When is it cost-effective to use thermal spray in petrochemical facilities?

Selected Answers

From James Weber of James K Weber Consulting on November 17, 2011:

Typically, thermal spray coatings are cost-effective in the petrochemical industry when you
consider the cost of inspection, especially under insulation.

Even the best, most expensive paints must be inspected in 3-7 year cycles when used in CUI
(Corrosion Under Insulation) conditions. Inspections most often mean scaffolding, removing all
cladding and insulation, intensive inspection, including a lot if UT testing of pits, blasting,
painting, re-insulating, re-cladding, removing scaffolding, etc. If thermal spray aluminum (TSA)
is used instead of paint, these inspection cycles are pushed out to 25 years (ExxonMobil) to 40
years (Shell).

In this case, blasting and recoating is not required, just inspection, as it is known that a properly
installed anodic TSA coating system will not corrode or “sacrifice” itself unless it is installed in
such a way that the TSA has to provide anodic protection for a large cathode (unfavorable
anode to cathode ratio) when an electrolyte (water or wet insulation) connects the TSA to a non-
TSA coated area. We don’t do this in the petrochemical field, as we coat an entire vessel,
column, or pipe (flange to flange) instead of just a tiny area and expect it to protect the entire
structure.

Regarding the cost of thermal spray in a refinery, one must consider the entire erected costs
(scaffolding, cladding, insulation, grit blasting and disposal, etc.) of a coating job and not just
“the coating.”

Around 6 years ago, ExxonMobil reported that when the entire erected costs are considered,
TSA coatings cost them 0.5%-1.5% more than liquid coatings; however, some of the paints
used in CUI service have doubled and tripled in price since then. Many times, thermal spray can
be applied at lower costs than wet paint when you consider factors like weather conditions, no
VOC regulations, ease of or less need for touch-up, robust coatings that can be applied offsite
and then installed, etc. As a pipeline applicator who did both wet paint and thermal spray
coating, we charged less for thermal spray than a three-coat paint system.

Applications of Thermal
Spray Aluminum
March 15th, 2021
Thermal Spray Aluminum (TSA) is a durable coating capable of providing complete corrosion protection
and significant lifetime improvement for equipment. Thermal spraying techniques provide a versatile
and cost-effective way of imparting high-performance coatings, lending thermal spray aluminum to a
huge range of industrial and infrastructure applications.

Properties of Thermal Spray Aluminum

Thermal spray aluminum coatings are commonly applied in marine, pipeline and offshore infrastructure
applications, especially where structures and components are exposed to seawater. In these
applications, coating steels with thermal spray aluminum protects them against corrosion by setting up a
cathodic circuit: the difference in electrochemical potential between steel and aluminum means that the
steel effectively becomes a positive electrode (cathode) of a cell while the aluminum coating acts as a
negative electrode (anode). The circuit is completed by water, and the resulting electrochemical action
means that the aluminum corrodes preferentially to the steel, acting as a ‘sacrificial’ material and
protecting the steel structure.

Thermal spray aluminum also imparts resistance to erosion and other types of mechanical wear.
Additional benefits of aluminum include relatively low cost and high operating temperature (up to
538°C).

Thermal Spraying Fundamentals

The term “thermal spraying” denotes a group of distinct techniques, all of which involve heating a
feedstock material (usually in powder or wire form) and propelling it towards a target substrate. The
spray of melted or partially-melted feedstock material forms lamellae or “splats” on the target, which
build up to create a uniform coating.

Thermal spray aluminum most commonly uses wire arc spraying or flame spraying. Both of these
methods use aluminum wire as a feedstock, which is heated above melting point and sprayed across a
surface by a jet of compressed air or inert gas. The primary difference between these two methods is
the means of supplying energy to the aluminum wire: wire arc spraying uses an electric arc to melt the
aluminum, while combustion wire spraying uses an oxy-fuel flame. As the name suggests, wire arc
spraying uses a wire feedstock, which is much more economical than coating with powder – particularly
for large area substrates.
While arc spraying achieves higher throughput of wire, flame-spray has a higher build-rate for its lower
throughput, evening out the final coating rate. Flame spray torched also lead to higher, less-oxidized
coating quality and a more controlled spray pattern with less fumes and need for PPEs.

Applications of Thermal Spray Aluminum

Thermal spray aluminum is a simple, versatile and cost-effective coating. Its anti-corrosive properties
lend it to widespread use in coating bridges, ship decks, large metal tanks, and other metal structural
components that would be otherwise susceptible to corrosion.

