Metal Sprayed coatings can be applied to just about anything including Metal, Wood, Polystyrene, Plastic, Glass, Paper, Ceramics, as well as Chocolate (for demonstrative purposes only) and can be used in unlimited artistic applications. Metal Spray also provides the ideal surface to receive any top-coating from painting to powder-coating with any available colour! The Arc Spray process is known for its low heat input when spraying. Low heating of the substrate makes arc spray useful when it comes to thermally sensitive substrates. The low heat input also eliminates the risk of component distortion. The above video will help to emphasise this low heat input by showing examples that would lose definition, distort, warp or even melt when subjected to a high temperature.
The above video shows the Metal Spraying of zinc onto a polyurethane foam sculpture.
Zinc Sprayed Artwork with Paint Top Coat - Image provided courtesy of Ironic Art, Gatton QLD.
Polystyrene Arc Spraying
Metal spray coatings can be applied onto all sorts of surfaces including, but not limited to: polystyrene, polyurethane foam, rubber silicon, wood and even apples!
Polystyrene Zeus Head (Left), Bronze Coated Zeus Head (Middle), Polished Bronze Coated Zeus Head (Right)
Polystyrene is widely used for props in performing arts industries on movie and theatrical sets. Metal Sprayed coatings using the Arc Spray process are ideal for polystyrene props, providing the structural integrity required for props, without compromising any of the surface detail. Metal spray solidifies immediately on hitting the surface with very minimal heat, causing no deformation. Metal spray coatings are perfect protection for polystyrene as they add only minimal weight to the finished subject.
There is no limit to the size of job to be completed with the Metal Spray process, making it perfect for all shapes and sizes of props. Coatings can be applied in desired thicknesses, the thicker the coat the stronger the structure, however, thicker coatings will add a little extra weight to the finished product.
Different types of metals can be sprayed such as Bronze, Zinc, Steel and Brass. Metal Sprayed surfaces can be polished or painted as required for prop completion.
Polystyrene Mannequin Head (Left), Polished Arc Sprayed Zinc Mannequin Head (Right)
A 3D map of the world was created for part of a movie set. The map needed to be strong enough to take the weight of the actors who would be walking on it during filming. This strength and durability was provided by the metal sprayed finish.
Metal Spraying of a Polystyrene Map of the World (used as part of a movie set)
Another example has seen polystyrene shaped as books, then used for a library scene. These books were then metal sprayed for durability and painted to look like a row of books. Different coloured metals and materials can be used to offer a range of finishes. Post spraying techniques, such as polishing and acid ageing are available.
As well as being used on polystyrene, metal spraying can also be used to spray onto fibreglass, rubber silicon, polyurethane foam and carbon-fibre mouldings for decorative purposes.
Zinc helmet produced using a rubber silicon mould
Decorative Railings
The artwork below was Metal Sprayed with Zinc and then top coated with paint.
Image provided courtesy of Ironic Art, Gatton QLD.
Image provided courtesy of Ironic Art, Gatton QLD.
Decorative Statue
This hand statue (completed by Ironic Art Gatton) is situated in Bunya Mountains National Park, QLD.
Image provided courtesy of Ironic Art, Gatton QLD.
Decorative Water Feature
Image provided courtesy of Ironic Art, Gatton QLD.
Metal Spraying onto Wood
Wood is another material that can be subjected to the Metal Spray process.
An undercoat of zinc is usually applied - about 100 µm thick using either Flame or Arc spraying. This is then followed by a top coat that will produce a desired colour phase, such as Aluminium Bronze or Brass, deposited until approx. 3 mm thick. A grinder, buffing, wire brushes or a chemical treatment, can be used to create fantastic metallic arts, along with being utilised in a plethora of other applications e.g. copper work surfaces, decorative Pieces & Furniture, to name a few.
One of the benefits of such coatings on wood is the corrosion protection it offers. For example, the copper coating on the wood or fibreboard can effectively protect the wood from fungi and mildew. Thermal spray copper coatings have proved to have the potential to protect wood from biological degradation, while also serving as an antimicrobial coating.
