1、Specification forthe Application ofThermal SprayCoatings (Metallizing)of Aluminum, Zinc,andTheir Alloys andComposites for theCorrosion Protectionof SteelAWS C2.23M/C2.23:2003,NACE No. 12, SSPC-CS 23.00An American National Standard550 N.W. LeJeune Road, Miami, Florida 33126AWS C2.23M/C2.23:2003,NACE
2、No. 12, SSPC-CS 23.00An American National StandardApproved byAmerican National Standards InstituteMarch 17, 2003Specification for the Application of ThermalSpray Coatings (Metallizing) of Aluminum,Zinc, and Their Alloys and Compositesfor the Corrosion Protection of SteelPrepared byAWS C2 Committee o
3、n Thermal SprayingUnder the Direction ofAWS Technical Activities CommitteeApproved byAWS Board of DirectorsAbstractThis specification presents an industrial process for the application of thermal spray coating (TSC) on steel. It coverssafety, job reference standards, equipment setup and preparation,
4、 surface preparation, aluminum and zinc application,and sealer and topcoat application.NACE International SSPC: Society for Protective Coatings1440 South Creek Drive 40 24th Street, 6th FloorHouston, TX 77084-4906 Pittsburgh, PA15222-4643Key WordsAluminum, aluminum metal matrix composite, arc spray,
5、 flame spray, steel protection, thermal spray coating, zinc, zinc/aluminum alloyStatement on Use of AWS American National StandardsAll standards (codes, specifications, recommended practices, methods, classifications, and guides) of the AmericanWelding Society (AWS) are voluntary consensus standards
6、 that have been developed in accordance with the rules of theAmerican National Standards Institute (ANSI). When AWS standards are either incorporated in, or made part of, docu-ments that are included in federal or state laws and regulations, or the regulations of other governmental bodies, theirprov
7、isions carry the full legal authority of the statute. In such cases, any changes in those AWS standards must be ap-proved by the governmental body having statutory jurisdiction before they can become a part of those laws and regula-tions. In all cases, these standards carry the full legal authority
8、of the contract or other document that invokes the AWSstandards. Where this contractual relationship exists, changes in or deviations from requirements of an AWS standardmust be by agreement between the contracting parties.International Standard Book Number: 0-87171-713-1American Welding Society, 55
9、0 N.W. LeJeune Road, Miami, FL 33126 2003 by American Welding Society, NACE International, and SSPC. All rights reservedPrinted in the United States of AmericaAWS American National Standards are developed through a consensus standards development process that bringstogether volunteers representing v
10、aried viewpoints and interests to achieve consensus. While AWS administers the processand establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, orverify the accuracy of any information or the soundness of any judgments contained in its stand
11、ards.AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether spe-cial, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on thisstandard. AWS also makes no guaranty or warra
12、nty as to the accuracy or completeness of any information published herein.In issuing and making this standard available, AWS is not undertaking to render professional or other services for or onbehalf of any person or entity. Nor is AWS undertaking to perform any duty owed by any person or entity t
13、o someoneelse. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek the adviceof a competent professional in determining the exercise of reasonable care in any given circumstances.This standard may be superseded by the issuance of new editions. Use
14、rs should ensure that they have the latest edition.Publication of this standard does not authorize infringement of any patent. AWS disclaims liability for the infringementof any patent resulting from the use or reliance on this standard.Finally, AWS does not monitor, police, or enforce compliance wi
15、th this standard, nor does it have the power to do so.On occasion, text, tables, or figures are printed incorrectly, constituting errata. Such errata, when discovered, are postedon the AWS web page (www.aws.org).Official interpretations of any of the technical requirements of this standard may be ob
16、tained by sending a request, in writing,to the Managing Director, Technical Services Division, American Welding Society, 550 N.W. LeJeune Road, Miami, FL33126 (see Annex D). With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standardsmay be rendered. However, such
17、 opinions represent only the personal opinions of the particular individuals giving them.These individuals do not speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or inter-pretations of AWS. In addition, oral opinions are informal and should not be used a
18、s a substitute for an official interpretation.This standard is subject to revision at any time by the AWS C2 Committee on Thermal Spraying. It must be reviewedevery five years, and if not revised, it must be either reapproved or withdrawn. Comments (recommendations, additions,or deletions) and any p
19、ertinent data that may be of use in improving this standard are required and should be addressed toAWS Headquarters. Such comments will receive careful consideration by the AWS C2 Committee on Thermal Sprayingand the author of the comments will be informed of the Committees response to the comments.
