Fluoropolymer Coating Benefits

There are numerous advantages of coating with FluoroKote#1. FluoroKote#1 possesses a low
coefficient of friction which reduces torque requirements. When FluoroKote#1 coated fasteners are
used, galling and seizing become problems of the past. Due to the absence of nut locking oxides after
extensive exposure to corrosive environments, fasteners coated with our metal coating process do not
need to be removed by torching, cutting or nut splitting. The easy on/easy off properties exhibited by
these fasteners provide safe removal with wrenches. Lower your plant maintenance cost and increase
safety by using FluoroKote#1 coated fasteners.
Fluoropolymer metal coating advantages include extreme durability and low wear. However, during
assembly of fasteners in the field, the coating can sometimes be damaged. With most other fluoropolymer
coatings, this results in exposed bare metal that quickly begins to show corrosion and causes the coating
to fail. Our metallic base coat ensures superior corrosion resistance and continues to provide protection
even under the harshest conditions.

Metal Coating Quality Control

All orders that go through our metal coating process receive the highest quality control at Metal Coatings
Corp. Each order of FluoroKote#1 coated fasteners is checked for cure, thickness, adhesion and overall
coverage. Concentrations and temperatures of all solutions and chemicals used in the process are strictly
controlled and written records are maintained. Our advanced, computer controlled, automated equipment
keeps the coating thickness precise and extremely uniform. Great care is taken during the process so that
fasteners with a specified minimum hardness of Rockwell C32 or higher are not exposed to the
absorption and entrapment of hydrogen which can cause hydrogen embrittlement failure.

Metal Coatings Corp. is the sole licensee and exclusive applicator of FluoroKote#1. Competitors may
claim to have a similar coating but cannot match our quality control and efficiency of operation. With stateof-the-art equipment, fasteners are coated with FluoroKote#1 at a more competitive cost without
sacrificing quality. Acceptance of this revolutionary process has been steady and fast. Some of the world's
largest companies recognize the superiority of this process and have placed Metal Coatings Corp. on
their preferred supplier lists. They don't just ask for coated bolts...they specify FluoroKote#1 coated
fasteners!

Corrosion Resistant Coating Test

Data

Use Temperatures: -100 to 500F

Corrosion Resistance: Salt Spray (ASTM B117) ...up to 4,000 hrs (Nuts not frozen)

Pencil Hardness: 5H-6H (ASTM D3363-92A)

Kinetic Friction Coefficient: 0.06-0.08

Thickness: nominal 0.001" (1 mil)

Impact: 160 in. lb. (ASTM D2794-93)

Adhesion: 5B (ASTM D3359-95)

Dielectric Strength: 500 volts per mil

Elongation: 35%-50%

Tensile Strength: 4,000 psi

Operating Pressure: Up to 100,000 psi

Kesternich Test: Nuts not frozen after 30+ cycles (DIN 50018)

Thread Fit: Over tapping of nuts 0.010" (Recommended)

Salt Spray Resistance & Other

Corrosion Resistance Details:
ASTM

TEST

DURATION

RESULTS

D1308

Muriatic Acid 31% HCL

24 Hours

No Effect

D1308

Sulfuric Acid 93% H2SO4

24 Hours

No Effect

D1308

Caustic Soda 50% NaOH

24 Hours

No Effect

D1308

Methyl Ethyl Ketone MEK

24 Hours

No Effect

B117

Salt Fog

2,000 Hours

No Effect

Click here to Request a Metal Coating's Service Quote

or call us today at 713-977-0123

Wear-resistant ceramic coatings

Reactive maintenance procedures force the plant to make quick fixes where parts are
reinforced, patched, rebuilt, or completely replaced to get back up and running as
soon as possible. If repaired or replaced parts are put back into service without
somehow protecting the parts against recurrent damage, the service life of that
equipment will be less predictable.
Rachel Nashett and J. Adam Lyman, Henkel

04/08/2015

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Reliability and predictability are pivotal to the

operational success of industrial equipment. In aggressive industrial applications,
preventive and scheduled maintenance maximize the life and structural integrity of large
and small metal components such as mixing vessels, pumps, hoppers, housings, tanks,
chutes, pipes, and centrifuges. These heavy-duty parts are often exposed to aggressive
slurries, sand aggregates, particulates, and large stones that can damage and abrade
even the hardest reinforced steel substrates.
Damage to components can be caused by mechanical attack, chemical attack,
corrosion, or by a combination of these three modes. Mechanical attack involves dry
particulates or slurries dropping onto and traveling through chutes, pipes, pumps, and
other components. Over time, even soft flowing materials can abrade and wear away at
hard alloys such as AR400 steel. As the surface metal weakens, thin layers are
gradually stripped away from the parent substrate, reducing its thickness and structural
integrity.
Chemical attack and corrosion physically change substrates through chemical
reactions. For example, corrosion occurs when iron oxidizes, leaving a very weak and
loose layer of oxide on metal surfaces. Corrosion can be concentrated locally, forming a
pit or crack, or can extend across a wide area, uniformly corroding an entire surface. If
left untreated, active corrosion below the surface of a high build coating can cause the
substrate beneath to weaken, ultimately causing a critical failure in the structure.

