Metal Spray Solutions by Metallisation Ltd
Uploaded by
Marko IvančićMetal Spray Solutions by Metallisation Ltd
Uploaded by
Marko IvančićCommon questions
Powered by AIAnti-corrosion engineering coatings play a crucial role in protecting marine and offshore structures by preventing the corrosive effects of saline water, humidity, and other harsh environmental conditions. This is important because it helps prevent degradation of the structures, extending their operational lifespan and maintaining their structural integrity. Protecting these vital structures ensures safety, reduces maintenance costs, and minimizes the risk of costly and environmentally damaging failures .
The primary applications of engineering coatings applied by Metallisation Ltd's thermal spray processes include enhancing wear resistance, providing thermal barriers, and improving electrical and thermal conductivity. Applications span across aerospace engines, automotive valves, hydraulic rams, and more. These coatings enhance performance by extending the lifespan of components through reduced wear and tear, providing protective thermal insulation in high-temperature environments, and offering electrically conductive or insulating layers as required .
HVOF (High Velocity Oxygen Fuel) coatings use an accelerated oxygen/fuel flame to soften spray powders, which are then projected onto the substrate with high levels of kinetic energy. This method produces extremely dense and adherent coatings with very low levels of porosity, significantly enhancing the wear resistance and longevity of critical industrial components. These qualities make HVOF coatings ideal for high-stress applications such as oil/gas ball and gate valves, hydraulic rams, and aircraft landing gear .
Metallisation Ltd's engineering coatings offer properties such as hardness, wear resistance, and corrosion protection, making them suitable alternatives to hard-chrome plating. These coatings can provide equivalent or superior performance without the environmental and health concerns associated with hard-chrome plating processes, particularly regarding toxic waste disposal and workers' exposure to hazardous chemicals. This makes Metallisation's coatings an environmentally friendly and sustainable option for industries requiring durable, high-performance surface treatments .
Metallisation Ltd enhances the precision and efficiency of thermal spray applications by integrating robots and providing turnkey solutions such as spray booths/rooms, fixturing, turntables, and spray lathes. This automation allows for consistent, high-quality coating applications, reducing human error and increasing process repeatability. The use of robots also facilitates the coating of complex shapes and hard-to-reach areas with precision and efficiency, which is critical for high-standard applications across various industrial sectors .
The use of a high power laser beam in the laser cladding process allows for precise control over the heat input and area being treated, resulting in a highly focused weld pool. This ensures more precise application of metallic powders, leading to coatings with higher quality, better adhesion, and minimal thermal distortion of the substrate. The coaxial application of powder carried by inert shielding gas further enhances control and efficiency, making laser cladding suitable for applications requiring high-quality coatings with excellent wear and corrosion resistance .
Metallisation Ltd designs its thermal spray systems to be simple to use and easy to maintain by integrating intuitive controls and robust construction, ensuring reliability and ease of operation. Moreover, the company provides exceptionally high levels of service, both pre and post-sale, which includes discussing applications with customers and evaluating the most suitable equipment for their needs. These customer-oriented services help ensure that clients from various industries can operate the systems effectively with minimal downtime .
Metallisation Ltd’s thermal spray processes offer significant environmental and safety advantages over traditional surface coating technologies. These processes, such as plasma and HVOF, typically do not involve hazardous chemicals, thus reducing the risk of environmental contamination and health hazards associated with processes like electroplating. Furthermore, the dry application method eliminates the need for toxic waste disposal, making the processes more environmentally friendly and safer for workers .
Metallisation Ltd's Flamespray and Arcspray equipment offer the advantage of applying 'corrosion protection' coatings of zinc, aluminium, and zinc/aluminium alloys onto steelwork. This method is more versatile than traditional galvanising as it can be applied in situ to large structures like bridges, gantries, and ships, where traditional galvanising might be impractical due to the size and location of such items. Additionally, the thermal spray process provides an alternative that is less dependent on the shape and size of the object being coated, allowing for more tailored and specific protection against corrosion .
Plasma spray processes are advantageous for producing low oxide coatings because the use of an electric arc in an inert gas environment creates a high-temperature plasma that softens the spray powders while minimizing oxidation. This condition is ideal for applications requiring high purity coatings, such as those in aerospace engine components and electronic devices, where oxidative impurities could compromise performance, longevity, or compatibility .