20、 Guests are invited toattend all meetings of the AWS C2 Committee on Thermal Spraying to express their comments verbally. Procedures forappeal of an adverse decision concerning all such comments are provided in the Rules of Operation of the TechnicalActivities Committee. A copy of these Rules can be
21、 obtained from the American Welding Society, 550 N.W. LeJeuneRoad, Miami, FL 33126.Photocopy RightsAuthorization to photocopy items for internal, personal, or educational classroom use only, or the internal, personal, oreducational classroom use only of specific clients, is granted by the American W
22、elding Society (AWS), NACE Inter-national, and SSPC, provided that the appropriate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive,Danvers, MA 01923, Tel: 978-750-8400; online: http:/.iiiPersonnelAWS C2 Committee on Thermal SprayingE. F. Rybicki, Chair The University of TulsaT. Cal
23、l, 1st Vice Chair Power Spray, IncorporatedM. Bhusari, 2nd Vice Chair Praxair Surface TechnologiesE. F. Mitchell, Secretary American Welding Society*M. Alan Brookhaven National LaboratoryC. C. Berndt SUNY Stony BrookR. S. Brunhouse, Jr. A fax (303) 397-2740; Internet: .2. ASTM standards can be obtai
24、ned from ASTM International, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959.3. LaQue Center for Corrosion Technology, 702 Causeway Drive, Wrightsville Beach, NC 28480. Telephone (910) 256-2271; fax(910) 256-9816.4. The British Standards Institution, Customer Services, 389 Chiswick High Road
25、, London W4 4AL, UK. Fax: +44 (0) 20 8996 7001.viiTable of ContentsPage No.Personnel iiiForeword vList of Tables .ixList of Figuresix1. Scope .11.1 General11.2 Safety 11.3 Units of Measure.22. Referenced Documents .23. Definitions.34. Summary of Practice .35. Surface Preparation Requirements 45.1 Su
26、rface Finish .45.2 Angular Profile Depth.45.3 Angular Profile Depth Measurement Schedule 46. TSC Requirements 46.1 Feedstock and TSC Thickness46.2 TSC Thickness66.3 TSC Thickness Measurement Schedule .66.4 TSC Tensile Bond and Measurement Schedule .66.5 Bend Test 76.6 TSC Finish 76.7 TSC Porosity.76
27、.8 TSC QC Measurement Procedures and Instruments 77. TSC Application Procedure 77.1 General77.2 Thermal-Spray Equipment Setup77.3 Post-Blasting Substrate Condition and Thermal Spraying Period87.4 TSC Flash Coat.98. TSC Application98.1 Preheat 98.2 Thermal Spraying .99. Application of Sealers and Top
28、coats.109.1 General109.2 Sealer 109.3 Topcoat .109.4 Applying Paints.1010. Records1011. Debris Containment and Control.10viiiPage No.12. Work Procedures and Safety .1013. Documentation 1013.1 TSC Applicators Application Procedure1013.2 Job Reference Standard (JRS) .1014. Contract Pre-Award Evaluatio
29、n, Demonstration, and Validation.1115. TSC Applicator Warranty .1115.1 TSC Applicator Warranty1115.2 Materials Used.12Further Reading12Mandatory Annex .13Annex IApplication Process Method.13Nonmandatory Annexes21Annex AModel Procurement Specification .21Annex BModel Job Control Record 29Annex CProce
30、dure for Calibration of Portable Test Instruments to the ASTM C 633 Test Method .33Annex DGuidelines for the Preparation of Technical Inquiries for AWS Technical Committees35List of AWS Documents on Thermal Spraying .37List of NACE International/SSPC Documents on Thermal Spraying 37ixList of TablesT
31、able Page No.1 TSC System Requirements and Acceptance Tests 52 Blasting Media and Mesh Size Found Suitable for TSCs on Steel Substrates 63 Minimum Tensile Bond Requirements 74 Bend-Test Cracking Threshold: Mandrel Diameter vs. TSC Thickness .7I1 Flame- and Arc-Spray Standoff Distances and Spray Widt
32、hs, Nominal.17List of FiguresFigure Page No.1 Thermal Spray Coating Process.12 Job Reference Standard Illustration .43 Line and Spot Measurements.64 TSC Bend Test: Pass and Fail Examples .85 Thickness and Tensile-Bond Measurements for JRS Qualifications.11I1 Key Production and Quality Control Checkp
33、oints (QCCPs) for Applying Thermal Spray Coatings.13I2 Proper Spray Gun Adjustment .18I3 Line and Spot Measurements.18C1 Calibration Fixture .33AWS C2.23M/C2.23:2003, NACE No. 12, SSPC-CS 23.0011. Scope1.1 General. This standard is a procedure for the appli-cation of metallic Thermal Spray Coating (
34、TSCs) ofaluminum, zinc, and their alloys and composites for thecorrosion protection of steel. Required equipment, appli-cation procedures, and in-process quality control (QC)checkpoints are specified. This standard may be used as aprocurement document. Annex A presents a fill-in-the-blanks model pro
35、curement specification. The flowdiagram in Figure 1 provides an overview of the thermalspray coating process presented in this standard.Not included in this standard are requirements fordesign and fabrication, thermal spray equipment qualifi-cation, coating selection, and operator and inspectorcerti
36、fication. For successful thermal spray application,the steel structure and components should be designedand fabricated according to NACE Standard RP0178.Additional consideration should be given to weldmentswhose oxyfuel cut edges may affect hardness which maypreclude adequate profile depth.1.2 Safet
37、y. The basic precautions for thermal sprayingare essentially the same as for welding and cutting.Specification for the Application of ThermalSpray Coatings (Metallizing) of Aluminum,Zinc, and Their Alloys and Compositesfor the Corrosion Protection of SteelFigure 1Thermal Spray Coating ProcessAWS C2.
