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BRITISH STANDARD BS 4479 :

I _- I Part 7 : 1990
UDC 672/673 :621.795 :006

Design of articles
that are to be coated
Part 7. Recommendations for thermally
sprayed coatings

Conception des articles à revêtir Gestaltung zu beschichtender Gegenstände

Partie 7. Recommandationspour les Teil 7. mermisch gespritzte Schichten
revêtements appliqués par projection
thermique

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 ' BSI BS*4479: P A R T U ? 90 W 1 6 2 4 6 b 9 0071090 T 9

BS 4479 : Part 7 : 1990

Committees responsible for this

British Standard

The preparation of this British Standard was entrusted by the Surface Coatings
(other than Paints) Standards Policy Committee (SRC/-)to Technical Committee
SRC/10, upon which the following bodies were represented:

British Anodising Association

Institute of Metal Finishing
Institute of Sheet Metal Engineering
Institute of Vitreous Enamellers
International Tin Research Institute
Metal Finishing Association
Welding Institute
Zinc Development Association

This British Standard, having

been prepared under the
direction of the Surface Coatings
(other than Paints) Standards
Policy Committee, was published
under the authority of the Board
of BSI and comes into effect on
31 July 1990
Amendments issued since publication
O BSI 1990
First published, as BS 4479,
August 1969
Amd. No. I Date I %xt affected
First revision, as BS 4479 : Part 7
July 1990

The following BSI references

relate to the work on this
standard:
Committee reference SRC/10
Draft for comment &Y63491 DC
ISBN O 680 17906 2

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 \
Page
Committees responsible Inside front cover
Foreword 2
Recommendations
1 Scope 3
2 Definitions 3
3 General 3
4 Structural design considerations 4
5 Component design considerations 5
Appendix
A Diagrams illustrating preferred and deprecated design features for
articles to be coated by thermal spraying 6
Figures
1 Interior angles 6
2 Blind crevices 6
3 Narrow gaps 7
4 Crevices 7
5 Lapjoints 7
6 Corners 8
7 Flat surfaces 8
8 Pockets 8

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 I BSI BSrt1479: P A R T % ï 9 0 Lb24bb9 0873072 3 W
BS 4479 :Part 7 : 1990

Foreword

This Part of BS 4479 has been prepared under the direction of the Surface
Coatings (other than Paints) Standards Policy Committee and is based on a draft
prepared by the Institute of Metal Finishing. The BSI Rchnical Committee
acknowledges the contribution to this revision by the Institute') and by the
Committee for the Promotion of Electroplating.This Part of BS 4479 is one of a
series of Parts which together form a revision of BS 4479 : 1969. On publication of
all the Parts, BS 4479 : 1969 will be withdrawn. This revision of BS 4479
comprises the following Parts:
Part 1 General recommendations
Part 2 Recommendations for electroplated and autocatalytic coatings
Part 3 Recommendations for conversion coatings
Part 4 Recommendations for paint coatings and varnish coatings
Part 6 Recommendations for anodic oxidation coatings
Part 6 Recommendations for hot-dip metal coatings
Part 7 Recommendations for thermally sprayed coatings
Part 8 Recommendations for vitreous enamel coatings
Part 9 Recommendations for low pressure and vacuum deposited coatings
BS 4479 is directed towards helping to maximize the benefit obtained from
coating processes. There is a wide variety of coating processes, developed and
established industrially, intended to enhance or transform the surfaces of
manufactured articles. However, time and money are often wasted because the
design of many articles is unsuitable for the coating process to be applied.
Coating is only one part of the manufacturing process and should not be ignored,
or viewed in isolation, when considering the overall costs and quality.
This revision of BS 4479 has been undertaken to extend the range of coating
processes covered. It is not intended to cover every conceivable design detail,
type of article or service condition. Adherence to the general principles described
will, however, greatly assist in the achievement of the desired results. In any case
of doubt or difficulty, specialist advice in the particular type of process being
considered should be sought.
This Part of BS 4479 is not a specification and should not be used as such. The
recommendationsare intended to provide guidance towards good practice.
Compliance with a British Standard does not of itself confer immunity from
legal obligations.

I) Institute of Metal Finishing.

