When it comes to choosing the right engineering coating for your application, there are a lot of factors to consider. From the types of coatings available to external factors and the industry it is used in… There is a lot that goes into finding compatible substrates and coatings. In this blog, we will explore the necessary considerations that go into supplying the best solutions for our customers.
Understanding Engineering Coatings
Engineering coatings are defined as a coating material, which when applied to a substrate, alters its surface properties. There are numerous materials and applications that benefit from engineering coatings.
Over time, materials used in gruelling environments can tarnish and wear, causing degradation and loss of integrity. Engineering coatings are used to restore and reclaim the physical dimensions of these appliances back to their original form.
There are many industries that benefit from surface engineering. For perspective, think of any product manufactured that requires material protection or a prolonged component lifespan.
When surface technologies were originally engineered, techniques for coating applications included painting or electroplating. Nowadays, we have advanced to using more demanding coating technologies, such as plasma and arc spraying, and physical and chemical vapor deposition
Types Of Engineering Coatings
Thermal Spray Coatings– also known as Metal Spray Coatings, provide a protective layer for metal surfaces or enhance its properties.
- High Friction Coatings: Non-slip solution used to enhance production and traction efficiency.
- Wear Control Coatings: Prevents premature abrasion and component failure by controlling wear.
- Thermal Barrier Coatings: Confines heat where required and isolates conduction to areas where it is not.
- Corrosion Protection Coatings: Prevents onset corrosion and component failure.
- Abradable Coatings: Controls operational clearances in moving pieces of machinery.
Fluoropolymer Coatings– Offer a range of properties to allow for greater flexibility in design engineering.
- Low Friction Coatings: Prevents excessive friction, heat and wear in applications where it is unwanted.
- Non-Stick / Release Coatings: Prevent sticking in applications where slippery surfaces are necessary for efficient production.
HVOF Tungsten Carbide Coatings– Capable of various properties, including wear resistance, high or low friction, abrasion protection, etc. Most common use for roll surfaces in paper production.
Proprietary Surface Engineering Coatings– Technically sounding coatings customised for specific applications that require multiple property enhancements.
Factors To Consider When Choosing The Right Engineering Coating
1. Environmental Factors
- Extreme Temperatures: An application subjected to extreme temperatures, whether subzero or searing heat, may require coatings to withstand their environments. Extreme temperatures can alter surface properties and make components unsafe to operate.
- Humidity And Moisture: Moist environments may cause corrosion and rust, most commonly on metal surfaces. This can impact the integrity of marine or building structures and lead to collapses.
- Exposure To Chemicals: Components that are constantly exposed to chemicals and gases can deteriorate and erode, compromising their protective capabilities.
2. Material Of The Substrate
- Compatibility: Some coating materials on certain substrates may not be compatible, leading to poor adhesion, peeling, or cracking. This will lessen the effectiveness of an engineering coating.
- Adhesion Properties: Coatings have varied adhesion properties. Surface preparation will also impact a coating's performance. Poor adhesion may cause delamination and coating failure.
3. Mechanical Properties
- Durability: Depending on the application, surfaces will have various mechanical properties. Incompatible coatings may chip or wear more easily than others under mechanical stress.
- Flexibility: Coatings that are more rigid may crack on flexible substrates, which would expose the underlying material and be an ineffective coating solution.
Choosing The Right Engineering Coating: Industry-Specific Applications
The automotive industry heavily depends on metal spraying solutions in their applications. Whether it be how interior details, exterior panels, turbocharger coatings, or EGR value coatings, there are specific requirements that the automotive industry requires. Choosing the right engineering coating means these machines can achieve impressive performance and visual standards.
HVOF and Fluoropolymer coatings provide optimal protection in print and paper applications, which are subjected to demanding, aggressive wear and highly corrosive environments.
The stringent requirements of glass manufacturing require specially formulated engineering coatings, such as flame spraying and HVOF coatings. Resistance coatings are necessary for manufacturing moulds, chutes, and plungers that are subjected to extreme heat, corrosion, and wear.
Railway applications require corrosion protection and electrically conductive coatings. For safety and reduced maintenance interruption, rail installation must be highly durable and temperature resistant. Engineering coatings significantly decrease rail track replacement.
Medical equipment must be corrosion-resistant and non-stick. Metal coatings used on machinery such as a pacemaker can improve electrical conductivity. It also reduces the risk of potential threats such as abrasion, friction, corrosion and bacteria growth.
Choosing The Right Engineering Coating With Alphatek
There are many other applications and instances where coatings can be applied, making choosing the right engineering coating a difficult task. With so many options out there, how can you know what the perfect suit for your application is?
That's where Alphatek can help!
We are leading independent thermal spray coating specialists with over 20 years of experience in delivering effective solutions to our renowned clients.
Most of our engineering coatings are proprietary, with a quality guarantee, so you can anticipate that we will know an optimal solution for your application. We take pride in our reputation for delivering great value, reliable, effective, and high-quality solutions.
If you need any guidance when choosing the right engineering coating for your application or have any questions about our products, don't hesitate to contact us.
