Damaged metal parts and components is a constant problem in metal usage. Metallization was created to reduce material losses and extend the life of structures, and it is becoming increasingly common. This thermal spray method coats the surface with a thin metal layer protecting it against corrosion. This article will provide the overall method’s procedure and assess its benefits to current businesses, especially mechanical engineering.
About Metallization technology: Definition, application and benefits
Metallization is an effective method to protect materials from corrosion and environmental effects. Besides the protective properties, this coating offers many significant benefits. So it is not difficult to understand when it is becoming more and more popular in the marine, oil, and gas industries. So what exactly is this metal coating method? What benefits do they bring to the construction project? What are the main application areas? Let’s explore each issue in the following content.
What is Metallization? The definition and principle of creating metal coatings
Metallization, sometimes referred to as thermal spray coating, is the process of applying a thin layer of metal to the base surface of a part to protect the surface against corrosion and wear physical. Typically, aluminum, zinc, and their alloys are used, and they are heated electronically or using a flame and then sprayed onto the prepared substrate.
In many cases, aluminum is the widely used metal for this coating process because it is a good conductor of electricity, forming mechanical bonds with silicon. In practice, however, no single metal can satisfy all the desired properties for a metallic coating. Therefore, appropriate materials and coating methods will be selected depending on the desired result.
This coating process can protect the material from the effects of corrosion, abrasion, weathering, improve the aesthetics of the building or even create the desired functionality. These applications will be described in more detail in the following sections.
Benefits of Metallization process – The advantages of metal coating
Throughout development, metallization has been trusted and applied because of the benefits it brings. Some examples of the benefits brought by the metal coating process include:
- Increased corrosion protection of materials: Corrosion and physical wear are the top concerns when using metals, especially steel. The metallization process solves this problem by creating a comprehensive protective coating that limits the penetration and effects of corrosion, extending product life up to 20 years and beyond.
- Increased durability: Most metal coating processes produce a highly adhesive coating, which is less prone to peeling, cracking, or blistering than many other solutions, which increases the durability of the surface.
- Good weather resistance: Metal materials in outdoor buildings are easily affected by rain, sun, wind, and hoarfrost over time. Metallization creates a protective barrier between the surface and the internal elements, thereby maintaining the appearance and internal structure of the material.
- Provide materials with electrical conductivity: The metal coating approach provides a conductive surface for plastic and flexible materials. This is a significant advancement in the electronics industry.
- Reduce maintenance and material replacement costs: Metal-coated surfaces will not require regular maintenance and significantly reduce parts replacement and repair costs. In addition, it also provides a variety of colors to meet the aesthetic requirements of the works.
- Less construction time: Most metallization methods are done quickly and have no waiting time after completion. Thereby reducing downtime in factories and workshops.
- No environmental requirements: Unlike many other coating methods, metal coating can be performed in all temperature and weather conditions.
- Flexible and feasible in many cases: Metallization in spray form is a viable option for massive constructions that avoid deconstruction and substrate deformation. Moreover, it also has applicability to a wide range of materials.
Metallization applications – In which fields are metal coatings applied?
Since launching in the market, the application range of metallization has constantly expanded. Top applications include:
- Corrosion protection and protection of materials for the automotive, shipbuilding, construction, and aerospace industries.
- Coating for household appliances, electronics, components for vehicles.
- Protect steel and concrete structures from corrosion.
- Anti-wear coating on machinery and mechanical equipment.
- Lubricating coating in harsh environments where oils and liquids cannot be used.
- Coatings protect components from chemicals in the petrochemical and mechanical industries.
- Important applications in the IC and electronic device development industry.
Refer to this article to learn more about twin-wire arc metallization: Twin-wire arc: Thermal Spray Aluminium Coating provides an excellent barrier layer
It can be seen that metallization has overcome the disadvantages of traditional metal protection methods. At the same time, it provides many unique benefits, becoming the leading solution in anti-corrosion and metal protection applications. In addition, the variety of coating methods and materials is a factor in creating the suitable coating, possessing the desired properties for each project. However, this job will require help from experts and a team of experienced technicians. So, choosing a quality contractor is especially important to get the best metal coating solution.
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