How to Prevent Corrosion Before It Starts: Advanced Coating Solutions

Corrosion may be a natural chemical process, but this core industrial challenge is estimated to cost U.S. manufacturing and production industries over $500 billion per year according to the Federal Highway Administration. 

Whether it’s rusty pump components or eroded cylinders, corrosion plays a key role in the profitability of major sectors of industry including transportation, infrastructure, and mining. A corrosion-damaged pump or turbine can easily stall out oil and gas production for weeks, wasting valuable time, money, and labor. 

It’s no secret that corrosion prevention is critical to maintaining the profitability and efficiency of industrial and commercial operations. Effective corrosion prevention can reduce maintenance costs and extend the lifespan of your components. While there are several factors to consider when fighting against corrosion, selecting the right advanced coating solution may be the most beneficial.

What is Corrosion?

Corrosion is defined as the gradual degradation or deterioration of a material, usually a metal, due to naturally occurring chemical reactions within the environment. Most commonly, corrosion takes place when a metal, such as steel, iron, or zinc, interacts with moisture, oxygen, salts, or acids, leading to the formation of oxides or other compounds that weaken the material. This weakening of the material can lead to a compromised machine structure and eventual mechanical failure.

Some of the most common types of observed industrial and commercial corrosion include:

  • Rusting: This refers to the process where iron and/or steel form a corrosive barrier when exposed to water and/or air.

  • Galvanic: This chemical reaction occurs when two different metals are in electrical contact in a conductive environment. 

  • Pitting: This refers to localized corrosion that causes small holes or pits in the component, part, or asset.

  • Uniform: This degree of corrosion can be distinguished by its even placement across a metal surface, which will eventually reduce its thickness over time. 

  • Crevice: This type of corrosion happens in shielded areas where stagnant microenvironments form and shows up as an aggressive localized attack.

  • Stress: This variation of corrosion manifests as cracks and is due to parts, components, or assets lingering under tensile stress in a corrosive environment.

Why Does Corrosion Matter?

Corrosion can throw a wrench into the most productive industrial environments. Industries such as oil, gas, power generation, and mining all utilize components and chemicals that make them especially susceptible to corrosive environments.

Over time, corrosion can lead to:


  • A deterioration of structural integrity: A part or component that has been corroded will not function at its full potential. Corroded parts are weaker, which can cause infrastructure, machinery, and/or equipment failure. 

  • A rise in safety risks: Corroded equipment or parts may cause malfunctions, which can increase the likelihood of at-work accidents.

  • A negative economic impact: Corroded components cause billions of dollars in annual repairs, replacements, and downtime.

Stopping Corrosion in its Tracks

Thankfully, there are many ways to prevent corrosion before it becomes a problem. Since corrosion usually stems from environmental issues, taking stock of your current work environment can be helpful. For example, in regions prone to high humidity or moisture, a dehumidifying system can significantly enhance the efficiency and longevity of your operation.

Similarly, if your manufacturing company utilizes a high level of chemicals, you should look into implementing chemical inhibitors or even a cathodic protection system. Unfortunately, controlling industrial conditions is not always feasible, and even under the most regulated environments, ongoing maintenance and monitoring are necessary to help mitigate corrosion.

Consider selecting parts or machinery made from inherently corrosion-resistant materials such as stainless steels, alloys, or specially treated metals. However, it is important to note that these more durable materials may come with a higher price tag, and many will still experience corrosion under extreme temperatures or upon exposure to strong acids.

Finally, one of the most effective and versatile methods for combating corrosion—especially in environments where traditional materials and controls fall short—is the application of protective coatings and thermal spray technologies.

Special Coatings to the Rescue

Protective coatings or thermal sprays can be a formidable adversary in the fight against corrosion. These coatings create protective barriers that can shield your equipment or part from the destruction of corrosive elements. 

Coatings protect against corrosion through any of the following ways: 

  • They prevent destructive elements from coming together to start the corrosion process.

  • They actively prevent the electrochemical reaction from occurring.

  • They re-direct the corrosion process in a way that will not degrade or damage the component or part.

HTS Coatings offers an advanced solution to the challenge of corrosion through our proprietary thermal spray known as BTHC-0005™. This special thermal spray coating has been shown to significantly reduce wear and corrosion when compared to traditional hard chrome plating. It also displays lower porosity, higher fracture toughness, and increased resistance in salt fog testing, all of which directly relates to corrosion control. In addition to being more corrosion resistant than hard chrome, BTHC-0005™ can be:

  • Polished better than Ra < 1 μ-inch

  • Used in environments up to 932 °F

  • Applied up to 0.050 inches thick

Through the use of BTHC-0005™, many of our clients have greatly decreased repair and maintenance costs. With greater productivity and less unscheduled downtime, operations ranging from power plants to manufacturing centers consistently see elevated ROI from  investing in more sustainable coatings solutions. 

Understanding and managing corrosion is essential for prolonging the life cycle of industrial assets, ensuring workplace safety, and reducing rising maintenance costs. While there are several ways to take control of corrosion, implementing an advanced coating solution may be the most cost effective. With proven benefits including reduced downtime, extended equipment lifespan, and greater operational efficiency, BTHC-0005™ is an ideal solution for industries that demand reliability in the harshest of environments. 

Reach out to HTS Coatings today to learn how their innovative thermal spray technologies can protect your most critical components and save your bottom line.

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