38、23M/C2.23:2003, NACE No. 12, SSPC-CS 23.002Information can be found on Safety in the Safety Chapterin AWS Thermal Spraying: Practice, Theory, and Appli-cation; ANSI Z49.1, Safety in Welding, Cutting, andAllied Processes;5and NFPA 58, Standard for theStorage and Handling of Liquefied Petroleum Gases.
39、6Read and follow safety precautions in the manufacturersequipment technical instructions and manuals and thefeedstock Material Safety Data Sheet. This standard mayinvolve hazardous materials, operations, and equipment.This standard does not purport to address all of the safetyproblems associated wit
40、h its use. It is the responsibilityof the user of this standard to establish appropriate safetyand health practices and determine the applicability ofregulatory limitations prior to use.Potential thermal spraying hazards include exposureto vapors, dust, fumes, gases, noise (from the spray gun),and a
41、rc ultraviolet (UV) radiation. Additionally, improp-erly used thermal spray equipment can create potentialfire and explosion hazards from the fuel and carrier gasesand a potential electrical shock hazard from the electricaland electronic equipment and charged wire spools. Tominimize hazards, proper
42、safety precautions shall be fol-lowed. Operators shall comply with the procedures in thesafety references, the manufacturers technical manuals,and the material safety data sheets.Thermal spraying can be a completely safe processwhen performed by an operator who follows the recom-mended precautionary
43、 measures, has a proper understand-ing of thermal spraying practices, and has knowledge,skill, and exercises care in using thermal spray equipment.1.3 Units of Measure This specification makes use ofboth the International System Units (SI) of units and U.S.Customary. The measurements are not exact e
44、quivalents;therefore each system must be used independently of theother without combining in any way. The specificationC2.23M uses SI units. The specification with the desig-nation C2.23 uses U.S. Customary Units. The latter areshown in appropriate columns in tables or within paren-thesis ( ) when u
45、sed in the text. Suitable conversionsencompassing standard sizes of both can be made, how-ever, if appropriate tolerances are applied in each case.2. Referenced DocumentsThe following standards contain provisions which,through reference in this text, constitute provisions ofthis AWS Standard. For da
46、ted references, subsequent5. AWS and ANSI standards can be obtained from GlobalEngineering, 15 Inverness Way East, Englewood, CO 80112-5776. Telephones: (800) 854-7179, (303) 397-2740; fax (303)397-2740; Internet: .6. NFPA standards available from National Fire ProtectionAssociation, One Batterymarc
47、h Park, Quincy, MA 02269-9101.amendments to, or revisions of, any of these publicationsdo not apply. However, parties to agreements based onthis AWS Standard are encouraged to investigate the pos-sibility of applying the most recent editions of the docu-ments shown below. For undated references, the
48、 latestedition of the standard referred to applies.(1) ANSI Z49.1 Safety in Welding, Cutting, and AlliedProcesses(2) ANSI/AWS C2.18, Guide for the Protection ofSteel with Thermal Sprayed Coatings of Aluminum andZinc and Their Alloys and Composites(3) ASTM B 833, Standard Specification for Zinc andZi
49、nc Alloy Wire for Thermal Spraying (Metallizing)7(4) ASTM C 633, Standard Test Method for Adhesionor Cohesive Strength of Flame-Sprayed Coatings(5) ASTM D 4285, Method for Indicating Oil or Waterin Compressed Air (West Conshohocken, PA: ASTM).(6) ASTM D 4417, Standard Test Methods for FieldMeasurement of Surface Profile of Blast Cleaned Steel(7) ASTM D 4541, Standard Test Method for Pull-OffStrength of Coatings Using Portable Adhesion Testers(8) ASTM D 4940, Standard Test Method for Con-ductimetric Analysis of Water Soluble Ioni
