Thermal Spray Solutions provides corrosion resistant coating solutions!

Corrosion can be defined as surface deterioration caused by reaction to harsh environmental conditions, oxidation, or chemical action.

Thermal spray coatings can be an excellent application for providing protection against corrosion. Particularly in applications involving large structural components such as bridges, wind turbine towers, large expanses of pipes for example in petrochemical plants or refineries, water towers, or ship structures subject to salt water corrosion, aluminum or zinc coatings are applied as “sacrificial” coatings to protect the underlying substrate from corrosion.

These “sacrificial” coatings are designed to deteriorate but at a much, much slower rate than the substrate would. These aluminum or zinc coatings attract and capture oxygen molecules so they cannot reach the substrate and begin the destructive process of corroding it. Hence, they are in fact, “sacrificing” themselves to protect the substrate. These coatings last for decades and are extremely effective at providing corrosion protection over long periods of time against continuous exposure to corrosive attack.

Although commonly used on large structural components, these aluminum and zinc coatings are also used on pump housings, valve bodies, electrical enclosures, generator mufflers, exhaust pipes, and many other metal parts subject to atmospheric or salt water corrosion.

Ceramic coatings can also be used as effective corrosion resistant coatings especially in the case of chemical attack from acidic or alkaline solutions. Typical applications for these types of coatings would be pump shafts, sleeves, or seal rings usually in harsh environments such as in the pulp & paper, chemical, and mining industries.

U.S. Navy – One of the front-runners for using thermal spray coatings for corrosion resistance, the U.S. Navy started testing aluminum sprayed coatings in 1977 when initial tests were carried out on high temperature steam valves. It quickly became apparent that aluminum sprayed coating systems provided long-term corrosion protection to the steam valves and significantly reduced maintenance costs. The original steam valves coated in 1977- 1978 are still under evaluation and no recoating has yet been required. The success of these original applications has led to many more applications on Navy structures and equipment in corrosion-prone areas.