Saint-Gobain provides a complete range of flame spray coating technologies and metallic and ceramic
materials, including aluminum wire feedstocks for thermal spraying applications. Contact a member of
the team today if you would like to learn more.

Benefits of Flame Spray Coating

Compared to other thermal spray processes like HVOF and plasma spraying, flame
spraying has a relatively low operating temperature and produces low droplet speeds.
These process conditions do place some limitations on the materials that can be deposited;
and other thermal spraying processes can produce higher quality coatings. However, the
cost effectiveness and ease of the flame spray process mean it remains the most popular
thermal spray process today.
As the simplest thermal spray method, flame spraying is generally the cheapest way of
depositing a protective metallic or ceramic coating. Because flame spraying is generally
carried out by hand, it is well-suited to components with irregular or complex geometries.
Flame spraying equipment is typically portable and easy to use, and eliminates the need for
mechanical manipulators for most applications.
Applications and Materials
The quality of flame spray coatings is sufficient to meet the needs of a wide range of
protective applications. Flame spraying is still widely used for reclamation of worn shafts
and other mechanical equipment, and for protecting structures and components against
corrosion.
A wide range of materials including aluminum, bronze, low-carbon and stainless steel,
molybdenum and zinc can all be deposited via flame spray. With our equipment, high-
quality ceramic and carbide coatings can also be produced using our proprietary Flexicord
products and Rokide rods.

Flame Spray vs Twin Wire

Arc Spray: What’s the
Difference?
June 10th, 2021
Flame spraying and twin wire arc spraying (generally referred to simply as "wire arc
spraying") are two different types of thermal spraying process. With a great deal of overlap
in the capabilities of these two techniques, it can sometimes be difficult to know which one
is best suited to a given use case. In this article we take a look at the unique characteristics
of each technique, to help you decide which is the best coating solution for your
applications.
The term “thermal spraying” encompasses a wide range of different techniques, all of which
share the same fundamental operating principle: By heating a feedstock of deposition
material – often in wire or powder form – and accelerating molten or semi-molten droplets of
it towards a substrate, a coating can be formed. Thermal spray is used to coat structures
and components with a diverse range of metals and ceramics to provide protection against
corrosion, friction, or other harsh operating conditions.
Flame spraying and wire arc spraying were the first thermal spraying techniques to be
invented. They remain the simplest and most common types of thermal spraying.
Operating Principles of Flame Spraying and Wire Arc Spraying
The fundamental difference between flame spraying and wire arc spraying is the means by
which heat is supplied to the feedstock material. Flame spraying – as the name suggests –
uses a flame to do this, usually a combination of oxygen and either acetylene or propane.
Deposition material is introduced to the flame in either wire or powder form, and a stream of
compressed air accelerates droplets of the molten deposition material toward the substrate
to coat it.
Wire arc spraying, on the other hand, uses an electrical arc to heat the feedstock material.
The deposition material is always supplied in the form of two wires (hence the name “twin
wire arc spraying”), which are fed into the spray gun by drive rolls. Within the spray gun, a
potential difference is applied between the two wires such that electrical arcing takes place.
This causes the tips of both wires to melt. A high-speed flow of gas removes molten
material from the wire tips and accelerates it toward the substrate, while breaking down
larger droplets into smaller ones.
Practical Differences Between Flame Spraying and Wire Arc Spraying
The operational differences between flame spraying and wire arc may seem minor: both
techniques involve the application of heat and compressed gas to the deposition material to
melt it and spray it toward the substrate. However, the different operating principles have
several practical ramifications.
Flame spraying and wire arc spraying offer different performance. Wire arc spraying can
offer higher deposition rates (provided equipment is capable of delivering sufficiently high
power); lending it to applications where speed is important. However, flame spraying has
the advantage in a number of other performance areas: flame spraying can offer better
process control leading to more stable quality, less oxidation – especially important in
application where conductivity of the metal is imperative (copper, zinc) – and denser
coatings suitable for demanding anti-corrosion applications. In addition, flame wire spraying
offers higher deposition efficiency than wire arc spraying, meaning less loss of material
leading to lower cost per mass of coating and evening out the difference in deposition rate.
An important EHS favoring flame spray is the drastically lower amount of fine particle
emissions, which are cut down to 1/60th compared to arc spray [1] directly leading to
decreased risk of metal fume fever.
The simplicity of flame spraying typically means it has lower capital costs than wire arc
spraying. However, the running costs of flame spraying are generally higher due to the need
for fuel gases. Often, the choice between flame and arc spraying can be determined by a
lifetime cost analysis and the surface geometry: smaller surfaces benefit from the narrow
spray stream and less overspray of flame spray, while larger ones benefit from the speed of
arc spraying.
Whether flame spraying or wire arc spraying, Saint-Gobain offers a comprehensive range of
coating technologies and materials to help you achieve the result you need. To find out
more about our coating solutions, get in touch with Saint-Gobain today.

