Understanding Corrosion in Water Pipelines: A Guide for Pipeline Designers


Fused Coating

Last updated: August 6, 2018

What Does Fused Coating Mean?

Fused coating is a form of thermosetting powder. It is typically applied on pipelines and other industrial structures. It has been an established protection method for many years, and its application guarantees corrosion protection throughout the entire length of the pipeline or structure.

It is described as a heat curing polymer coating and classified as a protective coating in paint nomenclature. This method is known as fused coating due to crosslinking resin, and its application is different from traditional paint. The hardener and resin components in fused coatings remain unchanged at normal conditions for storage.


Corrosionpedia Explains Fused Coating

Fused coatings are composed of four essential elements:

  • Binder: Combination of the hardener and resin
  • Hardener: Also known as the curing agent, mostly composed of hydroxyl groups, epoxy ring and other molecular chains of epoxy
  • Extenders: Serve as an additive to fused coating to produce acceptable properties
  • Pigments: Give the coating its color

Normally, all of these elements are dry solids, even though small amounts of liquid extenders are added in its formulation.

Fused coatings are very beneficial in various industrial settings, as they offer protection from:

  • Impact damage: Its metallurgical bond guarantees high resistance and hardness against impact damage.
  • Abrasion and wear: Fused coatings that are infused with tungsten and cobalt coatings provide superior resistance to abrasion and wear.
  • Corrosion: It offers ultra-dense coatings with no porosity, which produces exemplary corrosion resistance.

Fused coatings are usually applied with the aid of gas and oxygen application. When the necessary coating depth has been reached, the coating is fused into the substrate object using a gas torch. The typical temperature required for fusing is about 1040° to 1120°C. In this high temperature, the fused coating undergoes partial melting and initiates a reaction with the base in order to form a highly dependable metallurgical bond which is comparable to various welding types.

This type of coating carries hardness ranging from Rc30 up to Rc65. Industries that make use of shafts, pump sleeves, rotors and bodies typically gain the most benefit from this type of coating material.


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