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Today we will try to understand Metallizing process.

Metallizing is considered a cold process in that the aluminum or zinc is deposited onto steel by spraying rather than by dipping the steel into a bath of molten zinc as with galvanizing.


The metalizing process always begins with proper surface preparation. Next, aluminum wire or zinc wire is continuously melted in an electric arc spray or gas flame spray gun. Clean, compressed air strips droplets of molten metal from the wire depositing these particles onto the steel forming the protective coating. This sprayed metal coating is both a barrier coating and a galvanic coating in one. A single metalized coating protects steel for 30 years or longer depending upon the application, coating thickness and sealing.

The metalizing or thermal spray process consists of surface preparation by abrasive blasting, metal spraying and sealing or topcoating the sprayed metal.

The three spray wires used for atmospheric or immersion service are pure aluminum, pure zinc or an alloy of these two metals . (The alloy is approximately 85% zinc and 15% aluminum by weight.)

A metalized coating may be bare sprayed metal, sprayed-metal-plus-sealer or sprayed-metal-plus-sealer-plus-topcoat.

The sprayed metal plus sealer is generally the most cost effective, lowest life cycle cost (LCC) option. [See website section headed "Sealer and Topcoats" for more information on sealing.]

Coating thickness may vary according to application from .004" to thicker coats of zinc in the range of .012" - .014" for seawater splash zones.

Metallizing is considered a cold process in that the aluminum or zinc is deposited onto steel by spraying rather than by dipping the steel into a bath of molten zinc as with galvanizing.

The steel remains relatively cool at about 250º-300ºF. There is virtually no risk of heat distortion or weld damage by metalizing.

There are no VOC's (volatile organic compounds) in the metalized coating. There is no cure time or temperature to limit metalizing, so metalizing may be applied throughout the year .

Any steel structure that can be blast cleaned may be metalized.

Applications include:

Bridges

Piers & shore facilities

Lock & dam gates

Thermal Spray Metalizing is a substitute for painting structural, ornamental, fencing and miscellaneous steel. Protects steel for decades longer than paint alone.

This is a proven process, which has been used around the world for 90 years. Steel of every shape and size may be metalized either in-shop before construction or on-site instead of less effective repainting.

Metalizing is the most versatile and effective coating for protecting steel structures.

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