Critical process and performance parameters of thermal arc spray coating

Usage of thermal spray coating for corrosion protection was started since early 1900. Even though it was successful, the application was limited. In recent years, most industries especially oil and gas companies have selected the thermal spray wire arc coating as a corrosion protection for steel structure. Advancement in coating research causes major developments in coating processes, equipments, and raw materials for coating. It leads to further expansion in functional coatings and applications scope from conventional coating to specialised industries. The selection of the thermal arc spray coating is due to its ability to act as an effective corrosion protection, able to withstand high process temperature, and cost saving. Previous research revealed that thermal arc spray coating provides better coating characteristics compared to other method of sprays. This paper reviews some critical part of thermal arc spray coating by discussing the process parameter of thermal arc spray technology and quality control of coating. Comparison between coating material usage was reviewed to determine the best applied material coating in certain critical environment. Coating performance against corrosion, wear and special characteristic of coating are discussed. The field application of arc spray technology is presented.