Thermal spray coatings can be used to combat acidic or caustic corrosion.

High alloys and ceramics can be used in these instance.

Im utilizes high temperature epoxies both as a sealer over thermal spray
coatings, and as stand-alone coatings to resist acidic and alkaline
environments. These epoxies are continuous and free of porosity,
prohibiting liquid penetration down to the component substrate.
Molten metal corrosion is among the most aggressive types of corrosion
experienced in industry. Thermal spray coatings have proven their
effectiveness in this area by protecting galvanizing and aluminizing pot
equipment.
Imco can engineer coatings to provide excellent wear protection while
maintaining coating integrity within varying pH environments.
Acidic and
Alkaline
Resistance
Corrosion resistant
The use of aluminum coatings
on exhaust stacks is one where
resistance to corrosion at mildly
elevated temperatures works
well.
The use of HVOF applied
stainless steel to many paper
industry components work for
resistance to the alkalis present
in white water.
ACIDIC AND
ALKALINE RESISTANCE 1
ATMOSPHERIC
CORROSION
From corrosion caused by weathering and chemical attack to corrosion caused by very aggressive molten
metals, thermal spray coatings have proved to be the best solution for many corrosion resistant applications.
Atmospheric
Corrosion
Atmospheric corrosion can be addressed by spraying areas to be protected with zinc, aluminum or zinc/aluminum
wires, this will provide prevention of rust caused by weathering or immersion in fresh or salt water. These materials
galvanically protect the underlying steel. The advantage of thermal spray over other methods is that the zinc or
aluminum can be applied to nearly any thickness, so it is possible to vary the amount of protection based on the
requirements of the application. Unlike galvanizing, thermal sprayed zinc or aluminum does not distort the parts as
they are being processed. Coatings may be used as sprayed or coated with an appropriate sealer.
Pictured here is a component from a shipboard refrigeration unit that has been sprayed with aluminum and then
sealed. Utilizing sophisticated automated equipment and state of the art quality assurance measures, it is possible
for such a component to be guaranteed against rust by the manufacturer even though the part is made of mild
steel and is exposed to salt water throughout it's life. This technology can be applied to any component that will be
exposed to salt spray or immersion in salt water with results that far exceed what is possible with any paint system.
The galvanic protection of the pure metallic coating is proof even against minor rupture of the coating.
Corrosion
Solutions
2
Thermal spray coatings are often used to protect against abrasion, erosion, adhesive wear, fretting, galling, and
cavitation.
Wear
Resistance
3 WEAR RESISTANCE
Abrasion and erosion are regularly addressed using
tungsten carbide coatings along with a series of
superalloys. These coatings outwear chrome plating by
several orders of magnitude. Ceramic coatings may also
be used to combat abrasion or erosion, especially in
combined abrasive and corrosive environments.
Adhesive wear can be reduced by carefully considering
the bearing match between the two materials that will
contact in use, and selecting an appropriate alloy for
one of them. A superalloy called tribaloy is one that
excels in this area.
Fretting can be combated with coatings of copper
nickel indium or bronze.
Galling again requires analysis of the bearing match between the two materials that may gall. Given our several
hundreds of available materials, it's fairly easy to prescribe an appropriate material.
Cavitation can be addressed by using variety of stainless steels, and several superalloys.
Wear
Resistance
Solutions
Imco provides coating processes and solutions to
various steel industry applications like:
Steel
Aluminizing pot rolls
Galvanizing pot rolls
Bridle rolls (often
replacing rubber)
Snouts
Looper rolls
Tower rolls
Tensiometer
Burr masher rolls
Continuous caster
molds
Furnace rolls
Seal rolls
Coiler segments
Pinch rolls
WEAR RESISTANCE
Imco has the ability to take our thermal spray processes
on site to apply coatings to components that are too big
to move or where scheduling will not permit delays. We
can mobilize very quickly and arrive at your site prepared
to apply our thermal spray coatings to your components.
We can also consult and recommend coatings for specific
environments and performance challenges.
Onsite
HVOF coatings have proven to be far superior to chrome
plating in terms of wear resistance and equal or better in
corrosion resistance.
