Sprayed coatings molten-metal process

A group of coating or welding processes in which finely divided metallic or non-metallic materials are deposited in a molten or semi-molten condition to form a coating. The coating material may be in the form of powder, ceramic rod, wire, or molten materials. See also flame spraying and plasma spraying. 

The laser spray process uses a high power carbon dioxide laser focused onto the surface of the part to be metallized. A carrier gas such as belium blows metal particles into the path of the laser and onto the part. The laser melted particles may fuse to the surface, or may be incorporated into an aHoy in a molten surface up to 1-mm thick. The laser can be used for selective aHoying of the surface, for production of amorphous coatings, or for laser hardening. 

Each type of metallic coating process has some sort of hazard, whether it is thermal energy, the reactivity of molten salt or metal baths, particulates in the air from spray processes, poisonous gases from pack cementation and diffusion, or electrical hazards associated with arc spray or ion implantation. 

In all metal spraying processes the particles emerge from the nozzle in a conical stream, and although the particles near the centre are molten, those at the periphery have solidified. In the powder process there are in addition solid particles which have not melted. The solid particles tend to become entrapped in the coating, making it porous. The effect is more pronounced in the powder process owing to the larger number of solid particles present. 

PROTECTIVE COATING. A film or thin layer of metal glass of paint applied to a substrate primarily to inhibit corrosion, and secondarily for decorative purposes, Metals such as nickel, chromium, copper, and tin are electrodeposited on the base metal paints may be sprayed or brushed on. Vitreous enamel coatings are also used these require baking. Zinc coating are applied by continuous bath process in which a strip of ferrous metal is passed through molten zinc. 

Zinc is frequently applied to the surface of iron or steel by other methods. In the Schoop process, molten zinc is sprayed onto the surface by a blast of air in a manner similar to that used in spraying paint. In addition to metals, objects made of wood, leather, paper, and the like may be coated with zinc by this process. In the process of sherardizing, iron is covered with a thin layer of zinc dust at temperatures of 700 to 800°C. Under these conditions, zinc penetrates the surface of the iron to a considerable extent. 

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