Metal spray coating is also known as thermal spraying. In this Alphatek blog, we’ll look at what these terms mean and the processes that are involved. We’ll answer the question, ‘What is metal spray coating?’ and also tell you how you can get in touch with metal spray coating specialists.
What Does Metal Spray Coating Mean?
Thermal spraying is the term given to a coating process that involves materials being used in a molten or semi-molten state to coat a surface. The materials used can be either metallic or non-metallic and in the case of metallic materials, this is also known as metal spray coating. A thermal spray procedure is used during the application process.
What Materials Are Used For Metal Spray Coating?
Here are some of the materials that are used to apply the coating:
- Tungsten carbides
- Ceramics
- Nickel-chrome carbides (such as chrome oxide, aluminium oxide, zirconia and titania)
Other materials that can be used in thermal spraying include aluminium, steel and plastics.
What Is A Metal Spray Coating System?
A metal spray coating system consists of several different components.
A spray gun is the main device. This performs the actual melting and accelerates the particles allowing them to be deposited on the surface that requires coating. The feeder is what supplies the powder, wire or liquid to the gun.
A media supply is also required. This can be gas or liquid that will generate the flame or plasma jet to melt the material. A robot is used to manipulate either the torch or the surface to be coated.
A metal spray coating system will also require a power supply including a standalone power supply for the torch, and a control console. This could be an integrated console for all the components or separate units for each of the parts.
Metal Spray Coating Processes
There are several different metal spray coating processes.
Plasma spraying
Plasma spraying is a coating process in which powder is fed into a plasma jet causing the coating materials to melt so they can then be sprayed over the surface to be coated.
Detonation spraying
Detonation spraying involves a high-velocity shockwave to propel melted or partially melted coating materials onto a surface.
Arc wire spraying
The arc wire spraying process involves two wires driven into an electric arc to form molten particles of spray, which are then forced out onto the substrate using compressed air.
Flame spraying
In flame spraying, the coating material is put into the flame and compressed air then atomises the molten particles and propels them onto the substrate.
High-Velocity Oxygen Fuel coating spraying (HVOF)
HVOF or High-Velocity Oxygen Fuel Coating Spraying uses a fuel gas and oxygen torch to propel molten powder onto a substrate at high velocity. The molten powder then sets and solidifies into the desired coating in a fraction of a second.
Warm spraying
Warm spraying is a coating process that deposits solid particles onto the substrate that have been heated and accelerated by a supersonic jet.
Cold spraying
In cold spraying, particles are accelerated to very high speeds by a carrier gas forced through a nozzle. Upon impact, solid particles bond to the substrate and form the specified coating.
What Are the Benefits of Metal Spraying?
There are many benefits to metal spraying. Firstly, it’s mainly used to coat structures in order to protect against extremes of temperature, corrosion, erosion and general wear and tear. It’s also possible to alter the electrical or biological properties of a surface using metal spray coating. Additionally, metal spray coating can improve the outward appearance of a structure.
Thermal spraying is faster and easier than other coating processes and it has additional benefits including:
- Protection against corrosion or erosion
- Protection against damage
- Resistance to wear and tear
- Improves durability
- Can alter electrical properties
- Can alter friction
- Reduced maintenance requirements
- Cost-effective
- Efficient process
Get In Touch
Here at Alphatek, we have more than 100 years of cumulative coating expertise in house. Working closely with our customers over the years, we have developed our products and services to deliver the best value. We have seen a lot in that time and believe there’s no real shortcut to experience.
If you have any further questions, please don’t hesitate to contact us. You can call us on 01706 821021 or email us at postbox@alphatek.co.uk. Alternatively, if you’d like to visit us, we are located 20 miles north of Manchester. Please check our opening times when planning your visit to Alphatek.
