Corrosion Tests by AWS

Corrosion Tests of Flame-Sprayed Coated Steel 19 Year Report
By: American Welding Society

This report presents the results of a 19-year study of the corrosion protection afforded by wire-flame sprayed aluminum and zinc coatings applied to low carbon steel. The program was initiated in July 1950 by the Committee on Metalizing (now the Committee on Thermal Spraying) of the American Welding Society. The first panels were exposed in January, 1953. This report presents the results of an inspection of the flame-sprayed coated steel panels made after all panels had been exposed for 19 years.


Aluminum-sprayed coatings 0.003 in. to 0.006 in. (0.08 mm to 0.15 mm) thick, both sealed and unsealed, gave complete base metal protection from corrosion in sea water and also in severe marine and industrial atmospheres.

Where aluminum coatings showed damage such as chips or scrapes, corrosion did not progress, suggesting the occurrence of galvanic protection.

The use of flame-sprayed aluminum and zinc coatings is recommended as a means to extended to extended the life of such iron and steel structures as bridges, highway or street light poles, marine piers or pilings, ship hulls, storage tanks, industrial structure, etc. Corrosion is thereby combated, and the natural resources needed in the manufacture of iron and steel are conserved.

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