Ceramic Objects
Ceramic objects can be Metal Sprayed to provide a decorative metal finish.
The above image shows the progression of a ceramic face being subject to the Metal Spray process. The first image shows the original ceramic object prior to Metal Spraying. The second image shows the progression once a Zinc coating has been applied and the third image shows a brass coating applied on the crown. The face can then be top coated with paint in certain areas in order to emphasise particular aspects.
Headstone Inscription
Another application that decorative coatings are used in Australia is the inscription of lettering on headstones using Metal Sprayed Aluminium.
Golden Lane - Working Metals Limited
Metallisation customer Working Metals Limited are specialist architectural metalwork fabricators and used Metallisation Flame Spray Equipment to complete a sprayed bronze coating on window and door frames, as well as a roof section used in the renovation and conversion of a project in Golden Lane, Islington.
Architectural Forged Iron Ornaments Restoration
Image Provided Courtesy of Metal Spray Hungary
The restoration work on forged iron ornaments was completed by Metal Spray Hungary.
Image Provided Courtesy of Metal Spray Hungary
The ornaments were more than a century old and had sustained serious marks and damage due to general wear and tear over time, as well as being situated in a C5 corrosion category urban environment saturated by exhaust fumes.
Images Provided Courtesy of Metal Spray Hungary
The damage caused thick layers of rust in some areas, and several layers of paint residue in others.
Image Provided Courtesy of Metal Spray Hungary
As a result, the surfaces were cleaned meticulously to remove the residues and rust. The ornaments were then Metal Sprayed with Aluminium using either a Metallisation Flame Spray or Arc Spray system.
Image Provided Courtesy of Metal Spray Hungary
A primer coat was then applied, followed by a UV resistant topcoat.
Image Provided Courtesy of Metal Spray Hungary
Artistic Metals
Artistic Metals, based in Uckfield, UK specialise in metal spray finishing with an aesthetic twist and provide a wide range of diverse decorative items ranging from a bronzed pear, dining tables and chairs through to the revolving doors of the Houses of Parliament.
Chris Bose at Artistic Metals, says: “We have taken this traditionally industrial anti-corrosion process to a whole different level. By developing some additional finishing we have created a range of durable contemporary metal finishes. We specialise in using our own applied metal finishes to create stunning effects. Antique bronze is especially popular because of its warm and luxurious appearance. While copper, brass and Verdigris give a real wow effect. We also use the ever-popular mirror polished stainless steel for a complete contemporary look.”
Chris’s has many years’ experience in metal spraying, which has enabled him to perfect the metal finish range used by interior designers and architects around the UK on commercial and non-commercial projects. Artistic Metals recently completed the bronze finishing on the surround of the London Bridge war memorial, which is located within London Bridge Station. This hugely successful project required the finish on the new surround to match the existing bronze plaque. To achieve this, Artistic Metals applied Bronze finish AM7 to a stainless-steel substrate using the MK60 pistol. Chris continues: “The bronze finish AM2 and AM7 have proven to be particularly popular over the years, as these shades have a timeless quality that reflect both style and substance. In the London Bridge war memorial project the client was delighted with the finish, which is exactly the response we aim for every time.”
The metal spray finish, used by Artistic Metals, can be substantially more cost effective compared to solid metal constructions. For example, an MDF desk finished in bronze antique, will mimic the look and feel of a real solid bronze desk, as the bronze applied is actual bronze, unlike bronze coloured paint, which is why this finish is so popular. The metal sprayed finishes work well on many surfaces including metal, wood, plaster, concrete, fibreglass, hardboard, some types of plastic or even thick card. Every project is different, and every customer’s needs will vary, and the Artistic Metals team are on hand to deliver a bespoke, professional service every time.
