The metallisation technology

Metallisation is a process involving the application of a thin metal film on the base material. It is used to improve the material resistance to corrosion, wear and tear, and the elements. It improves the component's appearance and the functionality of the final product. The metallisation process is used in diverse industries, such as:

  • Electricity (wind power stations)
  • Hydroelectric plants (turbines and turbine joints)
  • Military
  • Oil and gas
  • Solar power generation
  • Aviation
  • Space
  • Automotive

The applied metal can be in the form of a wire or dust. The coating thickness can vary from 0.1 mm to thicker layers of 0.3-0.4 mm.

Metallisation in three steps

  1. MATERIAL PREPARATION: The base material is usually treated with abrasive blasting to ensure the metal adheres well.
  2. MELTING & SPRAYING: By using electrical power, the wire with coating material is melted. It is then sprayed by means of compressed air in a spray gun.
  3. SURFACE BONDING: When the metal particles touch the surface, they adhere and mechanically bond with the prepared rough grounding. As the coating thickens, the particles bond to each other.

The ARC metallisation process

Blast Tehnik uses the electric arc metallisation method. This means two wires under voltage are fed into the gun. The wires together produce a current that melts the wires.

The compressed air passing through the nozzle sprays the melted metal onto the workpiece. There are three types of wire feeding (push, pull, and push/pull).

Series metallisation

With a robot in a dedicated metallisation chamber, Blast Tehnik provides repeatable quality, also for larger quantities.

We provide metallisation with all types of materials and their combinations:

  • Al, Zn, WC, Mg, Cr, Copper

The series robotic metallisation is performed with ARC technology (wire spray - flame spray technology).

The advantages of the metallisation process

  • Possible application on large surfaces.
  • No drying or setting time greatly increases the production flow.
  • Recyclable materials can be used for metallisation (Al, Zn...).
  • No environmentally hazardous emissions are produced in the metallisation process.
  • It is a low-temperature process, where the metallised surface temperature never exceeds 120-150°C, practically eliminating the danger of damage or steel banding due to high temperatures or overheating.

The purpose of metallisation

  • Improved protection against corrosion - rust on the exposed parts is a common problem for most metals (salt environment, acid rain, chemical exposure). Metallisation creates a protective coating to prevent corrosion and increase the product longevity for 20 years and more.
  • Improved durability - metallisation materials ensure excellent adhesion to the surface. The possibility of flacking, cracking, and crushing thereby decreases.
  • Ensuring electrical conductivity - The problem with plastic materials is they do not provide electrical conductivity. Metallisation of plastic surfaces enables the transfer of electric current, which is important for application in the electrical industry.
  • Better resistance to the elements - over time, the outside steel constructions are exposed to snow, rain, wind, and sun. Metallisation provides a protective coating by creating a barrier between the grounding construction and the elements, which can prolong the structure’s life span and preserve its look.
  • Lower maintenance costs - a metallised surface requires no paint or maintenance

Metallisation usage case studies

See the case studies by clicking on the individual images.

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