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BS 4479 : Part 7 : 1990

Recommendations

1 Scope The heat input to the substrate can be kept low,

and so thermal spraying is normally regarded as a
This Part of BS 4479 gives recommendations for the 'cold' process. A wide range of metals and alloys
design of metal parts that are to be coated by can be deposited in addition to some ceramics and
thermal spraying. It gives an outline of the process plastics. Thermally sprayed coatings are employed
involved in producing sprayed coatings of metals, to increase resistance against corrosion, oxidation
true and pseudo alloys, cermets, ceramics and and wear, to re-build worn or mis-machined parts,
composites. It also gives an appraisal of the design to impart low or high friction and other specific
features involved and itemizes many of the problem surface characteristics, and in some cases to form
areas that may be encountered. free-standing bodies. Most thermal spraying is done
NOTE 1. The production of thermally sprayed coatings of plastics with aluminium or zinc for the corrosion protection
is not included in this Part, but many of the features involved of iron and steel; these coatings may subsequently
are essentially similar to those described here.
be sealed with organic compounds to extend their
NOTE 2. It is recommended that Part 1 of BS 4479 be read in service life.
coqjunction with this Part. part 1 includes a list of British
Standards relating to processes covered by BS 4479 but not Thermal spraying involves two distinct stages,
necessaiiiy referred to in each Part. namely: surface preparation and spraying, Correct
NOTE 3. The titles of the publications referred to in this surface preparation is an essential prerequisite for
standard are listed on the inside back cover. the satisfactory functioning of a thermally sprayed
coating and should receive as much attention as
the spraying process itself.
2 Definitions
For the purposes of this Part of BS 4479, the Surface preparation is by degreasing followed, most
following definitions apply. commonly, by grit-blasting using chilled iron or
aluminous grit complying with BS 2451.
2.1 substrate Consideration should be given, when using chilled
The material upon which a coating is directly iron grit, to the possibility that embedded particles
deposited. might give rise to corrosion-initiationcentres. The
grit should be sharp, dust-free and not
NOTE. For a single or first coating, the substrate is identical with contaminated by paint, grease or other foreign
the basis material; for a subsequent coating, the intermediate
coating i s the substrate. matter; a given batch of grit should not be used on
different types of materials. Preferably, the
2.2 grit-blasting grit-blast unit should be reserved for thermal
Abrasive blasting with small, irregularly shaped spraying preparation. Compressed air for
angular pieces of steel, cast iron or non-metallic grit-blastingshould be uncontaminated by water or
particles of similar shape. oil. The surfaces to be coated should be completely
NOTE.This process should not be confused with sho€blastiig or
free from loose particles and dust. Grit-blasted
shot peening. surfaces should not be touched by bare hands; if
necessary, clean, lint-free gloves should be worn.
2.3 thermal spraying Spraying should begin as soon as possible after
A group of processes in which finely divided blasting, preferably within 4 h; if grit-blasted
metallic or non-metallic surfacing materials are surfaces begin to rust, they should be re-prepared
deposited in a molten or plastic condition on a before spraying. Reference should be made to
substrate to form a coating. CP 3012 for procedures that are generally
applicable.
2.4 thermally sprayed coating
Thermal spraying is effected by either manual
A coating obtained when finely divided metallic or means or automatic equipment. The control and
non-metallic surfacing materials are deposited in a inspection of sprayed metal coatings is fully
molten or plastic condition on a substrate. covered in BS 2569.
The following four main techniques are employed
3 General in thermal spraying:
It is essential that the design of any article required (a) flame spraying, in which the coating material,
to be coated should take into account not only the in the form of a powder, wire, sintered rod or
function of the article and its method of filled metal or plastic tube, is fed into an
manufacture but also the limitations imposed by oxylfuel-gas flame which heats and projects the
the coating. Expert guidance from the processor material;
should be obtained at the design stage. (b) arc spraying, in which the coating material is
Thermally sprayed coatings are produced by in the form of two electrically conducting wires
heating the coating and projecting it in the form of which are fed on a converging path; an arc is

- a dispersed spray on to the surface to be coated. struck between them at their point of contact

