METAL COATINGS Galvanising The coating of components with zine. Many components both for offshore and onshore use, are galvanised. Galvanising can give protection to steelwork for periods of up to 60 years dependant on exposure conditions. The components are chemically cleaned (acid), washed and fluxed, then totally immersed in a vessel containing molten zinc at approximately 450°. When drawn out, the zinc solidifies at an average thickness of approximately 100 um, Sheradising ‘Nuts and bolts and other similar components are coated with this method. Galvanising threads would make a significant difference to the dimensions and workings of fixings and fasteners, so Zine powder, just below the melting point, is used instead. After cleaning the components are tumbled in the powdered zinc, impact fuses the zinc onto the components and in effect, “cold welds” the powder onto the metal. Calorising Calorising is coating with aluminium, Aluminium has a melting point of 625 as apposed to 425® of zine so it is not really practical to tumble. One way of calorising a component is to dip it into molten aluminium. The resulting exothermic reaction is so severe that is alloys the aluminium with the steel. Calorising can also be done by immersing a component in a mix of fine sand and aluminium powder and heating. Anodising A treatment for aluminium, anodising is an electrolytic method of coating which results in the formation of a dense oxide. The component is immersed in a weak acid bath and oxidation is induced electrically. Electro-plating This is done by electrolytic deposition. If a current is released from an item into a metal salt solution through to a cathode, the metal salts ionise and deposit the metal ions on the cathode bar. Painting Inspection Grade 3/2. Rev 1 April 2004 TWI wouncamsror ‘Metal Coatings 16. ZZ ap MATERIALS JODNING Copyright © 2003, TWILtd TECHNOLOGYHot metal spraying Any metal, which can be easily melted, can be sprayed. Zinc and aluminium are the most commonly used metals for spraying. They are both below steel on the galvanic list and so will provide cathodic protection to the steel, and both metals have a reasonable low melting point. ‘Both metals have advantages and disadvantages, for instance zine performs far better than aluminium in rural areas and alkaline environments. Aluminium is considered to be superior to zinc in slightly acidic environments and because of its higher melting point is more widely used on high temperature surfaces such as exhaust stacks, compressor exhausts etc. where extremely high temperatures are encountered. Tt is specified for use on surfaces with working temperatures of up to 540™. Application of metal sprayed coatings can be carried out by any of the following methods. Powder system Powdered metal is fed into a heat source (usually butane or propane and pure oxygen burning) and propelled onto the substrate. Using this method a relatively low proportion of the metal powder is actually deposited on the substrate. Electric are system This method is ideal for production line type facilities such as gas bottle production and lamp standards eto. where components are of a uniform shape and the process can be mechanised. As in a welding process the metal (to be sprayed) acts as an electrode in a circuit and the electrode melts, The molten metal is atomised and blown onto the component by means of a heated air jet. This system gives a superb fine grain finish, Wire and pistol system By far the most common and widely used method for site application of metal spray. The metal wire, of a very high degree of purity, greater than 99.5%, is driven through a gun by means of two knurled wheels powered by compressed air. As the wire, 3mm ~ 5mm passes through to the front of the gun it passes through a ring of burners, with the flames focused about 35mm from the exit point. The fuel gases used are butane/propane and pure oxygen. The flames melt the wire and droplets of metal are propelled to the steel by the combustion gasses and compressed air ‘The coating is usually applied at a thickness of 100 — 125mm and is about 85% to 95% density of the original wire. This is because the resulting film is in an open cell structure due to individual particles forming a “fish scale” like structure, the interstices between the particles are not all filled. Painting Inspection Grade 3/2. Rev 1 April 2004 TWI wou caraerox Metal Coatings 162 Zap NSTERIALS JODING Copyright © 2003, TWILta TECHNOLOGYIf the coating is to be subjected to high temperature services it will need sealing with a silicone sealer, aluminium or carbon pigmented. If however the metal spray is applied to give an extended major maintenance free life to an anti-corrosion system, then either an epoxy sealer or etch primer would be applied prior to the specified system. Painting Inspection Grade 32. Rev 1 April 2004 Metal Coatings 163 Copyright © 2003, TWI Ltd ‘WORLD CENIRE FOR MATERIALS JOINING (EZM wecssorooy