Rusty furniture or peeling metal decorations aren’t too great of a sight. They can also lead to further damage or component failure in machines.

With the right preparation and spray coating, you can prolong the life of any metal surface. Restoring it so it looks brand new whilst also adding a protective layer from future damage.

Spray coatings are incredibly convenient. They’re easy to use and great for irregular surfaces.

The Best Spray Coatings For Metal

Of course, there are many different spray coating options available for metal. It all depends on which metal you’re using it on, and if you’ve done the right preparation.

Remember, it’s important for wielders to take safety measures before spraying. Wear gloves to protect hands, eye protection, and a mask to prevent any inhalation.

You should always use spray coatings in a well-ventilated area and read the caution labels. These cans contain very concentrated mixtures of chemicals and metallic elements.

Here’s some of the top thermal spray coatings for metal surfaces.

Flame Spraying

Quite often considered the original thermal spray coating method, it has been used in the industry for over 100 years.

This process involves the use of an oxy-acetylene flame (a very hot flame produced by mixing oxygen and acetylene) to apply the coating. The heat melts the coating material and it is applied onto a product using compressed air.

Arc Spraying

A rather popular method of thermally spraying metals. Typically because it is a more cost-effective method yet just as efficient as other spray coatings.

Generated electricity from an arc wire provides a heat source that then melts the coating material. For example, zinc or aluminium. Two electrically charged wires with opposite polarities are placed into the arc at controlled speeds.

When the two wires come together, the opposing charges react and create an arc which acts as the heat source, melting the wire tips. Compressed air then fastens the liquified material onto a component.

Arc spray coatings are very suitable for large areas as they have very high coverage rates and strong bond strength.

HVOF

One of our most commonly applied thermal spray coatings here at Alphatek is our High Velocity Oxygen Fuel (HVOF) thermal coating.

The HVOF coating process involves mixing oxygen and fuel in a combustion chamber. Gas escapes through a nozzle where Tungsten Carbide is introduced and then propelled onto a component surface.

Because the coating is built up by applying additional layers, there is extremely high bond strength, making it perfect as a coating for wear resistance.

Plasma Coating

When a gas becomes moderately ionised, it produces a stream of hot gas. This is where the material (in powder-form) is added and then projected onto the prepared component. The chemistry of the powder can be altered slightly when necessary in order to modify the result. Say resistance to corrosion, for example.

These coatings typically utilise higher temperatures than others so have a wider application range.

Alphatek: Why Choose Us?

We have a cumulative 100 years and more of coating experience.

Many of our thermal spray coatings are formulated individually to meet every need a customers have. Clients from different industries have different requirements and we pride ourselves on our ability to provide.

Whether you’re in the automotive or aerospace industries, we aim to deliver the best quality and performance.

You can contact us on +44 (0)1706 821021 or email us at postbox@alphatek.co.uk.

If you would like to visit us in person, we are located 20 miles north of Manchester – here’s our opening times.