热喷涂涂层的锌和铝-锌金属

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Information

A brief introductioLeabharlann Baidu to thermal sprayed coatings are of Zn (TSZ), Al (TSA), and their alloys (85/15 Zn/Al), and how they provide long term corrosion protection Some examples of where are these coatings are used and how they have performed A brief introduction to galvanizing and its comparison to thermal spray coatings An overview of the most popular types of equipment that apply these coatings Question & answer session
Thermal Spray Coatings of Zinc and Aluminum Zinc Metallizing

Prepared byJim Weber - Sulzer Metco (US) Inc. – Westbury, NY Thermal Spray Materials Development Systems Engineering Equipment Research & Development Field Service Manager Training Manager Quality Assurance Manager Currently the Product Line Manager for industrial markets, focusing on combustion (wires, powder, & HVOF) and arc equipment Latest industry focus - working with NACE International (National Association of Corrosion Engineers) and the petrochemical industry to solve Corrosion Under Insulation (CUI) problems with Thermal Spray Aluminum (TSA) coatings and with the Gas Technology Institute (GTI) solving natural gas transmission and metering station corrosion problems.
Substrate
Material Feedstock
Heat Source
Accelerated Droplet
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Coating
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What is Thermal Spray?

These coatings are typically mechanically bonded to a grit blasted surface
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Typical thermal spray applications or Zn, Al, and their alloys

Hundreds of bridges have been thermal sprayed (metallized) over the past 100 years. There are many document cases of >50 years of corrosion protection provided by thermal spray coatings. Zinc and zinc alloys are also sprayed directly onto concrete to protect the steel rebar within.

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Typical thermal spray applications for Zn, Al, and their alloys
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Typical thermal spray applications for Zn, Al, and their alloys Carbon steel equipment (petrochemical facilities, power generation, Naval ships, etc.) are coated with TSA, TSZ, and 85/15.

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Almost any material can be thermal sprayed onto almost any substrate
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What is Thermal Spray?

Thermal spray, especially with soft metals sprayed with the combustion wire equipment, is a relatively cold process. Substrate temperatures seldom reach >200F/95C.
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Petrochemical applications
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Petrochemical applications
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Petrochemical applications
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Navy corrosion applications

The Navy has many documented uses for thermal spray coatings of all types, including corrosion coatings High temperature (>900F/480C) steam valves and associated piping have been protected by thermal sprayed aluminum on Naval ships. It is documented that these coatings lasted longer than 5 years in areas where paint coatings had lasted only months.

Metals that feed into the thermal spray gun are the actual coatings. There are no solvents or VOC's.
The coatings are similar to the metals being sprayed, however there are some important differences There are metal oxide stringers and porosity in the coatings Metal particles in the coating create a layered effect within the coating structure Due to the rapid cooling of the metal particles as they adhere to the substrates, thermal sprayed coatings have unique crystalline structures not normally found in wrought metals
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How thermally sprayed coatings of Zn and Al, combat corrosion

For atmospheric, buried, and marine environment corrosion protection, Zn (TSZ), Al (TSA), and their alloys have proven that they provide long term corrosion protection and outperform most all other methods. Anodic (TSZ/TSA) metal coatings applied to steel cathodes (more noble than Zn or Al), are referred to as cathodic or sacrificial protection coating systems.




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What is Thermal Spray?

Thermal spray is NOT a welding process Thermal spray coatings are a melted, or softened ceramic, metallic, or polymer materials are transported by a gas stream to a properly prepared substrate


These thermal spray coatings provide corrosion protection by excluding the environment (or electrolyte) and acting as a barrier coating (like paints, polymers, and epoxies), but unlike typical barrier coatings they also provide sacrificial anodic protection.
TSA coatings are also specified as a solution to stress corrosion cracking (SCC) of austenitic stainless steel. Offshore oil rigs operating in severe conditions rely on thermal spray aluminum for corrosion protection. >20 service life with no maintenance has been documented. These coating systems meet specifications from organizations such as NACE, SSPC, AWS, US Navy, US Army Corps of Engineers, and many others.

Petrochemical users expect TSA coatings to provide >20 years with no maintenance or corrosion inspections.

A TSA coating has been operating in severe petrochemical vessel operating conditions. One coating in particular has protecting carbon steel equipment operating in cyclic service of ambient to 350F/175C, in contact with wet insulation, for >50 years with no visible corrosion .