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 BS 4479 : Part 7 : 1990

and the molten metal is projected foiwards by a Diagrams illustrating preferred and deprecated
blast of compressed air; design features for articles to be thermally spray
(c) plasma spraying, in which the coating coated are given in appendix A.
material (principally in powder form) is fed into a Many of the design recommendations given in (a)
recombinant high pressure, high velocity, plasma to (h) are equally applicable to any engineering
jet formed by the passage of, e,g. argon through structure that is to be coated by thermal spraying.
an arc; spraying may be done in air or in a low Reference should be made to BS 5493 for
pressure chamber (‘vacuum plasma spraying’); anti-corrosion coatings.
(d) detonation coating, in which the powdered (a) Any design features that introduce
coating material, in any oxy-acetylene mixture, is ‘shadowing’,i.e. the prevention of easy access for
fed into the breech of a ‘gun’;the gas is grit-blasting or for thermal spraying to relevant
detonated by a spark and the heated powder is surface areas, are highly undesirable and should
propelled by the exhaust gases down the barrel be avoided.
of the gun on to the substrate at a repetition rate (b) As in both grit-blasting and thermal spraying
of, e.g. four per second, the materials are projected essentially in straight
The efficiency and economy of satisfactory surface lines, the design should facilitate an approach at
preparation, as well as subsequent thermal 90° to the suiface being treated. The approach
spraying, are influenced by the design angle should never be less than 45O to the
considerations described in (1) and (2) as follows. surface.
(1)Components and structures to be thermally (c) As both the giit-blasting nozzle with its
sprayed should be designed from the outset attached high pressure, relatively inflexible air
with thermal spraying clearly in mind. Failure hose and the spraying pistol with its attachments
to do so is almost certain to increase the operate at nozzle distances of between 150 mm
difficulties and costs of application, and also to and 200 mm, there should be at least 300 mm
reduce the overall service life. access length in front of any surface to be
(2) The major guiding principles given in (i) treated.
to (iii) should be observed. (d) Enclosed spaces, e.g. tanks, should have
(i) The design should ensure that all surfaces adequate manholes to give the operators full
are fully accessible for surface preparation, access to all internal surfaces. A second outlet
for the subsequent removal of grit, and to should also be provided through which essential
permit complete and uniform application of positive ventilation can be arranged. Degreasing
the thermally sprayed coating. vapours, and the considerable quantity of dust
(ii) Structures should be designed so that created by grit-blasting, should be quickly and
corrosion has the greatest difficulty in positively removed in the interests of clean
establishing any focal point from which it surface finish and operating visibility. Thermal
can spread, Asmajor corrosive factors are spraying in a confined space also generates dust,
moisture and dirt in which marine and fumes and heat, and the maintenance of
industrial corrosive agents can collect and reasonable working conditions requires very good
concentrate, this aspect demands cleanness ventilation, in addition to an independent air
of design and the elimination of all features supply to the operator’s protective helmet.
that might facilitate lodgement or retention (e) If conventional blasting methods are used for
of moisture and dirt. the internal surface preparation of tanks or other
(iii) The overall design should be planned to internal spaces, provision should be made for the
facilitate full inspection, ease of cleaning, removal of heavy grit accumulations. The
and maintenance. availability of adequate access manholes and
ventilation outlets can considerably simplify grit
removal, as can the use of heavy-duty vacuum
4 Structural design considerations cleaners. Alternatively, the use of blasting
equipment embodying closed-circuit vacuum
The increased use of welded construction, and the recovery of spent grit prevents any heavy grit
general simplification of design that has resulted, accumulations from arising. Further, the constant
have made the following design recommendations cleaning of the grit minimizes the dust problem.
easier to meet. Good design for welding has much This equipment also considerably simplifies final
in common with good design for thermal spraying removal of grit residues and dust which, if left,
because, in general, design features that are can provide centres for the initiation of
difficult to weld are also difficult to coat corrosion,
satisfactorily by thermal spraying.