In the broader world outside the fairly narrow concerns
of military requirements, the uses of chrome are many and
more varied. Since thermal spray has available at least 400
different materials alloys, pure metals, cermets,
ceramics, etc. a material can be chosen with properties
tailored to a specific application. This was never possible
with chrome. Chrome plating is chrome plating and
properties vary within a fairly small range. Thermal spray,
on the other hand, will perform well across a very broad
range of service conditions and working environments. Thermal spray coatings will perform in hot
environments, acidic corrosive environments and a host of others where chrome plating would never even be
considered.
Outside of rarely encountered extreme environments, Imco has found that HVOF coatings will enhance wear
resistance to five or more times the wear resistance of chrome plating. In application after application HVOF
provides superior wear resistance and corrosion resistance.
Chrome
Plating
Replacement
Options
We have coated:
Tube walls in steel mill boilers
Turbine shells
Turbine blades
Chemical tanks and processing
equipment
Bridge members
Steel Mill Furnace hoods
Steam turbine cases
(water erosion)
Various dimension restorations
Traction coatings
Fan applications
Alumizite
Power plant turbine disks
Platten repairs
Casing and diaphragms
Boiler fans
4
HIGH ENDURANCE
BLASTING AND PAINTING
Imco applies coatings to a variety of engine components within the power generation industry. Imco also
holds Nadcap accreditations for chemical processing and coatings, which enables Imco to coat aircraft
components for both engine and airframe OEMs.
Industries
Served
Sulfur in the fuels of gas turbine engines and airborne salts like sodium and chlorine react with the Oxide layer
on engine components in high temperature environments, attacking the base metal. This reaction forms
sodium sulfates that expose the protective Oxide layer of the base metal to decay. Water is also produced as a
by-product of hydrocarbon fuel combustion, and this water can combine with the sodium sulfur compounds to
produce sulfuric acid, leading to base metal corrosion referred to as sulfidation. The sacrificial coatings applied
by Imco protect the base metal from these types of chemical reactions, drastically prolonging a components
life within service.
Technology
Imco prides itself on the implementation and operation of a fully automated
coating facility within its division. The first of its kind within the industry; this
state of the art cell has enabled Imco to tightly control coating thicknesses,
surface finishes, and cosmetic appearances across all finished product. The
robotic application method provides tight process repeatability for key
quality characteristics, and enables the efficient flow of product through the
cell. The result is an operation that supplies superlative quality and turn time
to customers both domestic and abroad.
Facility
5 SEALANTS
Imco - The proven metal impregnation system creates a better than vacuum impregnated pressure tight fit in
the finest pores!
Perform on-the-spot repairs, in-house.
Apply by dipping, brushing or spraying the metal or ceramic coatings.
Penetrate microscopic, porous holes and hairline cracks.
Sealer offers the benefits of resistance against aggressive chemicals.
Large and small coated parts are ready for grinding or machining within hours depending on thickness.
Plasma, arc spray and even HVOF coatings can resist premature failure by sealing with Imco
Continuous temperature-resistant up to 932F and pressure-resistant to 8700 psi.
Liquid available in pints, quarts, 1 and 5 gallon containers.
The Capillary
Sealer to
Impregnate
Thermal
Spray
Coatings
Eliminate
Premature
7
TUBE SHIELDS FOR BOILERS
AND CONDENSERS
Imco condenser and boiler tube shields are designed to minimize tube failure in highly abrasive or corrosive
areas.
Our many styles insure that youll be able to choose the most appropriate design for your application,
providing an inexpensive way to prolong tube life
Boiler tube
shields
Tube Shield from Imco are manufactured to exacting standards. Advanced equipment and material handling
permit us to offer the fastest turnaround times anywhere.
Advanced
Manufacturing
Facilities Mean
Fast Response
Imco is no newcomer to the field of industrial and utility boilers. Our understanding of and commitment to the
steam and power generation business enables us to solve your boiler tube erosion or corrosion problems
efficiently. Our technical staff can quickly recommend the proper material type and configuration to meet your
needs...and can quote your outage delivery requirements on a same day basis. Over 50% of orders can be
shipped within 24 hours.
