Problem Solving Forum (9)


When is it cost-effective to use thermal spray in petrochemical facilities?


Zinc metalizing has been applied to concrete surfaces to provide cathodic protection to rebar in the concrete. What are the problems, if any, with applying zinc metalizing to concrete, and what is the best approach to addressing them?


After applying a thermal spray coating on a petrochemical industry live line that operates at 48 degrees Celsius (118 degrees Fahrenheit), the coating sustained a brown discoloration on the bottom of the pipe. What would cause this discoloration of a TSA coating?


How do you prepare flame-cut edges for application of thermal spray metallic coatings? The problem is that these edges are often harder than the abrasive, so a very low profile is produced, resulting in lower-than-specified adhesion of the thermal spray to the steel.


Structural engineers often prefer mechanically galvanized bolts for accurate tightening while corrosion experts often prefer hot-dip galvanized bolts for superior corrosion protection. How do you resolve this inherent conflict?


On a recent project, complex pre-fabricated, hot-dipped galvanized panels exhibited thicknesses in the range required for the entire subsequent coating system. It was not practical or possible to accurately map the thickness of the galvanizing across all the various parts, and DFT gauges available only measure the entire non-ferrous coating, including the galvanizing. How should thickness-per-coat minimums and maximums be controlled and verified for subsequent coatings?


I’ve heard that the use of the proper blast media is critical for the successful application of thermal spray aluminum and other metallics. What mechanism would lead to the differing performance characteristics of the TSA based on the blast media?


How do you prepare flame-cut edges for application of thermal spray metallic coatings? The problem is that these edges are often harder than the abrasive, so a very low profile is produced, resulting in lower-than-specified adhesion of the thermal spray to the steel.


What is the best low-maintenance approach to coating power-tool-cleaned field weld joints on process pipework that is protected with thermal-sprayed aluminum?


 
 
   

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