ALUMINIUM THERMAL SPRAY

COATINGS
PROTECTING STEEL BRIDGE STRUCTURES FROM
CORROSION
2nd February 2021 | Thermally Sprayed Coatings, Surface
Preparation, Construction

Using Aluminium Thermal Spray Coatings is a great way of protecting a metal

surface and offering resistance to many processes such as general wear,
rusting & corrosion, abrasion or extreme temperatures. One common
application of our Aluminium Thermal Coating is on bridges to ward off
corrosion.
Bridges are an essential infrastructure across the world, crossing roads, railways as
well as bodies of water such as rivers and bays. Failure of a bridge structure could
lead to catastrophic consequences, so ensuring the integrity of the bridge is not
comprised through corrosion is of utmost importance.
The leading cause of corrosion occurring on steel bridges is the exposure of the
steel to atmospheric conditions. Due to things such as marine/salt spray and
environmental pollution, the rate of corrosion is greatly enhanced.

OUR THERMAL COATING SPRAY SOLUTION

Repairing damage caused by corrosion can be costly, both in time and money. For
this reason, a high performance, proven corrosion protection coating is often
required and specified.
 Our aluminium thermal spray coating is an excellent choice that works to provide a
layer of protection between the base material and environment. It can also provide
new levels of hardness and added wear and erosion resistance. Increasing the life-
cycle of the bridge and reducing the amount of maintenance means our customers
save money. 
All steel bridges can be given excellent protection from corrosion by the use of
thermally applied aluminium to ~100microns. Ideally, the surface is then sealed with
AFTs corrosion-resistant liquid topcoats such as AFC 2114.

As well as our aluminium thermal spray coating, zinc is another coating that can be

applied to bridges. Often, the choice of coating will depend on the environmental
conditions that the bridge is going to have to withstand. Our expert knowledge
means we can help with choosing the correct thermal spray based on the conditions
it will be exposed to.
The main benefits of using our aluminium thermal spray coatings include:

 The metal is protected from corrosion and rust

 Extends the life cycle of the bridge
 Reduces maintenance cost and frequency of repairs
 Super adhesion properties
 Limited drying time - handling of coated parts can be done almost immediately
 Quick turn around - like all of our coating solutions, one of our key strengths is
completing projects quickly!

PREPARING THE BRIDGE FOR SPRAYING 

As with any of our coating systems, the surface profile of the metalwork on the
bridge structure needs to be in the correct condition for good adhesion of the
thermal spray coating. No matter how good the liquid or thermally sprayed coating
is, it will not perform to its full capabilities on a poorly prepared surface.
AFT ensures all surfaces to be coated are clean from oil and other debris, which
could cause contamination. Controlled blasting of the surface increases the surface
area of the part ensuring good adhesion of the thermally applied coatings. 

ALUMINIUM THERMAL SPRAY

COATING
PROVIDES EXCELLENT CORROSION RESISTANCE
 If you are looking for a metal surface that displays excellent corrosion resistance,
our aluminium thermal spray coatings are one to be considered.
It also provides heat resistance and high heat conductivity, with it being widely used
on exhaust systems, new systems, street lighting columns and vehicle restoration
exhaust systems.
We commonly coat steel components and substrates that have to withstand
corrosion from the elements.

Reduced lead times

We can complete urgent orders quickly, keep your project on track and prevent on-
cost through delays.

Bespoke solution
The specific coating we select for your application can be tailored to your needs if an
existing grade isn't quite suitable.

Reliable partners
We pride ourselves on offering a high level of customer service, from quick response
to enquiries and short production lead times, to overnight turnaround in urgent
cases.

BENEFITS TO ALUMINIUM COATINGS

 Conductivity: It is an extremely conductive material, both electrical and thermal
 High yield strength: Aluminium is one of the most ductile metals on earth and
has exceptional strength-to-weight ratio
 Range of applications: Our aluminium coatings can be applied to a wide range
of substrates, including mild steels, low alloy steels and high carbon steels.
 Oxidation resistance: It is a corrosion resistant metal that naturally generates
a protective coating