Comparative study of surface preparation methods for thermal spray coatings applied via arc spraying process

Produktinformationen

M.Sc. Alexandre Maier Eurich, alexandre_me91@hotmail.com; Anderson Becker, anderson.becker@lactec.com.br; M.Sc. Irene Bida de Araújo, irene.araujo@lactec.com.br; Dr. Igor Giacomelli Zanella, igor.zanella@lactec.com.br; Dr. Anderson Marenda Pukasiewicz, anderson.pukasiewicz@gmail.com; 

https://doi.org/10.53192/ITSC2026584

The performance of arc-sprayed aluminum-based coatings is strongly influenced by the surface preparation method applied prior to deposition. This study compares the effects of abrasive blasting, Bristle Blaster, and pneumatic descaling on the adhesion, microstructural integrity, and corrosion resistance of arc-sprayed aluminum coatings applied as single-layer and duplex systems. Coating performance was assessed through microstructural characterization, mechanical testing, and corrosion exposure under salt spray and corrosion under insulation (CUI) conditions. Abrasive blasting provided the highest overall performance due to enhanced mechanical interlocking at the coating–substrate interface. However, the Bristle Blaster technique demonstrated satisfactory adhesion and corrosion resistance when combined with duplex coating architectures, indicating its potential as a more sustainable alternative in applications where environmental restrictions or field conditions limit conventional abrasive blasting. The results establish clear relationships between surface condition, coating microstructure, and functional performance, offering practical guidance for selecting surface preparation strategies for arc-sprayed aluminum coatings in aggressive industrial environments.

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Erscheinungsdatum

März 2026

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6