One of the issues faced when metal spraying large, flat panelled areas is the potential for distortion, which is caused by the surface preparation blasting. To balance this Chris and the team usually flash blasts the reverse of the panel to counter flatten and re-balance. The surface preparation is a crucial part of this process, as any flaw, no matter how tiny, will be visible on the finished surface.
Decorative Copper
A common application for thermally sprayed copper is decorative.
Metal Sprayed copper lettering prior to polishing
By coating an everyday item such as a table, worktop or bench with copper finishing, the end result mimics the look and feel of a solid copper table/bench.
Polished polystyrene bench Arc Sprayed with Copper
The copper finish can then be polished/etched for later processes. Surfaces treated with copper should generally be sealed according to the application to avoid oxidation.
Aluminium Bronze Coatings
Aluminium bronze can be used as an effective bond coat on cast iron or steel. Thermal sprayed Aluminium Bronze has also been utilised by OEM vehicle manufacturers for Cylinder bores for piston skirts to provide a scuff & wear resistant surface and not forgetting with its glistening “Gold” appearance, it also finds its way into many decorative coatings such as this Aluminium bronze coating over a GRP moulded bust.
Tin Zinc Moulds
Being a soft and easy material to polish, Tin Zinc also lends itself as a decorative coating and finally Tin zinc can also be deposited on to a suitable pattern for mould making. The sprayed metal moulds can be made in an extremely short time compared to conventional tooling methods and with the benefit of considerably lower costs.
Tin Zinc alloys commonly found in “Lead free solders” also finds its way into thermal spraying, available in 60/40, 70/30, 80/20 mixes. Fairly versatile in its use – Tin Zinc lends itself to numerous industries. Given its high solderability, this material is ideally suited to capacitor end coatings.
Guilding Bronze
Guilding Bronze (Gilding Brass) Wire is a 90% Copper 10% Zinc and is used extensively for decorative coatings due to its attractive rich golden colour, it is also known as Gilding Metal or Pomponne.
Developed in France it is the term used to describe 18th and 19th century decorative art objects such as clocks, candelabras etc and from the 19th century the term was used when referring to gilt metal or imitation gold.
This coating is not generally susceptible to dezincification or stress corrosion.
It is also readily soldered and brazed. Rarely used but is available as a 2mmØ wire.
Arc Spraying onto Plastic
Arc Spray was chosen as the preferred process for this thin walled plastic trophy because of the wide range of usable coating materials and the relatively low induced thermal and mechanical stresses on the item.
A Zinc bond coat was applied initially, followed by a top coating of Copper for a durable, decorative finish (below image is prior to polishing).
Arc Spraying Open Cell Foam
Open cell foam is a versatile material used in numerous applications due to its soft formable nature and although it has a springy structure, a zinc coating can be applied using the Arc Spray process to the open cell foam with no noticeable detriment to its performance.
This application not only highlights the low heat input of the Arc Spray process, but also shows an example of an application used on movie sets to provide sturdier props. Zinc spraying the open cell foam structure/workpiece reduces the need for replacement after being exposed to wear and tear on set.
Arc Spraying on Textiles/Fabrics
The modern tennis ball is made of a hollow rubber core, covered in a wool or nylon shell and although thermal spray has never been utilised in mass production for textiles or fabrics, it has been utilised extensively for extended the service lifespan of the textile manufacturing equipment. Textile machinery components are subjected to intense wear and tear, the man-made fibres are usually very abrasive in nature (most notably polyester and nylon) and the additives that are commonly used in textile industry (lubricants for example) are additionally corrosive in nature. When combined, these two types of materials will deteriorate the processing equipment’s life to a great extent.
The versatility of thermal spray coatings means you can achieve flexible Aluminium or Zinc coatings onto a diverse range of textile fabrics such as a tennis ball for decorative, conductive or wear resistant applications.
The above image shows the tennis ball after being Arc sprayed with Zinc and then the polished top coat of Aluminium Bronze.
Weathering Steel (Corten Steel) Coatings
Weathering / Corten Steel is a type of steel coating with a slow rate of corrosion.