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 (f) Baffles and fittings inside tanks and enclosed application. Similarly, small section ‘E’ or ‘T’
spaces should be made removable to facilitate stiffeners and deep, narrow, channel sections are
processing. If this is not possible, special likely to create ‘blind’areas that can be neither
attention should be given to access to all surfaces . adequately prepared nor sprayed. Their use
of such fittings. should, therefore, be avoided and ‘flats’or
(g) For the satisfactory preparation and thermal ‘bulb-flats’(see figure 1)stiffeners adopted
spraying of internal surfaces of hollow and instead.
tubular members, the limitations imposed by (b) Crevices and narrow gaps which arise when
‘access’ and ‘nozzle distance’ requirements back-to-back angles are used, or where stiffeners
should be considered. Generally, short straight are welded on by short intermittent fillet welds
sections greater than 100 mm diameter can be on alternate sides, should be avoided as they are
thermally sprayed by the use of special difficult to coat. Continuous welds are much to
attachments to the blasting and spraying be preferred.
equipment. Bent tubes and small hollow sections (c) Butt joints should be used in preference to lap
below 100 mm diameter are, however, joints unless the latter are sealed off by
exceedingly difficult ta process satisfactorily, and continuous, smooth welds.
their use should be avoided unless agreed as
practicable with the thermal spraying contractor (d) Corners should preferably be rounded as they
concerned. are easier to coat than those that are square.
They also simplify inspection, cleaning and
(h) For components and structures subjected in maintenance, and minimize dirt and moisture
service to thermal shock, rapid expansion and retention.
contraction, or heavy vibration (for example, jet
engine test bed silencers), it is important that the (e) Rounded edges are desirable in order to
design should reduce expansion and contraction provide greater surface area able to accept a
to a minimum and should incorporate fully uniform coating and to overcome the difficulty of
adequate stiffening of the thermally sprayed attaining adequate coating thickness on sharp
surfaces. edges. Coatings on sharp edges are also more
susceptible to damage.
(f) Blind crevices, narrow gaps, lap joints,
6 Component design considerations pockets, channels and horizontal flat surfaces are
Many of the recommendations relating to structural potential points for corrosion attack arising from
design given in clause 4 are also applicable, on a retention of moisture and dirt including the grit
smaller scale, to component design. The following used in surface preparation. Wherever possible,
recommendations should, additionally, be taken design provision should be made for evaporation,
into account. run-off or drainage of moisture, either by
presetting or provision of well-placed and
(a) Narrow gaps, blind crevices, deep pockets and adequate drainage holes.
interior angles (particularly acute ones) should be
avoided as these features are liable to prevent
uniform surface preparation and coating

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 Appendix

Appendix A. Diagrams illustrating preferred and deprecated design features for

articles to be coated by thermal spraying
Diagrams illustrating preferred and deprecated design features for articles to be coated by thermal
spraying are given in figures 1 to 8.

Small section s t i f f e n e r s or
T beams or channels F i a t s or bulb f l a t :
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(a) Deprecated design @) Preferred design

Figure 1. Interior angles

weid smooth and

s l a g a n d weid

Avoid unless i n t e r i o r is
c o a t e d b e f o r e welding

(a) Deprecated design (b) Preferred design

Figure 2. Blind crevices

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 BSI B S * 4 4 ? 9 : P A R T * ? 90 m 3b24bb9 O073097 2
BS 4479 : Part 7 : 1990

(a) Deprecated design (b) Preferred design

Figure 3. Narrow gaps

(a) Deprecated design (b) Preferred design

NUE. Angles back to back should be avoided as inside cannot be coated.

Figure 4. Crevices

Lap joints with Lap j o i n t s f u l l y sealed by continuous

discontinuous welds w e l d s . Smooth a n d f r e e from slag a n d
weld s p a t t e r

(a) Deprecated design (b) Preferred design

Figure 5. Lap joints

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BS 4479 : Part 7 : 1990

Rounded corners and

continuous b u t t welds
Sharp corners and
discontinuous welds

(a) Deprecated design @) Preferred design

Figure 6. Corners

NOTE. Design details that retain dirt and moisture NOTE.The web plate should be pre-set to assist
should be avoided. moisture run-off.

(a) Deprecated design @) Preferred design

Figure 7,Flat surfaces

NOTE.Shortened butt plates NmE. Butt plates should be

should be avoided. allowed to project.
(a) Deprecated design (b) Preferred design

Figure 8. Pockets
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 BSI BSs4479: PART*? 9 0 m Lb24bb9 0073099 b =
BS 4479 : Part 7 : 1990

Publications referred to
BS 2461 Specification for chilied iron shot and grit
BS 2669 Specification for sprayed metal coatings
Part 1 Protection of iron and steel by aluminium and zinc against atmospheric corrosion
Part 2 Protection of iron and steel against corrosion and 'oxidation at elevated temperatures
BS4479 Design of articles that are to be coated
Part 1 General recommendations
BS 6493 Code of practice for protective coating of iron and steel structures against corrosion
CP 3012 Code of practice for cleaning and preparation of metal surfaces

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BS 4479 :
Part 7 : 1990 I

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