In chemical attacks, damaging chemicals

passing through metal equipment can react with and eat away at the surface of the
metal, causing layer-by-layer damage. As damaged layers are continuously stripped
from the parent substrate, the thickness and structural integrity of the metal part
gradually decrease.
Examples of wear are easy to find in any industrial facility. Pump casings and impellers
wear as a result of abrasive slurries and solids, cavitation, and chemical attack, wearing
down internal sections of the equipment. Some of the common wear areas include the
cutwater, wear ring seats, impeller vane tips, and inside the volute. In the case of pipes
and ducts, most wear occurs at elbow bends where fluid flow changes direction. Some
plants are forced to repair or replace duct elbows every three months, adding
significantly to labor and material costs. In quarries and mines, iron ore can severely
abrade reclaimer buckets due to the continuous sliding caused by the digging and
reclaiming action.

Many facilities only conduct maintenance on large components once damage becomes
extremely apparent or a catastrophic failure occurs, such as a hole in a sidewall or a
part dropping off of equipment. When critical failure occurs, equipment must be shut
down for an unscheduled, costly, and time-consuming repair. Reactive maintenance
procedures force the plant to make quick fixes where parts are reinforced, patched,
rebuilt, or completely replaced to get back up and running as soon as possible. If
repaired or replaced parts are put back into service without somehow protecting the
parts against recurrent damage, the service life of that equipment will be less
predictable and the chances of another unscheduled critical failure increase.
To deliver long-term protection from wear, abrasion, chemical attack, and corrosion,
epoxy-based wear-resistant coatings containing ceramic fillers can be applied to
vulnerable metal surfaces to protect them and minimize planned and unplanned
downtime. These coatings act as a sacrificial and renewable working surface preserving
the structural integrity of the base substrate and preventing mechanical attack, chemical
degradation, and corrosion caused by abrasive particles, slurries, and chemical
exposure. These engineered coatings can be applied to worn equipment for restoration
or to new equipment before it is placed into service.
How does a wear-resistant coating work?
Ultra-smooth and high gloss, epoxy-based wear-resistant ceramic coatings increase
equipment efficiency and life expectancy. These coatings can be a quick and costeffective remedy to damage because parts are returned to service with little interruption
or process downtime.
Wearing compounds are two-part epoxy systems containing ceramic beads or ceramic
powder, and silicon carbide. The epoxy-base polymer that adheres the ceramic material
to the substrate is formulated to be extremely robust, offering excellent performance
under high-compression and high-impact loads. These coatings cure in temperatures

between 55 F and 90 F, with cure time dependent on mass and temperaturethe larger
the mass, the faster the cure. This is a result of the exothermic heat generated by the
epoxy reaction during the cure process. Higher substrate and air temperatures will also
result in accelerated cure.
Because ceramic is inert, it does not react with most materials that come in contact with
metal components. Ceramic coatings resist harsh chemicals and withstand
temperatures to 450 F. The size of the ceramic materialpowder or beadused in the
wear-resistant coating directly corresponds to the size of the particulate that will
ultimately damage metal components. For large particulates and stones, maintenance
professionals should use coatings with the largest available ceramic beads. For fine
slurries or wastewater, fine powder ceramics are sufficient to inhibit damage.
Designed for a wide variety of operating environments, wear-resistant coatings fall into
seven distinct categories: putties with beads, high-temperature formulations, ultra-hightemperature formulations, fast-set materials, brush-on formulations, sprayable
formulations, and impact-resistant materials.
Putties are thick pastes best applied using a trowel or a gloved hand on surfaces within
arms reach. These wearing compounds withstand abrasion from fine to coarse particles
in locations including elbows, cyclones, and other areas where fluid changes direction
and causes turbulence. Various sized bead fillers incorporated into different putty
formulations give them distinct strength and hardness characteristics to resist wear
based on the fluids or solids running through the system.
High-temperature formulations that resist up to 350 F are standard performers. Ultrahigh-temperature wearing compounds resist temperatures to 450 F, commonly found in
ovens and hot water or hot fluid slurries. These wearing compounds are often used to
protect the substrate from elevated temperature chemical attack.
Fast-set materials are used when equipment and parts need to return quickly to the
production line. These compounds cure to functional strength in as little as three hours.
Brush-on coatings are self-leveling, low viscosity materials that can be applied with
brushes or rollers, or simply poured onto a substrate and allowed to coat the desired
area. At just 1/8- to 1/4-in. thick, brushable coatings work best on equipment carrying
slurries with very fine particles such as sand, metal chips, shells, or seeds. They can
easily be applied to areas that are out of arms reach, like the inside of pipes, and will
reduce friction caused by moving fluids in applications like fluid pumps.
Sprayable coatings are low-viscosity materials similar to brush-on materials, but
achieving just 0.020-in. thickness. When applied with a spray gun equipped with an
atomizing mix tip, these ultra-thin coatings can be applied overhead, used on large
application areas and on hard-to reach, intricate, and small-diameter parts like curved
components and elbows. Because these coatings are so thin, they should not be
exposed to high turbulence or impact.

Impact-resistant coatings are specially formulated to absorb shock and withstand

damage from medium to large sized aggregate such as rocks, coal, and other
substances falling onto or otherwise striking a substrate. These materials are often
found protecting chutes at the end of conveyor belts in mining and construction.

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