Corrosion Control
Superior Corrosion Protection for Extended Bearing Life-Cycles
Since pot bearings are primarily fabricated from high-grade steel plates, the quality of corrosion protection is the single most critical factor influencing their operational life-cycle. Implementing advanced surface treatments not only ensures structural integrity but also significantly reduces long-term maintenance costs.
Advanced Metal Arc Spray Technology
To guarantee the highest quality, PILLAR applies Metal Arc Spray technology as a standard practice for all our pot bearings.
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The Process: Arc spraying utilizes an electric arc to melt metallic wires, which are then propelled onto the steel surface to create a dense, high-bond protective coating.
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Customized Coatings: While Zinc Arc Spray is our standard protection, we offer specialized alternatives such as Aluminum-Magnesium (Al-Mg) alloys to meet specific environmental challenges or client requirements.
Proven Performance: 20+ Years of Excellence
The real-world durability of our thermal arc spray has been rigorously proven in major international projects:
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Taiwan High-Speed Rail: After more than 20 years of continuous service in demanding conditions, PILLAR pot bearings show zero signs of corrosion, validating the superior performance of our coating technology.
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International Infrastructure: PILLAR Taiwan has supplied numerous pot bearings for major expressway projects in Vietnam, utilizing a specialized Al95%-Mg5% thermal arc spray.
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6,000-Hour Salt Spray Validation: Our coatings have successfully passed a grueling 6,000-hour salt spray test conducted by Vietnamese laboratories—far exceeding standard industry benchmarks for corrosion resistance.
Introduction to Thermal Arc Spray Technology
Thermal Arc Spraying is an advanced coating process that utilizes an electric arc as a high-intensity heat source to melt metallic wires. Once melted, an air stream propels the molten metallic particles onto the substrate (the steel plate), creating a dense and highly durable protective layer.
Thermal Spray Heat Sources
Thermal spray technologies are generally categorized by their heat source into two primary types: Electric and Gas. Within the electric category, there are two specialized technologies:
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Plasma Spray: Utilizes ionized gas for extremely high-temperature applications.
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Arc Spray: The preferred method for structural bearings, providing exceptional bond strength and long-term corrosion resistance.
Critical Surface Preparation: Grit Blasting
To ensure maximum adhesion of the metallic particles, the surface of the steel plate must be thoroughly cleaned and textured to the correct profile. We implement a rigorous grit blasting process prior to the arc spray application to achieve the necessary surface roughness, ensuring a permanent mechanical bond between the coating and the steel.
Enhanced Durability with Specialized Top Coating
Following the arc spray process, a high-performance top coating is applied. This final layer serves multiple critical functions:
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Surface Refinement: Seals the metallic layer for a smooth, uniform finish.
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Increased Hardness: Improves the overall structural integrity of the coating.
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Abrasion Resistance: Protects the bearing against environmental wear and mechanical friction.
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Extended Service Life: Maximizes the operational lifecycle of the bearing, reducing the need for future maintenance.
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Space-Efficient Process: The compact nature of the equipment and the speed of the process minimize the required workspace during fabrication.
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Exceptional Coating Efficiency: Achieve the total required film thickness in a single application, significantly reducing production lead times.
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Zero Drying Time: Unlike liquid paints, arc-sprayed metallic coatings solidify instantly upon contact, allowing for immediate handling and further processing.
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Enhanced Surface Longevity: Delivers a predictable and extended service life, making it a cost-effective investment for long-term infrastructure projects.
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Preserved Substrate Integrity: The low-heat input of the process prevents thermal distortion (torsion) or structural changes to the steel plate, maintaining the original properties of the substrate.
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Versatile Application: The process is highly adaptable and ideal for coating complex or irregularly shaped substrates where uniform protection is critical.
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Superior Corrosion & Abrasion Resistance: Provides an robust anti-corrosive barrier with excellent performance against mechanical wear and abrasive environments.
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Optimized for Top-Coating: The resulting surface profile is perfectly suited for immediate topcoat application, further enhancing the bearing’s chemical resistance and aesthetic finish.
The Thermal Arc Spray process offers distinct technical and economic advantages over traditional coating methods, ensuring superior protection for PILLAR pot bearings.
Key Characteristics of Thermal Arc Spraying
Key Characteristics of Thermal Arc Spraying
