Top 15 Metal Spraying Applications

Metal spraying is a popular surface coating choice due to its versatility and the range of properties these coatings can achieve. In this article, we explore the top 15 applications that it is used for and which materials are best suited to these applications.

1. Corrosion Resistance

One of the key benefits of using metal spray is the increase in corrosion resistance. It is easily applied in a uniform thickness and extends the life of components in aggressive environments. It is also a high quality, long-lasting alternative to galvanising providing over 20-years of protection.

Corrosion-resistant sprays are perfect for windows & door frames, rails, fencing and automotive exhaust systems.

Specify zinc spray (Apticote 800/128) and aluminium spray (Apticote 800/127) for the best corrosion protection.

2. Wear Resistance

Metal spray coatings can improve wear resistance and lengthen the lifespan of components. There are options for coatings that will protect against sliding wear or provide protection in harsh environments such as in oil & gas.

Perfect for breaking and suspension systems, packaging, printing rollers and extruders for recycling plastics.

Specify tungsten carbide (Apticote 800/24) or chrome carbide (Apticote 800/40) for the highest wear resistant coating.

3. Thermal Barrier

Metal spray coatings produce excellent thermal barriers and protect components from heat sources such as engines, combustion chambers and gas turbines. Thermal barrier coatings also enable the use of high-performance materials such as carbon fibre in applications where they normally can’t operate.

Thermal barriers are perfect for heat shields in aerospace, motorsport and automotive applications. Poeton have recently used a thermal barrier for a customer manufacturing furnaces for waste management systems where abrasion resistance was also required.

Specify aluminium oxide (Apticote 800/32) or Yttria Stabilized Zirconia (Apticote 800/60).

4. Chrome Replacement

Due to concerns over environmental friendliness, including in relation to the REACH legislation, metal spray is increasingly becoming a common alternative to chrome plating. Additionally, metal spray can provide better hardness and a better surface finish than chrome plating.

Perfect for landing gear, pistons and hydraulics across a range of industries.

Specify tungsten carbide (Apticote 800/24) or chrome carbide (Apticote 800/40) as a chrome replacement.

5. Moulding

When combined with non-stick polymers, metal spray is an ideal tool in mould release applications. Superb adhesion ensures long lasting and excellent release properties to prevent machine downtime and decrease maintenance.

Perfect for fabric manufacturing and packaging on sticky products.

Specify Apticote 810/TP or Apticote 810/SP for your mould requirements.

6. Decorative

Metal sprays can come in the form of cold spray – those that are comparatively cooler and remove any risk of warping components. This is especially useful for decorative coatings where substrates can be thinner.

Perfect for architectural railings, windows, door frames and balconies as well as artistic items such as statues.

Copper spray (Apticote 800/133) is ideal for decorative applications.

7. Abradables

One of the classic applications for abradable metal spray coatings is for bedding-in. This is where a coating that is easily worn away is applied to a stationary component and creates a perfect fit to the part it is mating to.

Great for turbines, impellors, shafts and all clearance control applications.

Specify abradable aluminium (Apticote 800/89) for this application.

8. Non-stick

Metal sprays can be combined with polymers to create advanced non-stick coatings. The unique properties of both materials create a surface that is both tough, hard and has a low coefficient of friction to prevent sticking. These coatings also help to reduce wear and corrosion.

Perfect for mould release applications, extrusions, packaging and bakeware, with food approved options available.

Specify Apticote 800/TP (food approved) or Apticote 800/SP.

9. Refurbishment

Components that have been damaged, worn or eroded can be reclaimed by using metal spray coatings. The damaged area is cleaned up, blasted then coated with new material before being machined or ground back to its final size.

Often used for valves, turbines, propellers, and pumps from aerospace applications.

Specify a material that closely matches the substrate – the Poeton metal spray team will be able to advise the best solution for your requirement.

10. Self-Lubricating

Metal spray can provide scruff resistance in dry-running applications and for frictional purposes.

These types of coating are often seen in automotive applications such as suspension components.

Specify Molybdenum based coatings (Apticote 800/17 or Apticote 800/125).

11. Anti-Spark

Important when ensuring an inert environment and in conditions where two differing metals clash together.

Ideal in mining applications and crane hooks.

Specify bronze and aluminium-bronze based coatings.

12. Electrical Conductivity

Metal sprays can be used to enhance the electrical conductivity of a component.

Applications include energy production and distribution such as nuclear reactors and overhead power lines, as well as medical MRI scanners.

Specify ceramic alumina coatings (Apticote 800/32) for these applications.

13. Electrical Insulation

Coatings can help to isolate components from electrical currents whilst also providing wear and corrosion resistance.

Electrically insulating coatings are used in applications such as electronics, automotive, and machinery.

Use materials such as ceramic oxides.

14. Non-slip

Uncoated surfaces, especially metal surfaces, can often become slippery when water or oils are applied to them. Metal sprays applied with deliberate surface roughness are very effective at reducing both slipping and corrosion.

Applications include military helicopter step-ups, and pedestrian footways, and industrial environments.

Specify aluminium spray (Apticote 80/127).

15. Endless Possibilities

Our final entry is the endless possible applications metal spraying can be used for.

From industrial windows, doors and steelwork, to turbines and engine housings, metal spraying has the range of materials and processing techniques required to provide a solution.

Speak to the Poeton metal spray experts and they will guide you through selecting the metal spray solution for your needs