Latest NTST News:
New Hi-Tech Coatings:
Aluminum Nitride (AlN)
Boron Carbide (B4C)
Cubic Boron Nitride (c-BN)
Hex Boron Nitride (h-BN)
Chromium Nitride (CrN)
Silicon Carbide (SiC)
Silicon Nitride (Si3N4)
Titanium Nitride (TiN)
Zirconium Nitride (ZrN)
Titanium Diboride (TiB2)
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Nevada Thermal Spray Tech.
4842 Judson Avenue, Suite 115
Las Vegas, NV 89115
Thermal spray coatings are
used in over 50 industries
Thermal Spray vs. Hot Dip Galvanizing
Thermal spray coatings of metals, oxides, and carbides are fabricated by feedstock materials melted in process that are transported by a gas stream to various prepared substrates. There are no solvents or VOC's. Thermal spray processes are non-polluting technologies with the only effluent being hot water and inert gases. Thermal spray waste is generally metal dust, which is collected by specially designed dust collectors. Thermal spray coatings are rapidly replacing galvanizing for many infrastructual applications (e.g. Figure 1).
Hot-Dip Zinc Galvanizing: Hot-dip galvanizing is a brazing process. The substrate is cleaned mechanically and chemically and then heated to 850°F in a molten zinc bath. The zinc reacts with the substrate and forms a coating of various layers of zinc and iron alloys. The final coating is approximately 40% pure zinc. The acids, fumes, contaminated rinse water, and other byproducts of the galvanizing process are considered hazardous. Due to environmental concerns new galvanizing lines are no longer permitted in many states.
NTST Corrosion Mitigation Coatings
The selection of a proper thermal spray coating for corrosion mitigation depends on the service environment, desired service life, operating duty cycle, and the repair and maintenance support provided during the coating lifetime.
Thermal spray coatings are commonly used for the protection of iron and steel in a wide range of corrosive environments. The long term effectiveness (20-40 years) in rural, industrial, and marine environments is documented in corrosion tests performed by the American Welding Society. These coatings can replace paint and chrome plating with no environmental concerns such as emission of volatile organic compounds. This is due to the predictable service life, coating quality, and lower life cycle costs.
There is a history of aqueous corrosion protection by aluminum and zinc thermally sprayed coatings for structural steel work including bridges, towers, tanks, rebar, masts, gantry structures, cranes, and railings (e.g. see Figures 2 and 3). In marine applications, ship structural areas and components are preserved with aluminum and zinc coatings. These galvanic corrosion resistant coatings are sacrificial coatings that preferentially slowly corrode while minimizing the corrosion occurring to the substrate.
NTST also fabricates coatings to mitigate corrosion due to acidic or alkaline environments. These coatings are fabricated economically providing extended life depending on the coating requirements. Metal corrosion resistant coatings such as inconel, hastelloy, nickel, stainless steel, nickel-chromium alloys, and cobalt-chromium alloys are routinely fabricated at the customer’s site or at NTST’s location. Oxide ceramics are also used as they are very corrosion resistant materials. Carbides with corrosion resistant metal binders are examples of coatings that provide protection to both corrosion and wear.
Corrosion mitigation coatings possess high bond strengths for even complex geometries. These coatings find widespread applications in the automotive, transportation, aerospace, aircraft, and infrastructural industries.
Figure 2. Various Metal Corrosion Mitigation Coatings