Prompt
Service - Well
Supply what
You Need,
When You
Need it
6 BOILER TUBE COATING
Amorphous technology form a structure in a very different from crystalline alloys. In the amorphous structure,
atoms are randomly place in a continuous coating, eliminating the corrosion-path grain boundaries. In crystalline
structure atoms are positioned in ordered planes. Pockets of crystals with grain boundaries (or areas free of atoms)
are formed, creating weak zones in the structure and serve as natural pathways for corrosive elements to the
substrate metal.
A very minimal surface roughness of less than a few atoms is achieved. The Glassy, Ultra smooth surface provides
very low coefficient of friction.
Patented
Amorphous
Technology:
Amorphousof liquid metal coatings resist the various wear factors like; Erosion, Atmospheric, Corrosion, Chemical Corrosion,
Erosion/Corrosion, Sliding Wear, Thermal Barriers and also enhance the life of most critical applications of Power Plants,
Petroleum, railway bridges structures, gas rings, Oil Exploration, Quarry, like;
Circulating Fluidized Bed Boilers (CFB), *Pulverized Coal Fired Boilers,
Biomass Boilers, *Black Liquor Recovery Boilers,
Digesters, *Evaporators
Flash Tanks, *Process Vessels,
Tanks *Steel Structures,
Dimensional Restoration
Features of Amorphous Coating Technology:
1 Amorphous alloys show no long range order to
microstructure, coating very dense etc.
2 In Amorphous are random atoms form no grain structure
conducive to corrosion & form no flaws inherent in crystal
matrix structure.
3 Amorphous wires are random atoms and the uniqueness of
this technology is the coating takes place at only 140C.
4 Amorphous wires being metallic glass like structure gives
maximum heat resistant and lowest coefficient of friction
without any spoiling or peal outs. REVOLUTION
Advantages of using Liquid Metal Coatings:
Fully automated systems for water wall boiler tube shop
applications
Quality and Consistency
Repeatability
Cost Savings
Highest Production
Coated & Uncoated Tubes
8 THERMAL BARRIER
Thermal spray coatings are used to combat extreme temperatures, hot gasses and thermal cycling. These
extremes are often encountered in gas turbine engines. Many other industries that deal with the so-called hot
processes also require coatings that resist heat and oxidation. Sometimes coatings of special alloys are enough
to provide protection for a given application. If alloy coatings alone are inadequate, special metal alloys with
ceramic top coats are often used for these applications. The combined system - metal plus ceramic - is referred
to as a thermal barrier.
Thermal
Barrier
Thermal barrier coatings consisting of a metallic layer and then a ceramic layer will resist temperatures in
excess of 3,000F. The hot gas of combustion often contains sulfur compounds that are extremely corrosive,
but the carefully designed coatings are up to the task.
For lower temperature protection, industrial exhaust stacks are often coated with aluminum to prevent
premature rusting.
Most rollers used to carry steel through various furnaces in the steel manufacturing process are coated with
one of several materials that resist heat and oxidation. Rollers immersed in molten zinc and aluminum used in
the continuous galvanizing and continuous aluminizing processes are coated with thermal spray coatings
without which they would last for a much shorter period of time in the molten metals.
Among the most severe applications for which thermal spray coatings are used are thermal barriers on
combustion liners, transition pieces and nozzles of gas turbines. Temperatures often reach 3,000F. in these
applications.
Heat, oxidation resistance and resistance to particle erosion are the environmental concerns in steam turbine
diaphragms. Chrome carbide/Nickel chrome coatings work well in this environment.
Heat &
Oxidation
Solutions:
Aircraft Engine
Combustion Liner
Land Based Gas Turbine,
Combustion Transition Piece
Aircraft Engine Dome Assembly
9
CERAMIC LININGS
& COATINGS
Imco Internally Insulated Wear Protection System is designed to protect components from erosive wear, while
at the same time reducing heat loss by radiation. Imco combines insulation and wear protection, consisting of
an insulation layer followed by a Imco wear protection lining. Economical and easy to install, Imco eliminates
the need for external insulation, lowers construction costs, and reduces component weight and size.
Features &
Benefits
Imco can be used in operating temperatures up to 2190F, with thermal conductivity at 1112F = 0.10 W/mK.
Mortar is used to fill any gaps, and the thickness of the insulation layer depends upon operating temperatures
and acceptable heat loss.
Technical
Specifications
Imco systems vary according to process parameters including temperature, media type, and component size
and geometry.
Sizes