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Laboratory Evaluation of Metalized Coatings for Use on Reclamation Infrastructure

Laboratory Evaluation of Metalized Coatings for Use on Reclamation Infrastructure
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Metalizing is not a new technology. It has been in use since the 1930s. Although it has seen limited use in comparison with conventional coatings, this is primarily due to economics. In past years, application rates for metalized coatings have been slow, making the process an expensive alternative to conventional coatings. 

Product Number: 41213-788-SG
Author: David Tordonato, Allen Skaja
Publication Date: 2013
Industries: Coatings , Corrosion Monitoring and Control
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Metalizing is not a new technology. It has been in use since the 1930s. Although it has seen limited use in comparison with conventional coatings, this is primarily due to economics. In past years, application rates for metalized coatings have been slow, making the process an expensive alternative to conventional coatings. However, the technology has fostered advances in equipment that result in faster production times due to greater reliability and greater material deposition rates. Regulations on VOCs and hazardous materials have driven significant changes in polymeric coatings making metallizing a more attractive option. Metalized/thermal spray coatings (TSCs) were investigated by the Bureau of Reclamation’s (Reclamation) Materials Engineering and Research Laboratory. Testing revealed that alloy composition and exposure condition significantly affect corrosion protection performance. Of the systems tested, the pure aluminum system is believed to offer the best combination of corrosion protection and expected service life in immersion or fluctuating immersion. In addition, aluminum is easy to apply, relatively low in cost, and exhibited greater adhesion strengths compared to the other alloy systems. The use of a polymer seal coat over the TSC system appeared to provide little increased corrosion protection. The best use of metallizing at Reclamation is on radial gates, partially exposed trash racks and other equipment subjected to a fluctuating immersion environment. Although metallizing carries an initial cost premium of 30-40% over a comparable polymer coating system, lifecycle costs may be lower. Metallizing should be considered for severe atmospheric service environments such as bridges and aboveground piping.

Metalizing is not a new technology. It has been in use since the 1930s. Although it has seen limited use in comparison with conventional coatings, this is primarily due to economics. In past years, application rates for metalized coatings have been slow, making the process an expensive alternative to conventional coatings. However, the technology has fostered advances in equipment that result in faster production times due to greater reliability and greater material deposition rates. Regulations on VOCs and hazardous materials have driven significant changes in polymeric coatings making metallizing a more attractive option. Metalized/thermal spray coatings (TSCs) were investigated by the Bureau of Reclamation’s (Reclamation) Materials Engineering and Research Laboratory. Testing revealed that alloy composition and exposure condition significantly affect corrosion protection performance. Of the systems tested, the pure aluminum system is believed to offer the best combination of corrosion protection and expected service life in immersion or fluctuating immersion. In addition, aluminum is easy to apply, relatively low in cost, and exhibited greater adhesion strengths compared to the other alloy systems. The use of a polymer seal coat over the TSC system appeared to provide little increased corrosion protection. The best use of metallizing at Reclamation is on radial gates, partially exposed trash racks and other equipment subjected to a fluctuating immersion environment. Although metallizing carries an initial cost premium of 30-40% over a comparable polymer coating system, lifecycle costs may be lower. Metallizing should be considered for severe atmospheric service environments such as bridges and aboveground piping.

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