out surfaces on the wire drawing drums
Applying stainless steel (and others) coating on rollers and shafts for textile, printing, pharmaceutical, chemical and
other industries
Reconditioning hydraulic rams
Providing tin based (90%) white metal coating on segmented bearing pads, liners for large ball mills, cement plants
etc.
Applying copper on printing rolls for printing, electric, electronics, chemical, petro-chemical and other industries
Bimetal bearings
Rebuilding mis-machined or worn-out parts in general.
Some of the most commonly used materials are:

Ceramics for pumps and pump components

Nickel/aluminum composite wire for bond coats and self-bonding coatings
Molybdenum for bond coats
Molybdenum for hard bearing applications, excellent resistance to adhesive wear, used on piston rings, synchromesh
cones and journals
High chromium steel for many applications requiring hard and wear resistant coating
Bronzes and Babbitt metal for bearing applications
Stainless steels, nickel and monel for anti-corrosion and wear
Aluminum, nickel/aluminum for heat and oxidation resistance
Zinc and aluminum for anti-corrosion cathodic coatings on steel.
Furthermore, metal spraying equipment is portable so the repairs can be carried out on-site if required, for instance
for the repairing of capital machines.

Thermal Spraying
Thermal spray coatings are produced from either wire or powder materials, which are melted or softened into
droplets and then propelled onto the selected substrate. On impact, the droplets bond to the surface, creating a
dense protective coating with no alteration to the substrates structure. Typical thermal spray coating processes are
the following.

1. Combustion Flame Spray, which is achieved by burning oxygen and acetylene in a torch with a flame accelerating
nozzle. For materials in wire form the flame is concentric to the wire fed through the nozzle axis. The combustion gas
melts, atomizes and propels molten particles onto the surface being coated.

2. Electric Arc Spray. In the arc spray process, the raw materials in the form of a pair of metallic or cord wires are
melted by an electric arc. The molten material is atomized by a cone of compressed air and propelled towards the
work piece; the molten spray solidifies on the component surface to form a dense, strongly adherent coating.
with a metal layer to
al spraying
izing”, is a process of
oating. During the
using compressed air
fine molten droplets

150°C), which means

allurgical changes or
aying a tremendous
where working

inations of base and

n a mild steel base,
l base and so on.

virtually endless. Here

etc

eutical, chemical and

mills, cement plants

nd other industries

on rings, synchromesh

oating

equired, for instance

d or softened into
surface, creating a
oating processes are

a flame accelerating
. The combustion gas
d.

ic or cord wires are

opelled towards the
adherent coating.
Thermal Spray Coating Technology
Abstract:
The importance of thermal spraying has risen significantly especially in the past 20
years, because of increasing demands on components.
Thermal Spray Coating involves melting or heating of powder or wire feedstock using
special torches, accelerating the particles towards the part to be coated where they
impact and cool to form a coating.
Thermal spray processes have gained acceptance and are widely used in different
industrial branches. The importance of thermal spraying has risen significantly especially
in the past 20 years, because of increasing demands on components.

The combination of structural and surface demands e.g., outstanding strength combined
with high corrosion or wear resistance) can often only be met economically by applying
coatings. Thermally sprayed wear and/or corrosion protective coatings as well as
thermal barrier coatings are examples of this strategy. Additionally, thermal spraying is
applied to repair parts. In the standard DIN EN 657, thermal spraying is defined as a
process, in which the feedstock is partially or fully melted inside or outside a spraying
gun and deposited on a prepared surface.
Usually, the component surface is not melted. The typical coating thicknesses range
from 50 μm to 2 mm, but there are also applications with thicknesses of up to 10 mm.
Thermal spray processes feature inherent advantages:
• All materials with a liquid phase or sufficient ductility below the decomposition
temperature can be applied
• A low thermal stress of the substrate is possible
• There is possibility to deposit coatings on large or locally very limited areas
• There is partial possibility to use equipment onsite
However, in general, there is a weak bond strength between the substrate and the
coating; the coatings contain pores. Post treatment (e.g., by remelting) hot isostatic
pressing (HIP) or shot peening helps to improve the bond strength and/or decrease the
coating porosity. Usually, exact coating thickness is achieved by grinding, which also
provide a low surface roughness.
Thermal Spray Coating involves melting or heating of powder or wire feedstock using
special torches, accelerating the particles towards the part to be coated where they
impact and cool to form a coating. Generally any material without a sublimation point
can be deposited using this technique.

Thermal spray can be used to apply high performance surfaces to resist wear, corrosion
or heat damage. Thermal Spray Coating can also be applied for special applications
such as electrical insulation or conduction, x-ray emission and thermal emission. A
common application is build up and repair of worn components.
Types of Thermal Spray Coating
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