At Alphatek, we fully understand that selecting the right metal spray material for optimal performance can make all the difference. As leading coating specialists, we offer an array of high-performance metal spray compositions, all with different finishes, benefits, and results.
In today’s blog, we will dive into the different alloys, ceramics, carbides, and polymers used for metal spraying. By assessing their properties, we will help you select the right metal spray for optimal performance.
Why Do So Many Industries Benefit From Metal Spraying?
You may have heard the process of metal spraying referred to as ‘thermal spraying’, or ‘engineering coatings’, all of which mean the same thing. Whatever your preferred term may be, metal spraying is a surface engineering process, wherein a semi-molten material is sprayed onto a substrate. Once the sprayed material has dried, the surface properties of the substrate are enhanced.
Metal spraying is a sought-after solution for numerous industries, wherein they require the advanced properties of specific materials, but perhaps not the weight or costly value they come with. For industries such as aerospace, automotive, marine infrastructure, rail, and oil & gas, metal spraying is an invaluable technique, guaranteeing energy efficiency, enhanced application endurance, and substantial cost-savings.
How a metal spray coating performs is dependent on the coating material used. Selecting the appropriate material for the process is decided by an application’s operating conditions, environmental exposure, and the desired performance outcome.
Common Metal Spray Materials For Optimal Performance
Metals And Alloys
Of course, metal and alloys are the most common materials used for metal spray coatings, hence the name. Advanced metals are commonly used for their strength, durability, and corrosion-resistant properties.
- Aluminium: For applications that are constantly exposed to harsh environments, like offshore structures, aluminium coatings are commonly deposited. Aluminium offers excellent corrosion protection and possesses lightweight properties.
- Zinc: Rusting can cause significant problems when it appears on structures, pipelines, and bridges. Zinc is widely used for its galvanic protection, especially in atmospheric conditions.
- Nickel-Based Alloys: For applications exposed to high temperatures, oxidation, and abrasion, we would recommend nickel-based alloys. Nickel alloys, such as Incoknel, are known for being highly durable, meaning they can withstand the intense rigour applications such as gas turbines and exhaust systems must endure.
- Copper: As you may know, copper is an excellent conductor of heat and electricity. Copper coatings are a suitable material for electrical components, heat exchangers, and moulds.
Ceramics
Ceramic coatings are recognised for their denseness, high-temperature resistance, and electrical insulation properties. Once the ceramic is molten, the materials are usually applied using plasma spray techniques.
- Alumina: Aluminium oxides are highly resistant to wear and tear and provide advanced thermal and electrical insulation properties. This coating material is often used in mechanical applications that face intense abrasion or intense temperatures.
- Chromia: Chromium oxide provides excellent corrosion and wear resistance, especially in high-temperature environments. Common applications that benefit from chromia coatings include industrial rollers and pump components.
- Zirconia: Zirconium oxide offers exceptional thermal insulation properties, ideal for applications exposed to high temperatures and thermal cycling. Zirconia coatings are often used in aerospace and power generation industries.
Carbides
Carbides are a chemical compound, which is derived from a metallic or semi-metallic element combined with carbon. Due to their exceptional hardness and fatigue resistance, carbides are widely used for metal spray coatings. Carbides are often applied using high-velocity oxygen fuel (HVOF) spraying.
- Tungsten Carbide: When deposited as a sprayed material, tungsten carbide enhances a substrate by offering excellent wear and high-temperature resistance. For applications subjected to constant wear and abrasion, carbide coatings offer adequate protection. This material is commonly used for hydraulic cylinders, pump shafts, and cutting tools.
- Chromium Carbide: Chromium carbide offers similar wear and high-temperature resistance to tungsten carbide but excels in corrosive environments as well. Common applications are seen in oil and gas and chemical processing industries.
Selecting The Right Metal Spray Material For Optimal Performance With Alphatek
When it comes to selecting the right metal spray material for optimal performance, our team at Alphatek are always here to assist you. We are well versed in the properties and benefits of available materials, and what would work best under different conditions, environments, and pressures.
Ensuring the longevity and performance of equipment and machinery can make all the difference to production efficiency and profitability. That’s why we at Alphatek are committed to quality, precision, innovation, and achieving the highest performance standards. You can find out more about our services here.
If you require expert advice when selecting the right metal spray material for optimal performance, contact our team at Alphatek today. You can email us with any enquiries at postbox@alphatek.co.uk or call us on +44 (0) 1706 821021.
