Parkol Marine Engineering, based in Whitby, has recently applied a thermal sprayed zinc coating using a Metallisation ARC150 arc spray system to a new whitefish trawler, the Resilient LK195, to protect it from corrosion.
Video Category: Arc Spray Applications
This video shows the automated zinc spraying of gas cylinders (LPG cylinders) with Metallisation ARC528E automated arc spray systems. This can be onto brand new cylinders or on reclaimed/repaired cylinders. The zinc coating is applied to give longer corrosion protection to cylinders compared to paints alone. The paint or powder coating are often damaged during manual handling and the zinc coating beneath provides a sacrificial coating.
Examples of corrosion protection with both ARC and Flame Spray Systems on a variety of substrates.
Typical Applications
- TSZ of wind towers with ARC528E/S1500.
- TSA on offshore oil platform.
- TSZ of wind towers with ARC140/S350.
- TSZ of ship with ARC150/S500.
- TSZ of fishing boats with ARC150/S500.
- TSA for corrosion under insulation with MK73.
- Spraying with the Flame Extension.
- TSA of footbridge with MK73.
- Typical equipment set-up – Flame.
- Typical equipment set-up – ARC.
This old video from the early 1970’s shows a number of metal arc sprayed coatings that were applied wit Metallisation systems in steel mills and foundries. These applications are still relevant and applied today. HVOF and laser cladding coatings have joined the arsenal of coatings used to combat the harsh environments of the steel mill. The film is showing its age but demonstrates that the metal spraying process is not at all new and has a long and proven history. Of particular interest is mention of the thick steel coatings (up to 50mm or 2″) applied in some applications.
Metal spraying is used to repair the weld seam area of ERW tubes and sections. Zinc, Aluminium or Zinc/Aluminium alloys are typically sprayed using the Metallisation ARC528E automated arc spray system. Pistols are mounted with extraction boxes to extract dust and fume. For some applications, flame spray systems are also used.
Metal spraying car body panels with zinc to repair corrosion, dents and seams with Metallisation MK73 flame spray system. Process as used by VW Vanshack
Thermal spray zinc coating applied to a new design of shell wind tower.
Metallisation ARC528E systems with 1500A energisers are robot mounted to produce high volume, high quality repeatable coatings to give corrosion protection and increase bolt joint friction.
The 1500A systems enable high production rates required to keep up with the demand for this unique design of wind tower.
Thermal spray zinc coating manually applied to a traditional cylindrical wind tower.
Metallisation ARC140/S350-CL systems are used to apply zinc coatings to the insides and outsides of wind towers. The long supplies packages make spraying the internal areas of long towers a more simple and efficient process. The hand-held pistol is flexible to move around the spray areas and has a manageable throughput.
Metallised zinc coatings are applied predominantly to areas that may be damaged during assembly and installation. The robust zinc coating will give sacrificial corrosion protection to areas where the paint coatings may be damaged.
Zinc Coat Metal Spraying
The video illustrates the coating process from blast, thermal spray zinc applied to the prime and top coat of a traditional wind tower cylindrical sections.
Metallisation Arc Spray Systems
Metallisation ARC140/S350-CL systems used with 20m supplies and 10m extension supplies were used in the application. Long term corrosion protection was the purpose the of HVOF application for protection against atmospheric corrosion and friction of bolted joint faces.
The material used was zinc (2.3mm), the process was prepared by grit blasting, thermal spraying, then zinc with primer, mid-coat and top coat.