Application: Spray corrosion-protection coatings into cavities and onto hard-to-reach components
What this application is about
The right solution starts with the entire process rather than an individual gun. Spray pattern, nozzle design, material pressure, delivery, component movement and cleaning must be considered together to keep the application stable and repeatable.
Purpose and benefits of the coating
The application mainly concerns steel, stainless steel, aluminium and coated metal components. The required effect occurs only when coating material, substrate, layer thickness and subsequent drying or curing fit together. The spraying process must therefore be adapted to the concrete material system and the real production conditions.
Alongside surface quality, material consumption, cleaning effort, system availability and reliable repeatability also matter. A sound technical solution therefore combines controlled atomisation with a stable material supply that is easy to regulate.
What matters with the application
Even small fluctuations in material pressure, viscosity, distance or movement control can change the coating visibly or functionally. Typical requirements include:
- Complete wetting of concealed interior surfaces
- even layer despite limited visibility and accessibility
- Prevention of runs and material accumulations
- suitable beam geometry for cavities, edges and back cuttings
- controlled material pressure over long lines or extensions
- safe cleaning and flushing after production end
Decisive parameters for cavity and interior coatings
In cavities, the spray pattern is not directly visible. The design must therefore be based on geometry, insertion depth, movement distance and quantity of material. Nozzle extensions and 360-degree sprayheads distribute the medium to internal walls, while feed or retreat speed affects the layer thickness.
Corrosion protection media shall take into account creepability, ventilation and possible discharge points. Too much material can collect at the lowest point, too little leaves unprotected areas behind.
- Internal diameter and length of the cavity
- Spray direction and cover over 360 degrees
- Speed of feed, withdrawal or rotation
- Wet layer and drain behaviour
- Ventilation, drying and safe solvent removal
Spraying technology and material supply from Krautzberger
Krautzberger treats application and material supply as a connected system. Depending on the task, manual and automatic spray guns, suitable air and material nozzles, material pressure tanks, diaphragm pumps, pump and lifting stations, and material pressure regulators can be combined.
In automated processes, spray guns can be integrated into mounts, lifting devices, axes or robots. Material changeover valves and flushing equipment support applications with several colours or media. The specific selection depends on viscosity, solids content, application quantity, cycle time and component geometry.
For fine surface finishes, various XLINE nozzle combinations and spray patterns are available. With highly viscous, abrasive or sedimenting media, sufficiently large flow cross-sections, suitable material combinations, agitators and pressure-stable delivery become more important.
The focus is on hand or automatic spray guns with straight, angled or rotating nozzle extensions, 360-degree spray heads, material pressure vessels, diaphragm pumps and material pressure controllers. The technically and economically suitable combination is selected for the specific medium, components and required production output.
Typical applications
The application is used in different industries and component groups. Typical examples are:
- Vehicle compartments and body structures
- Profiles, supports and frame constructions
- Machinery and plant construction parts
- Container sockets and hard-to-reach interior contours
- Tube sections, housings and welding structures
- Components for transport, construction and agricultural engineering
Process integration and automation
Manual application is suitable for changing geometries and repair work. In series processes, extension and spray gun can be reproducibly inserted into the cavity via axes, robots or lifting devices.
In addition, component feed, extraction or ventilation, cleaning, media change and accessibility for maintenance work must be taken into account during the system integration. This keeps the process stable not only in the pattern run, but also in everyday production.
Benefits for your production
- better coverage of concealed corrosion areas
- defined material application instead of uncontrolled flooding
- lower consumption and less rework
- Reproducible inner coating in series processes
- Adaptation to different cavity geometries
- Integrable flushing and material supply concepts
Process design at the Krautzberger technical centre
Liquid media and coating materials with similar names can differ considerably in viscosity, solids content, solvent base, wetting and drying. A reliable choice of spray gun, nozzle and material supply should therefore be made using the original material and a representative component.
In the test, penetration depth, beam direction, quantity of material, driving speed and retreat motion are adjusted in such a way that the required inner surface is safely reached.
On this basis, the spray pattern, material quantity, pressure, distance, movement and cleaning sequence can be defined. The result is an application solution suited to the medium, the geometry and the intended production process.
Related products
All products
Find the right application solution together
Looking for a spray gun, an automatic spray gun or a complete material supply for this process? Krautzberger helps you select and design suitable spray technology, nozzle configurations, delivery and regulation.
Contact Krautzberger to discuss your medium, component, production volume and desired result. Together, we assess how the process can be implemented safely and economically.
Industries for this application
Especially in cavities and on complex components, corrosion protection must also reach metal surfaces that are difficult to access. Depending on the application, moisture, salt and other aggressive media place different demands on coating application.
