GOVERNMENT POLYTECHNIC, MURTIZAPUR,

DIST: AKOLA

A Project Report on
“ Prepare a list of domestic and industrial component on which
metal spraying and powder coating is performed ’’
Submitted to Government Polytechnic, Murtizapur, in partial
fulfilment of the requirement for the award of

Diploma in Mechanical Engineering

Submitted By
Sanket Prabhakar Khade
Guided By
LECTURER IN ADVANCE MANIFACTURING PROCESSES

M. Ghulaxe
Department of Mechanical Engineering
GOVERNMENT POLYTECHNIC, MURTIZAPUR,
DIST: AKOLA.
 Index

Sr. Topic
No.
1 Introduction

2 What is coating?

3 Types

4 Working

5 Applications

6 Advantages & Disadvantages

7 Conclusion

8 Reference
 Introduction
Metal Spraying

Thermal spraying protects and extends the life of structures, equipment and vessels in many
hostile environments and situations, where protective surface coatings are vital for longevity.
Many will not have to have their first maintenance of the coating before 20 years’ service,
even in harsh environments, leading to significant maintenance cost reductions.
There are four main methods of thermal spraying, all of which project small molten or
softened particles onto a surface to adhere and form a continuous coating. The temperature
increase of the coated part is minimal, meaning heat distortion is rare – a major advantage
over hot-dipped galvanising or welding.
Thermal spraying for corrosion control is usually carried out by Flame and Arc spray – they
are the least costly and quickest to implement, so are suitable for corrosion protection of
larger structures. Plasma and HVOF sprays are used to apply engineering coatings and are of
higher quality, density, and bond strength.

Powder coating
Powder coating is a type of coating that is applied as a free-flowing, dry powder. Unlike
conventional liquid paint which is delivered via an evaporating solvent, powder coating is
typically applied electrostatically and then cured under heat or with ultraviolet light. The
powder may be a thermoplastic or a thermoset polymer. It is usually used to create a hard
finish that is tougher than conventional paint. Powder coating is mainly used for coating
of metals, such as household appliances, aluminium extrusions, drum hardware, automobiles,
and bicycle frames. Advancements in powder coating technology like UV curable powder
coatings allow for other materials such as plastics, composites, carbon fibre, and MDF
(medium-density fibreboard) to be powder coated due to the minimum heat and oven dwell
time required to process these components.

What is coating?
A coating is a covering that is applied to the surface of an object, usually referred to as
the substrate. The purpose of applying the coating may be decorative, functional, or both. The
coating itself may be an all-over coating, completely covering the substrate, or it may only
cover parts of the substrate. An example of all of these types of coating is a product label on
many drinks bottles — one side has an all-over functional coating (the adhesive) and the
other side has one or more decorative coatings in an appropriate pattern (the printing) to form
the words and images.
Paints and lacquers are coatings that mostly have dual uses of protecting the substrate and
being decorative, although some artists paints are only for decoration, and the paint on large
industrial pipes is presumably only for the function of preventing corrosion.

Types of metal spraying and powder coating

Powder Coating

Epoxies
Epoxies were the first widely used powders. They are very durable, offer excellent hardness
and have arguably the best chemical and corrosion resistance of all available powders.
Another plus of this type of powder is its ease of use and a wide range of cure schedules.
Epoxies adhere to metals extremely well, with various pretreatments of the metal providing
excellent adhesion, including phosphate coating and sandblasting.

Polyesters
Polyesters are the most commonly used powders and offer great value for money. The two
most widely used types of polyester powder: TGIC (tri glycidyl isocyanurate) and non-TGIC,
which is also known as TGIC-free or sometimes a ‘Primid’. Both TGIC and TGIC-free
polyesters offer good mechanical resistance, including great flexibility and impact resistance,
and good chemical resistance. One draw of this powder is its low cure temperature.

Super Durable Polyesters

Super Durable Polyesters have fast become the superhero of polyester powders. As the name
suggests these excellent value powders offer superior durability when compared with a
standard polyester. They are designed to hold their color and gloss to within set limits for 5 to
10 years more when compared to a standard polyester. Not only is their color and gloss
protection better

Epoxy-Polyester Hybrids
Epoxies and polyesters are often mixed together to form hybrids. These hybrids remain
closely related to pure epoxies but offer superior weather degradation properties. These
hybrids can be mixed in various ratios to emphasize the characteristics of either the epoxy or
polyester. The polyester will enhance the overbake resistance when compared with a straight
epoxy and they also create ultra-smooth, thin films.

