ISO 2063-1:2019
Thermal spraying — Zinc, aluminium and their alloys — Part 1: Design considerations and quality requirements for corrosion protection systems
This document specifies requirements for the protection of iron and steel surfaces against corrosion by applying thermal-sprayed metallic coatings of zinc, aluminium or their alloys.
In this document, requirements for the planning of the corrosion protection system and for the constructive design of the component to be protected are specified, where thermal spraying is intended to be the process for the deposition of the metallic corrosion protection.
Some field-related basic terms are defined and instructions for corrosion behaviour of the zinc and aluminium materials under different environment conditions are provided.
Characteristic properties of the coating, e.g. coating thickness, minimum adhesive strength and surface appearance, are specified and test procedures for thermal-sprayed corrosion protection coatings of zinc, aluminium or their alloys are determined.
This document is valid for applying thermal-sprayed zinc and aluminium protection coatings against corrosion in the temperature range between −50 °C to +200 °C, taking into consideration the service conditions of any sealants used. Heat-resistant protective coatings of aluminium are covered by ISO 17834 and are not in the scope of this document.
Other corrosion protection processes, e.g. hot-dip galvanizing (galvanic coating), sherardizing, electroplating or selection and deposition of organic coatings/paints are not in the scope of this document.
Requirements for the manufacturing of thermal-sprayed coatings are specified in ISO 2063-2.
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Foreword
Introduction
1 Scope
2 Normative references
3 Terms and definitions
4 Criteria for corrosion and corrosion protection by thermal-sprayed coatings
4.1 General
4.2 Corrosivity categories and environment conditions
4.3 Corrosion rate
4.4 Coating materials and corrosion behaviour
4.4.1 General
4.4.2 Zinc and zinc alloys
4.4.3 Aluminium and aluminium alloys
5 Requirements for the corrosion protection systems and their planning
5.1 General rules — Technical requirements
5.2 Used spray materials and coating thickness
5.2.1 Spray materials
5.2.2 Coating thickness
5.3 Construction design requirements for iron and steel components for thermal spraying
5.3.1 General
5.3.2 Recommendations for the design of the part — Avoidance of corrosion creating areas
5.3.3 Requirements for welding in combination with thermal-sprayed protective coatings
5.3.4 Thermal spraying of corrosion protected fastenings
6 Pre-conditions and requirements for the manufacturing process
6.1 General — Requirements
6.2 Reference areas
6.3 Preparation of the surface to be coated
6.4 Thermal spraying
6.5 Sealing of thermal-sprayed coatings
6.6 Metallic coatings and additional organic top coatings
6.7 Requirements for the tests — Test procedures
6.7.1 General
6.7.2 Visual inspection — Appearance
6.7.3 Coating thickness
6.7.4 Adhesion strength
6.7.5 Metallographic investigation
7 Requirements for the manufacturer
7.1 General
7.2 Coating specification — Requirements for the spray coating
8 Documentation
Annex A (informative) Corrosivity categories — Environment conditions — Exposure
Annex B (informative) Summary of the corrosion behaviour of thermal-sprayed coatings of zinc, aluminium and their alloys
Annex C (informative) Recommended values for the thickness of the metallic coating
Annex D (informative) Examples of design and explanations
Annex E (informative) Example test certificate for work specimen for thermal sprayer used on-site in accordance with ISO 2063-2
Annex F (informative) Appearance of surfaces in different treated conditions
Annex G (informative) Checklist for this document — Work and test steps and connection to relevant standards or recommendations
Bibliography
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Foreword
Introduction
1 Scope
2 Normative references
3 Terms and definitions
4 Criteria for corrosion and corrosion protection by thermal-sprayed coatings
4.1 General
4.2 Corrosivity categories and environment conditions
4.3 Corrosion rate
4.4 Coating materials and corrosion behaviour
4.4.1 General
4.4.2 Zinc and zinc alloys
4.4.3 Aluminium and aluminium alloys
5 Requirements for the corrosion protection systems and their planning
5.1 General rules — Technical requirements
5.2 Used spray materials and coating thickness
5.2.1 Spray materials
5.2.2 Coating thickness
5.3 Construction design requirements for iron and steel components for thermal spraying
5.3.1 General
5.3.2 Recommendations for the design of the part — Avoidance of corrosion creating areas
5.3.3 Requirements for welding in combination with thermal-sprayed protective coatings
5.3.4 Thermal spraying of corrosion protected fastenings
6 Pre-conditions and requirements for the manufacturing process
6.1 General — Requirements
6.2 Reference areas
6.3 Preparation of the surface to be coated
6.4 Thermal spraying
6.5 Sealing of thermal-sprayed coatings
6.6 Metallic coatings and additional organic top coatings
6.7 Requirements for the tests — Test procedures
6.7.1 General
6.7.2 Visual inspection — Appearance
6.7.3 Coating thickness
6.7.4 Adhesion strength
6.7.5 Metallographic investigation
7 Requirements for the manufacturer
7.1 General
7.2 Coating specification — Requirements for the spray coating
8 Documentation
Annex A (informative) Corrosivity categories — Environment conditions — Exposure
Annex B (informative) Summary of the corrosion behaviour of thermal-sprayed coatings of zinc, aluminium and their alloys
Annex C (informative) Recommended values for the thickness of the metallic coating
Annex D (informative) Examples of design and explanations
Annex E (informative) Example test certificate for work specimen for thermal sprayer used on-site in accordance with ISO 2063-2
Annex F (informative) Appearance of surfaces in different treated conditions
Annex G (informative) Checklist for this document — Work and test steps and connection to relevant standards or recommendations
Bibliography