Combustion Flame Spray Masking Materials

Combustion Flame Spray Coating (also known as traditional thermal spray coating) involves using a combustible gas as a heat source to melt feedstock in the form of a powder, wire, or rod and to propel the melted droplets at the component surface. The droplets impact the surface and thus the coating is formed. Masking for flame spray coatings can be challenging as heat is a factor.

Flame spray coatings are commonly used in industries such as Aviation/Aerospace, Energy (Industrial Gas Turbines), Semiconductor (Parts Cleaning), and General Industrial applications. Common applications abradable coatings, wear coatings, and corrosion resistance.

Why is Masking Necessary?

In most applications, the coating is targeted. When coating a component, the coating will serve a purpose in the target zone, but often the coating is not desirable in areas outside the target zone. Masking is used to prevent a build up of coating in areas where it can be detrimental. Proper masking also improves the precision of the placement of the coating allowing for clean coating lines, no cracking, and no contamination.

Masking Options...Finding the Better Way

• Contamination Free Surface: Taconic thermal spray masking tapes, fabrics, and compounds are designed to leave no residual silicone adhesive nor fluid on the component surface.
• High Abrasion Resistance: Taconic thermal spray masking materials are designed to withstand the high abrasion associated with the surface prep blasting process as well as the spraying of abrasive coating particles (ie. Carbide particles).
• Flexibility & Conformability: Taconic thermal spray masking tapes, fabrics, and compounds are designed to conform to challenging profiles without lifting, sagging, or moving. These traits make Taconic materials idea for critical masking tasks.
• Peel Adhesion: Taconic pressure sensitive tapes offer industry leading adhesion to metal and face-to-back adhesion. The situation of tape lifting during coating can be catastrophic. For this reason, Taconic tapes are used to ensure the masking survives the coating process consistently.
• Prevent Bridging or Cracking: Taconic tapes can avoid bridging and can also avoid the cracking of coatings when the masking is removed.

Finding a Better Way to Save Time & Money While Improving Masking Efficiency…

Use Strong Tape & Apply Fewer Layers of Tape – The stronger the masking tape, the fewer layers of tape that are required. Each layer of tape adds time and cost increasing the overall cost associated with a masking job. Using a strong tape allows you to mask in 1-2 layers which saves time and money.

Reusable Masking – Silicone coated Fabrics and silicone rubber compounds have the ability to speed up masking – to cover and/or large intricate areas quickly. Masking tapes are always single use – they are thrown in the garbage after use. Silicone fabrics and rubber compound molds can be used over and over. Fabrics are ideal for arc spray due to the large areas that can be protected quickly and economically.

Post Coating Properties – After the coating process is complete, the maskant must release as clean as possible. Removing adhesive residue, glass, and other unwanted potential contaminants adds extra time and cost to the entire process. Taconic masking materials will prevent chipping and cracking upon removal – saving time and money by avoiding rework. Taconic masking materials are designed to remove completely clean from component surfaces.

What does the above mean for coating shops?

• Reduces time
• Reduces tape consumption
• Reduces overall spend
• Improves throughput
• Reduces clean up
• Eliminate Rework

Product Recommendations:

Taconic PSA Tapes:

• 6605-07: Basic single sided glass cloth tape suitable for non-critical masking. A good choice for single layer secondary masking.
• 6615-07: Double sided glass cloth tape that exhibits strong adhesion. Good for bonding masking layers together. 
• 6525-08: All purpose plasma spray masking tape. Tape is suitable for grit blast and air plasma applications. Construction is silicone rubber coated fiberglass complete with silicone adhesive.
• 6625-09: Aluminum foil Flame Spray masking tape suitable for masking against Plasma and Flame Spray coatings. 
• 6525-16: Double layered Flame Spray masking tape. Double layer allows for single layer application for each job. In cases where 2 layers of standard tapes are required, the 6525-16 can reduce masking times by up to 50%.

Taconic Coated Fabrics:

• 7102W: Thin flexible silicone coated fiberglass fabric suitable for light duty APS masking – generally as a secondary mask.
• 7322W: All Purpose thermal spray masking blanket constructed of silicone coated fiberglass fabric. This fabric is ideal for secondary masking of large components for most spray styles.
• 7422W: Heavy silicone coated fiberglass fabric for more demanding jobs requiring protection of large surfaces. This fabric is more abrasive resistant and more suitable for primary masking jobs (as well as secondary).

TacMold Masking Compounds:

• TacMold (A2023-A / A2023-B) masking compound is a 2 part silicone putty which is designed to withstand all forms of thermal spray including GF-HVOF and LF-HVOF. This putty is intended to assist with masking holes or complicated intricate profiles. In some cases, the compound is reusable.
• TacBloc - A soft, conformable, putty-like material for masking holes, grooves, key slots or any unique configuration. Unlike TacMold, TacBloc is formulated to adhere to metal in areas where anchorage is not possible. TacBloc is good for all forms of thermal spray.

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