Overview of metallization: Definition, classification, advantages

 Metallization is a protective coating technique widely used in many industries, because thermal spraying brings many benefits. So what is thermal spray? How can this method be applied? What are the benefits of this technology? Find out with us in the article below!

What is metallization spray? Information on protective and anti-corrosion coating methods

Corrosion is a natural process taking place after a long time of metal being exposed to the environment. Corrosion causes serious deterioration of buildings, structures, and equipment details. Metallization is a technique that can limit this phenomenon and effectively refresh the surface of the material. The following content will explain more about this protection method.

1. What is metallization? Definition of metallization coating technique

Metallization or thermal spray coating technology is the process of molten coating metal or alloy materials onto the surface. The precursor coating material is heated by plasma or arc. In addition, a chemical combustion reaction can heat the material. Metallization can provide a thick coating. The coating thickness depends on the purpose of the coating process, the input materials, and the adhesion rate on the surface. This technique has a higher surface bond than electroplating, physical, or deposition methods.

Materials commonly used for metallization are aluminum or steel, and these materials are produced in powder or wire form. The materials used for coating work are heated and sprayed in the form of micrometer-sized particles onto the surface. 

Metal coating quality is assessed by measuring porosity, adhesion, smoothness, oxide content, and surface roughness. The coating quality is directly proportional to the spray particle velocity.

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2. The most common and basic classification of metallization coating methods

The classification of thermal spray coating methods makes the construction process more accessible. This is also a way to help businesses choose the right technology for their intended use.

Classification of thermal spray coating technology by spray agent:

- Spray by flame (Flame Spray)

- Arc Spray (Arc Spray)

- Spray with Plasma (Plasma Spray)

- Spray HVOF (High-Velocity Oxy-Fuel)

Classification of metallization coating by temperature:

- Hot spraying (the surface temperature of the detail during spraying is >250 degrees Celsius)

- Cold spray (the surface temperature of the detail during the spraying process is <250 degrees Celsius)

Classification of the method by type of spray material:

- Powder spray.

- Spray wire.

The common feature of metallization methods is that they have many applications. Materials used to perform various techniques: Metal, non-metal, alloy, ceramic... Coating thickness from 50 micros to 12mm, depending on the needs and purposes. The temperature of the sprayed object is small, so it does not cause surface deformation due to too high a temperature.

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3. In addition to creating a protective layer, what are the benefits of metallization application?

Metallic thermal spray is applied to restore worn cavitation surfaces after an extended use time. Restore the properties of the surface of the material. Repair machine parts to increase longevity. This technique is also used to create a surface layer with high mechanical properties and to repair defects that appear during mechanical processing.

Metallization produces a highly protective coating that is resistant to abrasive and corrosive agents. This method meets minimal maintenance needs. The thermal coating technique is not hazardous to health and is friendly to the surrounding environment.

Uniform coatings are created for details with complex geometric shapes. Robotic manipulation of the nozzle and workpiece helps form a uniform coating of faceted workpieces. High bond strength allows the part to withstand harsh operating conditions. 

The bond strength between the coating and the surface of the part, measured in tensile strength, is sufficient to withstand severe applications or particularly severe wear conditions. Additionally, thermal diffusion helps form a subsequent coating to provide resistance to oxidation and corrosion.

Metallization is also used to limit rust in the atmospheric environment, especially high temperature, pressure, chemicals... This technology is also used to increase the aesthetics of the surface. In addition, this method can increase weather resistance. Over time, the impact of snow, rain, wind, and sun on exterior constructions weakens the metal. The metallization forms a protective layer between the underlying structure and the elements, possibly extending the life of the building and preserving its beauty.

This technology also can reduce maintenance costs. When you paint the typical coating, surfaces will need to be repainted over time to retain their structure and stability. The metallization coating is no desire to repaint or harden the coated surface, which reduces maintenance costs. Moreover, like paints, aluminum coatings are in the market in various tempting colors to meet aesthetic needs.

In general, the method of metallization has many advantages and high flexibility. Hopefully, the article has helped you understand more about the application and the advantages of this technique. You can read more of our articles if you need to learn about coating and anti-corrosion techniques.