The corroded surface offers a protective self-regenerating coating to the underlying material, similar to how oxides form on the surface of bare aluminium protecting the material underneath.
(Left) MDF board, (Middle) Corten Metal Sprayed Coating on MDF, (Right) Weathered Corten Sprayed Coating on MDF
Weathering steel often finds use in outdoor sculptures & architecture due to its ability to withstand wind, salt and water: the Leeds broadcasting tower (below), the Courtyard Theatre in Stratford upon Avon and the famous Angel of the North (above) all use this material for its distinctive colouring and protective features.
Weathering steel is also popular in the construction of Intermodal Shipping Containers.
Due to the slow rate of corrosion (when compared to other steels), in some environments it may take up to 6 months for the rusted appearance to form. When used for architectural or decorative purposes it may be beneficial to use a chemical catalyst to speed up this process to achieve the required finish in as little as a few hours. The beauty of this material is the natural inconsistencies in the final finish.
Arc Brass Coatings
Brass was used in the manufacturing of sesterces coins and many Romans also liked it especially in the production of golden coloured helmets. It is only in the last millennium that brass has been appreciated as an engineering alloy.
Sprayed Brass is generally used for its electrical conductivity and its appearance in decorative work, brass coatings can be finished in multiple ways resulting in attractive yet durable surface for interior and exterior architecture such as wrought iron, steel, resin, and wood to produce a variety of different finishes.
Polyurethane Foam Zinc Coating
This Polyurethane foam sculpture was Arc Sprayed with Zinc to provide structural integrity.
The below images show that the detail of the structure was not compromised by the process and no deformation occured due to the low heat input of the Arc Spray process.
Before Zinc Spraying
After Zinc Spraying
Glass Reinforced Plastic Arc Spraying
The Arc Spray process can also be used to provide protective or decorative coatings to glass reinforced plastic.
This instance shows Zinc being sprayed and then polished to provide a mirror-like appearance.
Did You Know?
The NRL trophy is Metal Sprayed with phosphor bronze!
In 1999 sculptor Rodger Apte created this masterpiece. For more details and to view some of Rodger's other masterpieces, Click Here.
Vulcan
“Vulcan” the colossal statue overlooking Birmingham, Alabama, was designed by Italian artist Giuseppe Moretti and cast from iron in 1904. The 56 foot high sculpture Vulcan is the Roman God of the Forge.
In 1999 the 50 ton statue was in desperate need of repair; in 2001 work began. After cleaning, the castings were lightly grit blasted and a thick layer of Zinc was applied using the Metal Spray process to both the interior and exterior surfaces of the statue. After being sprayed, the castings were stored outdoors without fear of corrosion and then brought into the shop for repairs.
After repairs another layer of Zinc was applied using the metal spray technique. This was followed by primer coat and polyurethane coating before being re-erected in June 2003.
Bronze Seed
- Figure 1: Three different seed segments were shaped by the artist in large blocks of white styrofoam. The individual segments are approximately three feet tall.
- Figure 2: Stainless steel skeletons were made for each of the three different shapes. These served as structural support for the outside shell and a base plate for anchoring.
- Figure 3: Copper mesh is shaped to the models; here, the back section is shown. The mesh is easily formed, often by hand, and can be cut and joined to accommodate any contour.
- Figure 4: The front half of the seed is metal sprayed with zinc to solidify the shape taken from the model. The openings in the mesh readily accept the sprayed zinc. The mesh becomes encapsulated when sprayed from both sides, lending great strength to the shell.
- Figure 5: The front and back sections are assembled and sprayed together on the skeleton. The seams will need minor grinding to disappear.
- Figure 6: The final shape is touched up and lightly grit blasted, then metal sprayed with silicon bronze. It is then highlighted by polishing.
- Figure 7: The three completed seed pods on site with a chemical patina finish.
READ DECORATIVE APPLICATION EXAMPLES
If you would like more information on Metal Spray equipment or consumables, call us on 07 3823 1004, or email us using our contact form.
