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Thermal Metal Spray

Thermal Metal Spray coatings (TMS) offer the highest level of corrosion protection and wear resistance compared to any other coating system. Thermal Zinc Spray is a great alternative to hot dip galvanising and offers the same, if not better, performance against corrosion and abrasion.

The metal applied to form the coating is usually zinc, aluminium, or a mixture of the two; other metals can also be applied. TMS coatings can also be used in conjunction with liquid coatings, to form a duplex coating system, providing excellent corrosion resistance and a high level of aesthetics. Due to the nature of the equipment and set up requirements, TMS coatings are usually applied at our facility, however, with the right set up they can also be applied at site, although this is generally a slower, more complicated process. With our team of experts and our facility that can handle items of all shapes and sizes, we will see you right. We can even come to you, with our dedicated site team and equipment to see the job is done right - first time, every time.

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How does TMS work? Thermal Metal Spray works by melting the feed metal, whether wire or powder, and spraying it onto the substrate (surface) to be coated. There are 4 methods for application: 1.Flame Spray: Where a flame is created with a mix of oxygen and CNG (or similar) and the metal is passed through the flame, atomising it. The molten metal almost simultaneously impacts and bonds onto the substrate, creating a layer that protects against harsh environmental conditions. (maybe add a picture like this one: under + ‘What is the process of protective coating?’) 2.Arc Spray: 2 wires are electrically charged to arc and instantly melt. Compressed air is then used to atomise the molten metal and apply it to the substrate. 3.Plasma Spray: A plasma gas (an ionised gas that is electrically conductive) arc is used to hit temperatures of greater than 10,000°C. A metal powder is passed through, instantly melting and atomising it. This process leads to a finer spray, enabling a denser coating of metal. 4.High Velocity Oxyfuel Spray: This uses a specialised gun to compress a combination of oxygen and hydrogen that when combusted and combined with metal powder, propels at supersonic speeds. This process is generally only used when specific alloys need to be applied to the substrate.

What metals can be used to produce a thermal metal spray coating? The most common metal is zinc, then aluminium or an alloy of the 2, for corrosion or anti-slip protection. However, metals such as copper, tin, and specialised alloys can also be applied.

What substrates can TMS be applied to? TMS coatings can be applied to most substrates from metals, ceramics, composites, and plastics.

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