Thermal spray coatings are used for an extensive range of applications such as corrosion, wear, thermal insulation, across multiple industries like the automotive, aerospace, railway, and industrial sectors.
The term spray coatings refers itself to the numerous variety of coating processes. A material, often metal or an alloy, is applied to a surface via the spray application method. Hence why they are called spray coatings. They offer several different characteristics and features which make them advantageous for so many applications. This is why they are widely used across industries.
We’re going to take a look at some of the characteristics and features of spray coatings.
Characteristics and Features
The main characteristics of thermal spray coatings is the lamella structure, porosity, oxides, and rough as-sprayed surface. Sometimes additional treatment is also necessary – finishing, grinding, sealing. Even remelting can be performed to improve things like impact resistance.
To protect critical components from damage whilst working to improve their functionality, applying spray coatings is the ideal solution. It is down to the features and characteristics of spray coatings that make them so widely used.
Versatility
One of the best features about spray coatings, something that makes them popular among industries, is their versatility. They can be thoroughly applied to a multitude of surfaces, including more than just metals: plastics, glass, ceramics, composites, and many more.
It is this versatility that allows them such a diverse use in industries which includes the marine, electronics, construction, automotive, and aerospace industries.
Uniformity
The process of the spray coating, often thermal, allows for a really even distribution of the coating material which results in a uniform thickness all over the surface. Such even uniformity means that the appearance is consistent and so is the protection offered.
Level of Thickness
As thermal spray coatings are quite quick to dry, the thickness can be easily controlled as multiple applications can be made. In addition, the spraying parameters can be adjusted which means that the pressure, nozzle size, and distance of the spray can be altered.
This control of thickness means that coatings can be done precisely.
Application Speed
Compared to the more traditional methods like brushing, thermal spray application is a faster method. The speed at which a coating can be applied can lead to an increase in productivity alongside reduced downtime in industrial processes.
It takes a shorter amount of time to thermally spray a coating to a component which means that components are out of operation for less time.
Adhesion
When applied correctly, spray coatings have excellent adhesive qualities. As long as the surface is prepared properly and thoroughly and the right coating material is applied, good adhesion will be achieved.
Shape Coverage
Due to the nozzle shape and size, the thermal spray coating process is the most ideal when you need to coat machine components that are complex in shape or size. Complex and intricately shaped parts are easier to coat with spray nozzles.
Thermal spray applications are best suited for components that have irregular geometries and hard-to-reach areas.
Material Range
There are many different types of coating materials that can be used in spray coatings. Though many people are aware that metals are great for spray coatings, and they are most common, other materials include paints, polymers, ceramics, and glass.
Such a range of coating materials allows for a large range of properties: corrosion resistance, high temperature resistance, resistance to wear, and more.
Improved Performance
A key feature of spray coatings is that they can seriously help to improve the performance of the components they’re applied to. They provide additional layers of protection to substrates which improves mechanical properties and the overall durability of the substrate.
Repairability
Spray coatings can easily be recoated if the need for it arrives due to sustaining damage or becoming worn. So the service life of coated parts is always being extended and the maintenance costs will be reduced compared to parts without protective coatings.
Overall, there are many versatile and efficient means of surfaces having protective layers that are functional due to spray coating applications. When surface performance is critical, this makes spray coatings the top choice across a wide range of industries.
Alphatek Hyperformance Coatings Ltd
Our collective coating experience spans over a century so we’ve seen a lot when it comes to spray coating applications. The good, the bad, and the ugly. And we know how to deliver the good.
Application requirements can seem limitless but if there’s one thing you should know about our team, it’s that we love a puzzle. And we’re pretty good at solving them, too. We can guarantee that there’s no coating requirement too challenging for us.
We have a global reputation for a reason.
Come and see us in person. Located just 20 miles north of Manchester, we’re conveniently supported by motorways, railways, and airports.
Send your enquiry via postbox@alphatek.co.uk or speak to us over the phone on 01706 821 021.
