Thermal spray coating applications are a vast topic, a few of the more unusual but interesting are found here.
This concrete statue coated with copper to make it appear as if the structure was metal. Many sculptures have been coated in this way as the aging of the coating gives it a certain patina.
The thermal spray process is used to repair and preserve Classic and Custom vehicle body work. Applying Thermal Sprayed material onto a rust peppered body panel is a revolutionary way of restoring and protecting original panels. Traditional methods would mean the damage would have to be cut out, new replacement sheet metal formed and welded in, which can cause warping due to the heat generated by the welder. Now using Metal Spray, Zinc or a Zinc Alloy is sprayed over the dents or exposed perforations, filling and replacing what has been lost and also galvanizing the repair preventing further corrosion. The coating can also be applied to entire body shells, chassis, decks and panels as its galvanic properties provide long term corrosion protection. Automotive paint systems are easily applied over the coating. See the video here.
From loading ramps, decks, stairs, manhole covers, truck beds to bridge expansion joints - Untreated these steel surfaces can become very slippery, especially in wet conditions, and are prone to corrosion. To ensure safe walking and industrial operating conditions, vital to personal safety and productivity, 28E ARCTEC coating provides a durable non-slip anti corrosion coating. Traditionally, steel structures are hot dip galvanised, or painted, to protect against corrosion. The disadvantage of hot dip galvanising is that the surface can become slippery and it does not easily accept paint without the need for special primers. Many large steel structures, including oil platforms, refineries and bridges, have been routinely protected against corrosion by thermal sprayed aluminium (TSA), zinc or an alloy of the two.
While providing unrivalled corrosion protection in very aggressive corrosive environments, pure TSA is not durable enough to prevent long term wear on floor plates. Ideally, steel structures need a durable coating that protects against both slip and corrosion and that’s exactly what the Metallisation 28E ARCTEC coating does. 28E ARCTEC coating is a thermally sprayed coating that can be applied with a rough texture and has excellent non-slip properties, while being extremely hard and resistant to wear.
The coating provides a suitable level of grip, to avoid personal slips or industrial skidding and comparable corrosion protection to aluminium, as used in aggressive environments.
Application is easy by a long-standing process, covered by international standards and the surface result is an acceptable non-slip protection as defined by the U.K Highways Agency standard HA104. The resultant coating is corrosion resistant and because of its durability, site owners can be confident that once applied, they can forget rust or slipping for many years.
Architectural & Decorative
Metal spray coatings for decorative, artistic or architectural applications can be substantially more cost effective compared to solid metal constructions and work well on many surfaces including metal, wood, plaster, concrete, fibreglass, hardboard, plastic, polystyrene or even thick card. Bronze, copper and brass are often used and can be left as sprayed, sanded and polished, waxed or sealed.