Metal spray coatings are a solution for maximising consumer profits by extending component’s life and minimising downtime needed for maintenance.
Many engineers are reaping the benefits of metal spraying. Read on to learn more about how metal spraying could save your business money.
Understanding Metal Spraying
Metal spray coating (or thermal spraying) is the process that utilises heat to turn metallic and non-metallic materials into a molten or semi-molten state, which is then sprayed onto a component’s surface.
Once projected to a surface, the molten particles ‘flatten’ and cool with sufficient force to adhere, forging a reliable bond. Repetition of this process means a coating may be customised to a desired thickness.
Hence, the coating has changed the surface properties of a component. The new coating is now suitable for its required operations, such as machining, grinding, polishing etc.
Metal Spraying Applications
The application of metal spray coatings is utilised across a wide scope of sectors, including automotive, aerospace, power generation, gas, oil and chemical processing. Its popularity is largely accredited to its versatility and the range of properties coatings can achieve.
The possibilities are truly endless. However, here are some examples of metal spraying applications:
Corrosion And Wear Resistance
Thick coatings are used to extend the lifetime of components in aggressive environments.
Thermal Barrier
Protects components and engineers against intense heat sources.
Chrome Replacement
Due to environmental concerns, metal spray coatings are valued as an alternative to chrome plating.
Self-Lubricating
Coatings provide scruff resistance in dry-running applications and for frictional purposes.
Moulding
Impressive adhesion quality ensures long-lasting release properties in mould release applications.
Refurbishment
Damaged, worn, or eroded components can be reclaimed by using metal spraying.
Aesthetic
For artists or architects, cold sprays can be used for decorative coatings wherein a substrate tends to be thinner.
Abradable
A coating that wears easily is applied to a stationary component, creating a perfect fit for the part it is adhering to, also known as ‘bedding-in’.
Non-Stick
The application works to prevent sticking.
Non-Slip
The spraying application intends to create a deliberate surface roughness to reduce slipping.
Electrical Conductivity And Insulation
Used to enhance either the conductivity or insulation of a component.
Financial Benefits Of Metal Spraying
Now that you understand the uses of metal spray coatings, we will illustrate how this investment saves you money. There are many financial benefits to metal spraying, such as:
Cost Savings
The hefty costs accrued by constantly needing to replace equipment can ruin a business. It makes much more sense to protect your assets, rather than spending frivolously to replace them.
Metal spray coatings maintain components for longer. Therefore, it is the perfect solution to protecting your assets (and bank balance).
Also, the waste associated with metal spraying tends to be significantly lower than other coating methods. Therefore, when incorporating expensive materials, it is a more viable option.
Efficiency
As we have already established, there are various ways in which metal spraying can be used across industries. In each case, the efficiency of components is increased.
By providing corrosion protection, or thermal insulation, the long-term effects of energy expenditure are reduced. Metal spraying can improve the energy performance of components, so that desired results may be achieved at a lower cost.
Extended Lifespan Of Components
Metal spray coatings are a common method for engineers because they extend the lifespan of a substrate. Strong coatings provide an effective barrier against erosion, decomposition, and other forms of surface damage.
This method also allows thicker coatings to be applied at higher deposition rates. When compared with other coating methods, metal spraying achieves a stronger barrier against wear and tear.
Maintenance Reduction
Maintenance disruptions and charges are an unwanted detriment for any business. They can interrupt a project timeline, make deadlines no longer achievable, be costly and halt operations entirely.
Due to metal spray coatings providing reliable, consistent performance, components require less maintenance. The durability of your components is overall increased, leading to fewer malfunctions.
Fewer malfunctions mean fewer maintenance invoices. It’s that simple.
Saving Money With Alphatek
We hope you agree with us- metal spraying undoubtedly saves you money!
Since 1993, Alphatek has worked with a diverse client portfolio to provide cost-saving solutions across various sectors. Our metal spraying services are technically sound, quality-assured, and delivered with top-quality service. Don’t just take it from us, take a look at our clients.
If you would like to know more about how we at Alphatek can save your business money, please don’t hesitate to get in touch.
