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IntroductionSurface defense against corrosion is crucial, especially for certain industries. Technological advances give engineers more options and flexibility when it comes to surface protection. Different materials and industries call for specific protection methods, aluminum coating is one of those specific methods.
What Is Aluminum Coating?The aluminum coating is the process of applying a protective layer of aluminum-based material against corrosion and other contaminants. The process itself is quite straightforward. The base material is dipped into an acidic degreaser for decontamination so that the dirt and debris wouldn&#;t be buried under the coating material. After the degreaser, the material is dipped into a rinsing bath to get rid of the degreaser solution. Aluminum coating sticks onto the surface through the principle of attraction of opposite poles, therefore the base material needs to get electrically charged before coating. Charged material is dipped into the coating solution, which is charged as well and dissolved in deionized water. This is a very similar process to powder coating. When the coating is done, the base material gets taken into a drying oven.
Advantages of Aluminum CoatingWhen it&#;s compared purely by unit price with other coating methods aluminum coating may seem expensive at first. However, other similar metal coating methods such as galvanization are not as long-lasting as aluminum coating. When the longevity of the material gets taken into consideration, aluminum coating proves to be a competitive point on the performance and price chart.
The aluminum coating is extremely resilient to corrosion due to aluminum&#;s self-protective characteristic against oxidation. Aluminized metals can withstand extreme atmospheric conditions that other metals can&#;t. Additionally, due to the sulfidation and carburization-resistant properties of aluminum, aluminized products are resilient to acidic corrosion as well.
Another benefit of aluminum coating is extreme heat resilience. Due to the high reflective properties of aluminum, 80% of light rays coming onto an aluminized surface bounces right off. The aluminum coating can protect its base material from thermal deformity under temperatures up to 800 Celcius. This makes aluminum coating four times more protective against heat, compared to galvanization with its recommended maximum temperature value of 200 Celcius.
Finally, the flexibility of aluminum allows for reshaping the base material without damaging the coating itself. That gives aluminization a huge benefit compared to other coating methods.
Disadvantages of Aluminum CoatingWhile aluminum coating provides excellent protection against thermal and chemical deformities, it&#;s not the best option when it comes to surface hardening. Many experts do not recommend aluminum coating on surfaces that are expected to experience surface impact during their lifespan.
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Common Uses for Aluminum CoatingDue to aluminized products&#; high thermal resistance, they are used in heating appliances such as ovens, heaters, incinerators, and burners. Combined with thermal resilience, the corrosive resistance of aluminum coating makes this surface protection method a perfect fit for cooking ware.
Aluminized steel is an amazing option for the aerospace and automotive industry. The ability to reshape the protected surface after coating and the corrosive resilience provides excellent flexibility during production.
The food industry is another niche that often takes advantage of aluminum coating. Many health and safety regulations regarding food, insist that no exposed metal surface should touch the final product. Aluminum coating provides galvanization and stainless steel with a competitive alternative at conforming with the health and safety regulations of the food industry.
Finally, the acidic and oxidic corrosive resistance of aluminum-coated products, makes them irreplaceable for the construction industry. Aluminized products can be commonly seen on HVAC components, and pipes as well as chimneys and even on corrugated rooftops of oil-gas industry plants. Some manufacturers have recently started to use an aluminum coating to protect pressured air system pipes which are usually made out of stainless or galvanized steel. Aluminization protects the pressured air pipes against ionized condensing water.
Final WordsNavigating through the different options of surface protection can be challenging. Correct parameter and price comparison is key to ensure preferred results. If the question at hand relates directly to oxidic or corrosive deformity, the aluminum coating seems to be a well-rounded and price-efficient option.
While aluminum coatings offer many benefits in the way of chemical attacks, they are not the right choice in terms of surface hardening. Aluminum is one of the softest metals that exist and is therefore not fit for applications that are put under a lot of stress. If you are looking for a treatment that improves surface hardness, boronizing is a better choice for you. At BorTec, we make use of our own patinized boronizing treatment that can not only increase hardness up to HV but also displays great wear resistance and resistance against acid chemicals. While aluminizing is a good choice for applications that require good resistance against acids, boronizing is more of an allround answer because we can improve other mechanical properties as well. Read more about boronizing here.
The thermochemical diffusion process starts by heating aluminum in a furnace along with the workpiece, forming an oxide layer at the surface once it cools. This acts as a barrier against acids and other chemicals.
Aluminum coatings can be applied through various methods. The most common is hot dipping, a galvanic coating that uses high temperature baths to create protective coatings. The steel workpiece must be cleaned before hot dipping to ensure that the aluminum atoms will adhere to the surface of the material. The material is then submerged into a bath made of aluminum and silicone (11%) at temperatures between 700 and 750 °C. The silicone is added to stretch the aluminum layer even thinner. Once the workpiece is air dried, the aluminum will already be diffused into the surface of the steel work piece.
Aluminum coatings can be applied to a wide range of areas. The most common are found in applications that have to withstand high heat, humidity and chemical attacks. Therefore, aluminum coatings can be found in boiler parts, chimneys, ducts, plants, and tubes and pipes. Generally, aluminizing is applied when decent corrosion resistance is needed.
If you&#;re not sure whether aluminum coating meets your demands, you can contact us here. We offer a specialized and patented boriding treatment that significantly improves hardness, corrosion resistance and thermal stability for numerous steel types. We would love to advise you on the best hardening treatment for your metal workpieces.
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