Inspection of Thermal Spray

Coatings
Presented by: Dean Hooks, Thermion
 Scope
• This webinar defines thermal spray coating
(TSC) and provides an overview of its
inspection
 Introduction
• This webinar will review the procedures for
the inspection of metallic thermal spray
coatings (TSCs) of aluminum, zinc, and their
alloys and composites for the corrosion
protection of steel
• Inspection requirements in accordance with
SSPC-CS 23.00/AWS C2.23/NACE No.12
What is Thermal Spray?
 Thermal Spray Coating (TSC) Materials

• Aluminum, zinc, and their alloys in the form of

powder or wire heated to a plastic or molten
state
 How does TSCs Protect Steel?
• Sealed: Good barrier protection
• Unsealed: Galvanic (sacrificial) protection
 Special Properties
• Very good resistance to high temperatures,
sunlight, and weathering
• Good application properties: adhesion to
metals, film build, edge retention, and transfer
efficiency
• Good impact and abrasion resistance
• Attacked by acids or alkalis unless topcoated
 Environmental Advantages
• No volatile organic compounds (VOCs) to
cause air pollution (100% solids)
• No hazardous air pollutants (HAPs)
• Limited overspray into surrounding areas
 Economic Advantages
• Long-term protection (40+ years) of steel
structures resulting in low life-cycle costs
(costs per year)
• Reduced rework for original coating defects
• Reduced maintenance over coating life
SSPC-CS 23.00/AWS C2.23/NACE No.12

• Revised May 2016

• A procedure for the application of metallic
thermal spray coating (TSCs) of aluminum,
zinc, and their alloys and composites for the
corrosion protection of steel
• Required equipment, application procedures,
and in-process quality control (QC)
checkpoints are specified
 Pre-Surface Preparation Requirements

• The steel surface temperature shall be at least

3°C (5°F) above the dew point temperature
• Verify compressed air cleanliness in
accordance with ASTM D4285
• Verify cleanliness of abrasive in accordance
with SSPC-AB 1, 2, or 3
 Surface Cleanliness
• Before TSC application, steel substrate shall be
prepared in accordance with:
– SSPC-SP 5/NACE No. 1 for immersion service; or
– Minimum of SSPC-SP 10/NACE No. 2 for other
service applications; and
– Level of nonvisible contamination specified
 Surface Profile
• Unless otherwise specified:
– Minimum angular profile depth of 65μm(2.5 mil)
– Maximum angular profile depth of 125μm(5.0 mil)
• Measured in accordance with SSPC-PA 17
using ASTM D4417:
– Method B – Depth Micrometer
– Method C – Replica Tape
 ASTM D4417 Method B
• Depth micrometer
• Profile measured using a fine pointed probe
 ASTM D4417 Method C
• Replica Tape
• A composite tape is impressed into the blast
cleaned surface forming a reverse image of
the profile
 Job Reference Standard (JRS)
• A JRS shall be prepared
for each TSC application
or product
• Intended to be used as a
“comparator” to evaluate
the application process
• TSC thickness and
adhesion measurements
shall be performed on
the JRS
 Inspection of TSC Thickness
• TSC thickness measured in accordance with
SSPC-PA 2
• Coating Thickness Restriction Level 4
– Spot readings can be between 80% of the
specified minimum and 150% of the specified
maximum thickness
– Area average must be within specified thickness
Thermal Spraying onto Blast Cleaned Steel
 Inspection of TSC Adhesion
• TSC adhesion measured in accordance with
ASTM D4541 Methods C, D, E, or F
Thermal Spray System Requirements
 Nonmandatory Adhesion Testing
• Bend Test
– 180 degree bend on a Mandrel
– Qualitative, testing proper surface preparation,
equipment setup, and spray parameters
– Mandrel diameter for threshold of cracking
depends on substrate and coating thickness
 Bend Test
• Passes
– On the bend radius, there is no cracking or
spalling, or only minor cracking that cannot be
lifted from the substrate with a knife blade
• Fails
– Coating cracks with lifting from the substrate
Bend Test
 Nonmandatory Adhesion Testing
• Hammer and Chisel Cut Test
– A procedure to identify areas of metallized coating
that are poorly adhering
– Involves impacting the coating with blow from a
hammer to a masonry chisel
– Any disbonding or peel of the coating is
considered a failure
Hammer and Chisel Cut Test
 Hammer and Chisel Cut Test
• Pass
 Hammer and Chisel Cut Test
• Fail
Questions?