What You Need to Know About Thermal Spray Metal Coating Thickness

To control thermal spray metal coating thickness, various methods are used. The thickness of a coating is precisely stated in the specs. Depending on the substrate being coated, the material used for coating, the application in which the substrate will be used, and more, thicknesses can vary.

There are different methods through which the thickness of a thermal sprayed coating can be controlled. Let’s break them down and take a closer look at each one.

A Report on Coating Thickness

Before starting a project, ordinarily, a detailed coating thickness report should be carried out by the painter of the construction. This is so that the metal spraying process can be performed correctly by workers. This will include requirements by the contract or design as they apply to the metal coating’s thickness.

A Test For the Thickness of a Coating

To ensure that, within the required thickness range, a metal coating’s thickness is controlled effectively during the spray construction process, ordinarily, the following is done before the start of a project:

Onto a test panel or the waste component, construction personnel execute a metal thermal spray test.

What does this accomplish? This gives the sprayer the opportunity to use the spray equipment and master its performance (use). It gives the sprayer a chance to experience the precise spray process and spray techniques as they apply to a particular situation. This will better assure a thermal spray coating where the thickness is effectively controlled.

Thickness Control During the Construction Process

The painter or inspector must inspect the coating thickness in a timely manner (during construction) according to two things:

  • Point measurement method
  • Line measurement

If a problem arises (i.e., coating thickness isn’t matching up with requirements), it must be corrected in time. The following two situations may arise during construction and must be remedied.

  • Coating thickness is greater than contract values and design – If the thickness of a coating is greater than the contract value and design, in a timely manner, the site inspector must be informed. They will record the problem area and negotiations will begin with the purchaser or owner. A thickness discrepancy must be recorded if it is 150% greater than the contract value and design.
  • Coating thickness is less than contracted values and design – If, before the construction closing, it is found that a coating thickness is insufficient, by the method of refilling, the thickness can be added to, to match the contract and design.

Where Is the Problem?

What usually causes problems with coating thicknesses? Factors which are frequently improperly controlled (leading to thickness issues with coatings) are as follows:

  • Wire run speed
  • Spray lap width
  • Spray distance
  • Gun speed
  • Spray technique

Avoid Coating Thickness Issues With A&A Coatings

A&A Coatings has experts and technicians that are familiar with specifications regarding thicknesses, coating types, coating methods, and more. If it has to do with the thermal spray business, we are on top of it. That’s what makes us leaders in our field. To find out what thermal spray can do for your business, and how it’s already being used in your industry, contact us today.

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