Thermally Sprayed Metal Coatings

Thermal spray process can be described as a coating process in which the

coating material usually in the form of powder or high purity wires, is melted and
projected onto the substrate to form a coating. Thermally sprayed metal coatings
are depositions of metal, which has been melted immediately prior to projection
onto the substrate. The metals used and the application systems used vary, but
most applications result in thin coatings applied to surfaces requiring
improvement to their corrosion or abrasion resistance properties. Metal spray
coatings have been used for a number of years and they have proved to be far
superior to conventional paint coatings.
Thermally sprayed metallic coatings are used on various projects such as
motorway and railway bridges, offshore flare booms and on oil & gas metering
valves. Aluminium has been found to be the most effective material for the
protection of steel on offshore structures. However, strict health and safety
measures must be taken for the operators, and on the quality control of the
application process.
Sprayed metal coatings have been found to provide superior life to paint systems
assuming that adequate preparation of steelwork and relevant application
procedures are carried out. Sprayed aluminium may be left exposed, but when
sealed may be regarded as a superior priming system for overcoating.
Although both flame spray and arc spray methods are available, arc spray, a
newer method of application, has been shown to give faster output and superior
adhesion. For fabricated structures, both methods may be used especially where
access to difficult areas favours flame application and where broad plated areas
favour arc spray.
Aluminium and alloys with 5% magnesium is currently widely specified, though it
is not conclusive that this gives the best offshore protection.
The application of thermally sprayed aluminium requires greater operator training
than paint coatings together with strict attention to health and safety.
Major benefits can be gained by the use of a coating which can be handled
almost immediately after application, showing little damage when used as a
fabrication coating, and which can be applied to part of a structure. (For example
leaving welds for later completion or repair.)
Aluminium alloys containing 5% magnesium are thermally sprayed to exposed
structures for marine use and hence is highly efficient for offshore platforms and
ships topsides, utilising the galvanic advantages of the metal. Sealers are of
benefit on exposed aluminium coatings, but areas not exposed to driving rain
(undersides of platforms and bridges) are better left unsealed to reduce the effect
of "sweating" or condensation.
Aluminium spray has been shown to be effective against corrosion under
insulation, which might have become wet due to leakage of rainwater.
TSA works well at elevated temperatures, in conjunction with epoxy sealers up to
0
120 C. Silicone aluminium sealer is commonly used above that temperature.
TSA relevant Codes and Standards
 B S 2569 Sprayed Metal Coatings
Part 1. Protection of iron and steel by aluminium and zinc against atmospheric corrosion.

 B S 5493 Protective coating of iron and steel structures against corrosion.

Handling, transport, storage and erection.

 DIN 8566 Teil 1 und Teil 2 Zusatse fur das thermische Spritzen.

 ISO 1463 Metal and oxide coatings - measurement of coating thickness - microscopical method.

 ISO 2063 Metallic coatings - protection of iron and steel against corrosion - metal spraying of zinc,
aluminium and alloys of these metals.

 ISO 2064 Metallic and other non-organic coatings - Definitions and conventions.

 ISO 2178 Non-magnetic coatings on magnetic substrate's

- Measurement of coating thickness
- magnetic method

 ISO 4624 Paints and varnishes - Pull-off test for adhesion

 BS 7079 Part A,B,C,D (ISO 8501 1-4) Preparation of steel substrate's before application of paints and
related

 NPD Guidelines for Corrosion Protection of Installations

 NS 476 Rules for the Approval of Surface Treatment Inspectors

 NS 1975 Rules for the Approval of Surface Treatment

 SS 2626 Thermal Spraying equipment - requirements and testing

 SSPC Steel Structures Painting Manual Volume 1 & 2