Machine Shop - Thermal Metal Spraying

Thermal metal spraying, also known as spray metalizing, is a surface coating process where molten or semi-molten metal is sprayed onto a substrate to form a protective or functional layer. The process involves feeding metal wire or powder into a heat source—typically a combustion flame, electric arc, or plasma jet—where it is melted and then propelled onto the surface using compressed air. The resulting coating enhances corrosion resistance, wear resistance, and thermal protection, making it ideal for industrial components exposed to harsh environments. Unlike hot-dip galvanizing, thermal spraying allows for controlled thickness and material selection without subjecting the substrate to high temperatures. Some common application of themral metal spraying include:

• Corrosion Protection
  • Steel bridges, marine structures, pipelines: Zinc or aluminum coatings are applied to prevent rust in aggressive environments (e.g., saltwater, humidity).
  • Oil & gas equipment: Protects offshore platforms, tanks, and structural components from corrosion.
• Wear Resistance
  • Mining and construction equipment: Hard materials like tungsten carbide are sprayed on high-wear parts (e.g., hoppers, chutes, crusher parts).
  • Agricultural machinery: Enhances service life of tillage tools and rollers.
• Thermal Barrier Coatings
  • Aerospace components: Ceramic and metallic coatings are used to insulate turbine blades and engine parts from high heat.
  • Automotive parts: Coatings on exhaust systems or piston heads to reduce heat transfer.
• Electrical Conductivity or Insulation
  • Electronic components: Silver or copper coatings for conductivity; ceramic-based coatings for insulation.
  • Bus bars and connectors: Improved performance and longevity under load.
• Dimensional Restoration / Repair
  • Shafts, journals, and bearing surfaces: Worn components are rebuilt with sprayed metal to original tolerances.
  • Molds and dies: Repaired without re-machining or replacement.
• Decorative Finishes
  • Architectural elements: Bronze, brass, or stainless coatings for aesthetic metal finishes on wood, concrete, or plastic surfaces.
  • Public art or signage: Durable metallic coatings with customizable finishes.

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