Technology Behind Metalizing

Metalizing

By definition, “Metalizing” is a process by which a metallic coating is deposited onto a surface. Metalizing is by no means a new technology and has been in use for the last 100 years. Extensive studies prove that metalizing is the best corrosion fighting system in the world, however, it had limited usage due to application problems when using old metalizing methods. Now, MTM Metalizing’s process overcomes the limitations of the old methods and offers a variety of metal coatings, depending on required specifications. Metal spray applied using the thermal spray process can provide a protective coating that will remain corrosion resistant for many years.

Our Process

Before the metalizing procedure can begin, the surface must be prepared to create the required surface roughness profile for metalizing. The prepared surface must be clean and grease free. Our spraying technology utilizes an electric arc between two wires to melt their tips. By atomizing with compressed clean air, the molten metal coating is propelled at a very high speed onto the substrate. This provides a permanent bond between the coating material and the surface. At this point, several passes of the metal coating can be sprayed to increase the thickness depending on the specifications. Because of the design of the process, all the metal from the multiple passes form one homogeneous layer.

Heat generated from the fusion process dissipates almost immediately upon hitting the substrate, preventing any heat transfer to adjacent areas or scorching of areas of below surface. Metal fusion wraps around angles and stiffeners similar to electrostatic paints applications. Due to the instant curing, the coating does not shrink like paint products, which contain solvents and does not pull away from sharp edges. This process can be completed in a matter of minutes depending on the scope of the job.

Our Equipment

The set up time for metalizing is short. Metalizing requires dry clean air pressurized at around 125 psi and 185 cfm. A constant voltage rectifier of minimum 600 amp at 100% duty cycle and three phase power source 100 amp of 440 vac or 300 amp of 220 vac. Our metalizing unit consists of metalizing wires, patented metalizing machines (ASMM and RedDevil) with wire feeder and feed tubes, heavy duty electric cables, a moisture separator, 19mm (3/4”) air lines and fittings. Our metalizing machines measure 40 cm high, 80 cm long and 36 cm wide, weighing no more than 20kg which are extremely compact, light and portable. These machines are capable of spraying wire diameters up to 4.76mm.

Metalizing Material

MTM Metalizing offers a variety of metal coating depending on the requirement of the job application. Here are a few examples of commonly sprayed metal.

Zinc
Copper
Stainless Steel
Aluminum
Bronze

Hastelloy
Lead
Brass

Titanium
Nickel
Babbitt
Monel
Inconel

The following table highlights the suitable material for different application.

Type Coating	General Qualities	Suggested Applications
Aluminum	Highly resistant to heat, hot water and corrosive gases. Excellent heat distribution and reflection.	Hot water storage tanks; vegetable oil tanks; exhaust manifolds, railway tank cars; airplane cylinder fins; sun deflection on glass; boat hulls and marine applications; capacitor cases; non-metallic surfaces; electrical circuit boards; motor bell housing; heat exchanger tubes; irrigation equipment, pattern build up; piston heads and valve seats; refinery equipment shielding and grounding on plastic radio parts; refrigerator coils and components; smoke stacks; sheet metal repair; industrial handling equipment; covering tubing welds; external diesel cylinder liners, heat distribution on cookware; towers; paint base.
Babbit	Excellent bearing wearability.	Large bearings (can be sprayed without molds), refrigeration pistons.
Brass	Machines well, takes a good finish.	Reclaiming defective or work brass casting; decorative ware and artwork; brass repair work.
Bronze	Excellent wear resistance; exceptional machineability; denase coatings (especially Al, Bronze).	Water wheel runners; pump casting; and impellers; bushings; valve plugs; molds motor block bearings; shafts; decorative coatings.
Copper	High heat and electrical conductivity.	Carbon brushes (for better electrical contact); electrical circuits, shielding plastic radio parts; solder connections; sprayed on glass for solder seals.
Iron	Excellent machining qualities.	Repairing castings.
Lead	Good corrosion protection fast deposits and dense coatings.	X-ray shields and x-ray tube housings; protecting fan blades acid fimes balancing.
Molybdenum (Molybond)	Self-bonding for steel surface preparation.	Piston rings, crankshafts, pressfit applications; mixing machine blades; mandrels; ring hubs; packing glad areas; plug gauges; rear axle seals; spindles; transmission shafting and seals; aluminum castings; hard surfacing aluminum and other materials.
Monel	Excellent machining qualities; highly resisttant to corrosion.	Repairing castings.
Nickel	Good machine finishing; excellent corrosion protection.	Machine elements subject to corrosion but not requiring high wearability. (Excellent for repairing defective castings hen used with Mogul Dot-Weld Equipment).
Nickel-Chrome	High temperature applications.	Undercoating for ceramic deposits improves bond. Spraying heating elements.
Steel	Hard finishes, good machineability.	Clutch plates; shaft build-up bell housing or bearing press fits; plug type valves; sprayed on aluminum parts for better wearing qualities (available in various hardnesses).
Chrome Steel (Tufton)	Bright, hard finish, highly resistant to wear.	For hard wearing surfaces; packing glands, pump rods; crankshafts.
Stainless	Excellent corrosion protection and superior wearability.	Clutch plates, shafting build-up; crankshafts; electrical motors and generator bell housings and shafts; inking roll buildup; centrifugal and rotary pumps; roller bearings; pump couplings keyways; impellers; ring hubs; gear box parts and all surfaces; packing glands; rear axle seals; transmission bearing housing; plug type valves; Teflon undercoating. (Available in various grades.)
Tin	High purity for food applications	Protection of dairy and food product equipment.
Zinc	Superior corrosion resistance and bonding qualities.	Storage tanks; bridges, towers, laundry extractor baskets; conveyor equipment, mine cars, refrigeration equipment, building up pistons skirts; boat hulls and marine applications; capacitor cases; electrical circuits; motor bell hosing; irrigation equipment; covering tubing welds; oil well derricks; pattern buildups; pipe seal rings; covering plaster and wood refinery equipment; wind tunnels; conduit fittings; packing house, repair of welded, galvanized atmospheric corrosion resistance.