Metal spraying

HVOF (High Velocity Oxy-Fuel Spraying)

HVOF is a process which makes use of a torch that allows the flame to spread whenever the
nozzle is used. This creates rapid acceleration which speeds up the particles in the mixture.
The end result is an exceptionally thin coating which is evenly applied. Despite being thin,
this coating is strong and adheres well. Its resistance to corrosion is better than plasma
coatings, but it is not well suited for high temperatures.

Combustion Flame Spraying

Combustion flame spraying is an excellent option for surfaces which aren’t designed to
handle extreme stress. The coating which results from this process is not strongly attached to
the surface since the spraying mechanism is powered by a lower flame velocity. The flame
will be generated via oxygen which has been combined with fuel, and this will melt the
mixture. Combustion flame spraying is popular for low intensity applications due to its low
cost.

Plasma Spraying

Plasma spraying makes use of the plasma torch as the main tool for heating and spraying the
coating. After the powder material has been melted down, it is then placed on the product in a
manner which is similar to combustion flame spraying. The coatings which result from
plasma spraying may be a few micrometers thick to a few millimeters think. While powder is
the most widely used material, metals and ceramics are also used. The plasma spraying
process is highly popular due to its adaptability.

Vacuum Plasma Spraying

Vacuum plasma spraying is done in a controlled environment, but utilizes low temperatures.
This maintains the vacuum while also reducing damage on the material. A variety of gas
combinations can be used to get the necessary pressure for spraying. Vacuum plasma
spraying is used for items such as car bumpers, the dashboard or housings for door mirrors.
This process can also be used for the pre-treatment of polyethylene moldings, which provides
adhesion for epoxy adhesives which are water based.

Working

Metal spraying
Metal spraying is a process used across a vast range of different industries and
involves using a high degree of heat in order to achieve a molten state.
Once the molten state is achieved, the material is then meticulously atomised into tiny
particles, and then sprayed onto the surface you are working with. Once the particles hit the
surface, they instantly even, flatten and harden to the surface forming a strong, durable and
water resistant layer.
Although this technique is used across a number of different sectors, it is mostly associated
with the anti-corrosion and engineering markets where precision, quality, fire prevention and
protection and durability are essential.  With this in mind, you will quickly discover that this
technique is used to add finishing coatings, create anti-corrosion layers and thermal barriers,
as well as to optimise wear resistance.

Powder coating
contrast to the liquid coating process, which utilizes a liquid coating suspension,
powder coating is a dry finishing process which employs powdered coating material. During
the powder coating process, the powder is applied to a substrate’s pretreated surface, melted,
and then dried and hardened into a protective/decorative coating. There are three stages to
this process: surface preparation, coating application, and heat curing. Each stage employs a
set of materials and equipment indicative of its particularities (e.g., the curing stage utilizes a
curing oven), and, when properly completed, contributes to the production of a durable, even
surface finish.
 Applications

Powder coating

Appliances

The appliance industry makes up the largest portion of the powder coating market,
accounting for about 1/3 of all industrial powder coated parts. Powder coating is popular
within this segment due to its two-fold benefit of being both aesthetically pleasing as well as
resistant to abrasion and corrosion. Some of the more common appliance applications of
powder coatings include:
 Ranges, Microwaves and Refrigerators: Extreme heat and cold can affect numerous
paints and coatings. Powder coatings can handle a great deal of temperature cycling
without wearing off or flaking. For this reason, powder coating is commonly found on
oven, microwave and refrigerator panels and components.
 Vending Machines: Cooled or not, hundreds of people can use a vending machine
every day. When placed outside, vending machines can take on a great deal of
environmental stress. To protect their appealing exterior varnishes and help increase
the lifespan of the appliance, vending machine manufacturers often finish many of
their panels and components with powder coatings.
 Washers and Dryers: Standard washers and dryers used to contain parts covered
with porcelain enamel, but as technology advanced and washers and dryers became
more powerful, the strain on porcelain enamel-coated components proved to be too
much. Now, powder coating has replaced porcelain enamel as the finishing method of
choice for washers and dryers across industry.
Products Outdoor

