Leading Anti-Corrossion Solutions
Metallisation rust protection
So what exactly is metallisation? There are various forms of metallisation however regardless of the type used it is a thermal spraying process that basically shoots molten particles onto a surface. The molten particles are generally created via the melting at high temperatures of metal; the most common metals for this process are aluminium and zinc. The molten metal particles are then projected onto the surface via an air nozzle that effectively atomizes it and applies it to the surface where it flattens on the surface and bonds.
The process rapidly coats the surface and this immediately offers protection against corrosion, however it is ultimately the thickness of the applied coat that will determine the length of time and under which conditions the surface will remain rust free and protected. Unlike hot galvanizing the metallisation process does not cause heat stress to the metal on which the layer is being applied as it is applied (albeit rapidly) to one specific point at a time which allows the heat to dissipate; this is further the case as it is applied layer by layer.
Depending on who you ask traditional galvanizing may or may not be preferred to metallisation however it is generally accepted that the reliability of both processes depends on the skill of the person and the process used as well as of course the thickness of the layer applied. Comparatively hot galvanizing or dip galvanizing as it is also known has a shorter lifespan then metallization when zinc is used and the thickness is 250(um) and completely sealed.
As mentioned there are various metallisation processes; one of which is the arc spray process. The arc spray process works by using electric to melt wires and then atomize the metal with compressed air to create a spray stream which applies the coating. Metallisation is used for both anti-corrosion applications as well as engineering coatings.
Engineering coatings fall under surface engineering which is generally used to make a surface more able to withstand wear as well as to improve flow efficiency and temperature control or to be able to withstand exposure to certain chemicals.
Anti-corrosion coatings on the other hand generally aim to ensure that the surface can withstand corrosion; generally the application process has a substantial effect on what the applied coating is best suited for; for example an even flat layer may be more resistant to corrosion.
The video above is a quick introduction to Arc Spray Metallisation which can be used for small projects as well as large projects, to put things in perspective metallisation has been used on structures such as the Dubai Burj Al Arab Hotel and other large buildings, wind turbines as well as small applications such as gates fencing and railings.
Cold Galvanizing Malta
As with all galvanizing the main focus of cold galvanizing is to protect or improve the surface of the metal which it is applied onto. The main difference between hot and cold galvanizing is in the way the galvanizing layer (zinc or aluminium) is applied. Depending on the use of the coated item one will generally consider metallisation, hot galvanizing and cold galvanizing. Especially if the intent is to protect against corrossion the environment and actual way in which the item will be used will determine the best approach. Often cold galvanizing is used in cases where hot galvanizing or metallisation may be impractical. This is especially true with large items such as ship hulls.
Cold galvanizing is the application of paint like substance that has a very high concentration of zinc onto a surface. Cold galvanizing can be applied to the surface in a number of ways including spray as well as brush roller or aerosol. It is important that the surface to which it will be applied is properly prepped. It is also common for cold galvanizing to be used to repair breaks and cracks in hot galvanized metal.
We recommend getting in touch with a professional to discuss your options based on your specific situation.
Other protective coatings, fluid efficiency coatings and spray painting
There are of course other specialized applications such as the highly respected corrocoat and fluid efficiency coatings. The final touches are often achieved by different types of spray painting including Electrostatic, Airless, Air Assisted & Conventional. These will be covered in detail in another article which will be linked once published in the next few days. We hope that these articles provide a good understanding as to what is available to you in the Maltese market from professional companies like XN-Teq Anti-Corrosion specialists. <- Kindly visit their page for more information with regards to the services offered or alternatively use the contact details to get in touch and ask the experts.
Contact the Anti-Corrossion Experts
Company Ltd – An Engineering Approach to Corrosion Problems
T: +356 2166 7116 |
A: MRA15A Industrial Estate, Marsa, MRS 3000, Malta