Thermal spray aluminium coating: Technology to protect, prevent corrosion of materials

Thermal spray aluminium coating is evaluated as an effective anti-corrosion method for works near the sea or under the sea. The following article will introduce the aluminum spray coating method, the benefits of applying this method and the corrosion resistance of this method.

thermal spray aluminium coating


What is thermal spray aluminium coating? Advantages when using aluminum spray coating solution

Structures near the sea and under the sea are often eroded by seawater and heat. The speed of waves and collisions on the sea also have a significant impact on the works. This leads to costly repairs. Therefore, investors often look for measures to protect the works. Thermal spray aluminium coating is a method widely applied in large projects. The following content will introduce the aluminum spray coating method, its corrosion resistance and its benefits.

What is thermal spray aluminium coating? The ideal thickness of aluminum spray coating

Thermal spray aluminium coating describes a thermal spray method that is resistant to corrosion, protects and increases the life of the material. Aluminum heat injection is a process whereby a powder or metal wire is melted. The molten aluminum is then pushed or sprayed onto the surface of another metal or structure.


Based on the rate of wear of the metal, a thick aluminum coating has the potential to extend its service life. A common coating thickness for aluminum is around 0.015 inches or 0.38 mm. However, the thickness of the aluminum thermal spray coating often depends on the purpose: corrosion control, wear resistance, traction, or restoring dimension… The two most common and effective methods for applying coating Aluminum is Twin Wire Arc and the Fed wire system.

thermal spray aluminium coating


Thermal spray aluminium coating method has high corrosion resistance

For many years, thermal spray aluminium coating has effectively protected offshore structures from the corrosive effects of seawater and the marine environment. According to NACE International, coatings are applied on undersea structures to protect carbon steel from corrosion because they act as a bad agent barrier. In seawater, aluminum has a low rate of self-corrosion. The aluminum spray coating acts as an anode and provides a significant degree of cathodic protection at ambient temperatures and above. Even if the aluminum coating is damaged and thins over time, corrosion does not occur rapidly.

Thermal spray aluminium coating solutions offer a wide range of benefits

Thermal spray aluminium coatings provide much better resistance to corrosion than paint or many other coatings. In seawater, the aluminum spray coating can even cover large cuts and limit scratches from strong impacts.


The properly applied aluminum coating has been shown to protect materials up to 40. It is the coating of choice for corrosion under insulation at many large petrochemical facilities. Aluminum coating is gradually replacing both paints and galvanized for the following reasons:


  • Minimum Maintenance Needs

  • Low cost

  • Outstanding adhesion

  • Great longevity

  • Resistant to mechanical damage

  • No health hazard from solvents or other organic substances

  • No drying/curing time; Can be processed almost immediately after application

  • Wide operating temperature range: -50 degrees F to 1000 degrees F (-45 degrees C to 538 degrees C).

  • Provides sacrificial anode effect on steel in marine environments.


Above is information about the aluminum spray coating method. In short, aluminum thermal spraying is a highly appreciated method because it offers many outstanding advantages. In addition to marine works, aluminum spraying can be applied in other fields such as oil and gas, mechanical engineering, and buildings. You can read our other articles to understand more about measures to prevent corrosion and increase the life of other materials.

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