Rough use and exposure to the elements are to be expected when you place appliances and
furniture in the great outdoors. While these products are built to last in such conditions, their
normal paint jobs often aren’t. Powder coating is seen in many outdoor applications, such as:
 Farm Equipment: Tractors and agricultural equipment experience hard daily use,
and they are often left in the outdoors for hours. To protect their colors from the
elements, such equipment is usually powder coated, providing a durable finish that
will last for years in even the harshest conditions.
 Sports Equipment: From golf clubs and ski poles to bicycles and basketball hoops,
outdoor sports put equipment to the test. In rain or shine, powder coating provides a
quality finish that can stand up to hard use and nasty weather.
 Outdoor Furniture: Everything from playground and park equipment to lawn chairs
use powder coating. The finish provides an aesthetically pleasing look and helps to
protect the equipment from corrosion, no matter how many years the fixtures spend in
the baking sun and unforgiving cold.
 Signs: Signs are crucial to public spaces, providing directions and instructions for
automotive and pedestrian traffic and promoting for businesses. A worn-out sign
causes confusion, and it can lead to automotive accidents and lost business. To help
avoid this, many signs are finished or primed with powder coating to increase their
lifespan of legibility.

Architecture and Construction

One of the fastest growing markets for powder coating is the architectural and building
market, primarily due to the durability provided by powder coatings. With the wide variety of
colors and finishes available in powder coatings, more and more construction companies are
turning to powder coatings to provide long-term exterior finishes for outdoor venues and
public works projects. Some of the most common applications for powder coatings in
construction include:
 Stadiums: With exposure to the sun’s UV rays and frequent use by visitors, stadium
seating for outdoor venues is prone to quite a bit of wear and tear. To help protect
seating while maintaining high-quality color, many architects finish their stadium
seats and handles with a powder coating finish.
 Windows and Doors: Extruded aluminum door and window frames and doorknobs
are commonly finished with powder coatings. The finish helps protect the materials
 from harsh weather conditions, but it also helps maintain colors and finishes no matter
how many hands touch them or how many storms they weather.
 Fencing and Poles: For both public and private property, fences and poles for
signage, property protection and structural support need to maintain aesthetic appeal
while warding off corrosion. You can accomplish both goals with a powder finish.
 Building Facades: Industrial buildings and modern structures often feature metal
components or facades, facing weather conditions from rain and snow to unforgiving
heat. Most paints will crack or peel or otherwise degrade under severe conditions, but
not powder coating. For a quality color that stands the test of time, architects working
with metal facades often turn to powder coating.

Automotive Items

Powder coating is commonly used throughout the automotive industry as both a basecoat and
a finish for a variety of automotive components. Some of the more specific applications of
powder coating include:

 Surface Primer: Numerous luxury and sports car manufacturers use powder as an

intermediate coat on certain car models. Door handles, trims and bumpers are
especially popular subjects for powder coating, as they tend to undergo more stress,
therefore requiring more protection and coat bonding. It’s also popular as a base
coating for sports vehicles like ATVs and snowmobiles.
 Under-hood Components: Break components, radiators, shock absorbers, oil filters,
battery trays and coil springs are all interior automotive components. Heat, stress and
elemental wear and tear all contribute to these parts wearing down and corroding over
time. Powder coating helps protect these components and extend their lives in even
the harshest conditions.
 Wheels: Wheels and hubcaps are exposed to the brunt of a car’s elemental stress.
Water, snow, ice and the occasional scrape against the curb can all contribute to the
wheel’s color and finish wearing down over time. Powder coatings provide additional
protection from the elements, and they’re gaining popularity among specialty and
alloy wheel manufacturers.
 Motorbike Frames: Motorized bikes, especially those meant for extreme sports,
undergo daily stresses that typical paints can’t survive. Instead, they are powder
 coated, providing either a colored finish or a base coat for another finishing technique,
effectively extending the lifespan of the motorbike’s outer layer.
 Public Transportation: Hundreds of people touch the bars and handles inside of a
bus or train on a daily basis, and therefore are more prone to wear and tear. Powder
coatings help protect these parts, preserving their color and finish for years.

Metal spry coating

Wind turbines
Atmospheric corrosion causes damage to wind turbines. It’s for this reason many
manufacturers specify thermal sprayed zinc or zinc/aluminium alloys as a method of
corrosion protection. Thermal sprayed coatings – using the arc spray process – give a resilient
finish, which is less susceptible to damage than many paint coatings.

