Metal Coating - Everything you have to know about this technology

 Metal coating technology is increasingly exciting thanks to the benefits and efficiency. With the development of techniques and technology, coating methods have been improved to bring better efficiency. So let's learn about metal coating characteristics, practical applications, and advantages/disadvantages of this method through the sections presented below.

Metal coating - Advantages and industrial applications that we should know

Metal coating technology has been widely used throughout European countries and gradually proves its superiority in large and small projects. In addition to providing corrosion protection and performance enhancement, thermal spray coatings are used to repair and restore corroded or misc-machined parts. So how exactly is this method done? And what makes this coating so outstanding? This article will answer everything about the metal coating method.

What is the meaning of metal coating and the way it works

The metal coating was invented by Max Ulrich Schoop - a Swiss engineer - in the early years of the 20th century. The principle of this technological method is to use heat sources (arc, combustible gas, plasma) to make the metal melt. Then, the liquid metal is blown strongly by the compressed air stream, which creates mist particles to spray on the surface of the prepared object (cleaning, roughening). A layer of coated metal with high quality is built. Custom thickness, in which metal particles overlap in layers. At first, metal spraying was only used for decorative purposes. However, by the second world war, this technology began to be used on a large scale. Metal spraying technology is being used in most European countries and is showing more and more advantages.

Read more: The 5 most common metal coating types and their benefits

How many advantages does the metal coating method have?

• Create heat spray coating used in many projects with different large and small scales.

• Long service life: Some applications have been rated to last more than 50 years.

• Higher life-cycle costs: a method that extends equipment life and effectively reduces temporary maintenance.

• High mobility and easy automatic control are suitable for the on-site and local processing of large structures or intricate details.

• Ease of application in cold weather: Unlike most coating systems, metal coating on surfaces can be applied at any temperature.

• Easily control coating thickness: The combination of optimal coating with modern engineering applications can be controlled precisely to ensure optimum deposition is achieved.

• Applies for surfaces with complex shapes: Even components with complex-shaped surfaces can be efficiently coated using the robotic application of metal coating.

Does metal coating method have any disadvantages or weaknesses?

Besides the above advantages, the metal coating method still has some disadvantages that need to be overcome:

• Higher initial costs due to technical and technological requirements

• Requires a higher surface preparation level and involves removing other surface defects to achieve a good effect.

• Requires highly skilled and experienced technical workers, heavy and hazardous working conditions.

• Much spray material loss.

Read more: Can HRSG Cleaning a cooling tower prolong its life and increase its performance?

The application of metal coating method in modern industries

Today, the development of metal coating has extended to many different fields of application such as aerodynamics, nuclear, mechanical engineering to create wear-resistant, anti-corrosion coatings, electrical industry, insulation,... Particularly in recent years, plasma coating technology has made significant progress thanks to achievements in laser particle flow measurement. 

This method can spray materials with high melting temperatures such as tungsten, molybdenum, chromium,... This method is significant in coating layers in rocket engineering, electrical engineering (coating non-conductive materials), and machining parts subject to high temperatures.

The scope of application of the metal coating method can be classified as below:

• Recovery spraying

• Spraying special coatings with wear-resistant, anti-corrosion, heat-resistant,...

• Spray coatings (conductive coating, good thermal conductivity, magnetic coating) on parts where the base material does not have these properties.

• Repair defects of castings.

• Repair defects in parts of machining.

• Create a decorative layer.

In particular, the purpose of spraying to restore worn machine parts and protect against corrosion of steel structures is the most applied.

Despite some limitations, the metal coating is still considered a method of corrosion protection that shows great promise in the future. It provides a long-lasting solution and effectively protects surfaces over the years. That's why this method is used for most industries.