Oil industry
Oil industry pipes, risers and structures  are often exposed to harsh elements and oil and gas
platform structures benefit from the application of thermal sprayed aluminium (TSA). This is
done using the arc or flame spray process, where the molten material is atomised by a cone of
compressed air and propelled towards the pipes. This spray solidifies when it hits the surface
to form a dense coating, which protects against corrosion for in excess of 20 years in the
harshest of environments

Bridges
There’s usually heavy footfall or traffic over bridges so metal spraying them is ideal, as not
only does it protects from corrosion – it also helps extend a bridge’s life. The flame spray
process, where the wire is fed by a driven roller system through the centre of an oxygen-fuel
gas flame and is melted, is ideal for protecting bridges. Metal spraying is proven to be the
best protection from corrosion and can provide protection for up to 20 years to first
maintenance.

Petro-chemical plants
In the Petro-chemical industry, Corrosion Under Insulation (CUI) – where accelerated corrosion
can occur under wet insulation – consumes a significant percentage of maintenance budgets.
By protecting against CUI, companies can move towards inspection-free and maintenance-
free piping systems and significantly reduce maintenance costs. Metal spraying is the ideal
solution for the protection of refinery and process plant vessels, tanks and steel fabrications,
as it’s proven to be a very robust coating solution for protecting against CUI.

Structural steel work

The Burj Al Arab hotel in Dubai is one of the most famous steel structures that’s been metal
sprayed. In total, 10,000m2 of steelwork was arc sprayed, including the heli-deck framework,
roof mounted mast and 6 diagonal support braces. The aluminium coating should protect the
Burj Al Arab from corrosion for around 15 to 20 years, even in the harsh, coastal
environment in which it’s situated.

Seam spraying of ERW tubes

Tubes are produced on a tube forming mill by Electrical Resistance Welding (ERW) the
longitudinal seam. During 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
ideal way to protect it is to metal 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.

LPG cylinders
Metal spraying is used to protect LPG, propane gas or butane gas bottles against corrosion.
Gas cylinders are often refurbished and, as part of that process, the surface of the bottles is
grit blasted to prepare it prior to spraying with zinc. LPG cylinders are usually metal sprayed
using the arc spray process.

Architectural coating
There are many creative architectural coating solutions for things like balcony parts, such as
support columns, balcony decks and curved railings, and decorative window and doorframes.
If used externally, they will be subjected to the corrosive effects of the weather so need to be
protected. Metal spraying is ideal for this, as being a cold process there is no risk of distortion
or fettling, unlike with hot dip galvanizing. There’s also the opportunity to use different
coatings, such as bronze or copper, to fit with the overall design scheme.
 Advantages & Disadvantages

Powder coating
Advantages

 It is More Durable

 Protecting the Environment

  It Can Save Money

Disadvantages
Although powder coating has many advantages, it also has disadvantages as well, including:

 Hard to achieve thin coating layers

 Will break down if exposed to UV rays
 Colour change difficulties
 Start-up costs are high

Metal spraying
Advantages
1. Wide selection of spray materials.
2. Wide selection of substrate materials.
3. Speed of coating formation is fast.
4. Wide range of substrate dimensions.
5. On-site work possible.
6. Coating can be formed while keeping
substrate at low temperature.
7. Spraying is a dry process so
environmental impact is low.

Disadvantages
1. Thermal spray coating does not always indicate the characteristics of the original
material.
2. Thick coatings are difficult to achieve.
3. Low degree of adhesion (spray efficiency) on small substrates and substrates with
small curvature.
 4. The coating formation process is not sufficiently clear and the relationship
between the causes (parameters) of the application process and coating
characteristics is also unexplained.

Conclusion
In conclusion, powder coating and Metal (Thermal) spraying is a very effective and efficient
method of protecting the surface of a given metal item.
It protect them from corrosion and rusting and various types of erosions
 Reference
https://www.sciencedirect.com/topics/materials-science/thermal-spray-coating
https://www.ofic.co.jp/en/r_and_d/thermalspraying/
https://www.performancecoating.com/advantages-disadvantages-powder-coating/
http://www.surtech-ind.com/common-uses-powder-coating.html
https://www.irsltd.co.uk/advantages-and-disadvantages-of-thermal-spray-coatings/