Free Sampling: Flat shapes - Thermal Spraying / Flame Spraying . Masking in industrial surface treatments

The masking of flat profiles is a critical phase in industrial surface treatment processes such as industrial painting, cataphoresis, anodizing, galvanizing, and sandblasting. Effective protection ensures the preservation of bearing planes, sealing areas, and functional surfaces, preventing rework and scrap.

In thermal spraying / flame spraying, the main industrial masking methods include the use of masking plugs and caps, high-temperature tapes, and films, depending on the type of sprayed coating and the process stages (preparation, spraying, and any finishing).
Plugs and adhesive dots (made of materials suitable for the process) are used to close through holes and blind holes, preventing particle ingress, overspray, and coating buildup that could compromise tolerance restoration.
Protective caps and tubes provide external protection for pins, ends, and cylindrical surfaces, limiting coating adhesion in non-coatable areas and reducing rework.
High-temperature tapes and rigid masks are used to define flat areas, edges, and complex profiles, ensuring sharp edges.

Thermal spraying (including ) is a coating treatment in which a material (powder/wire) is brought to suitable conditions and projected onto the workpiece to form a protective or functional layer.
During the process, masking for thermal spraying/flame spraying is essential to protect functional surfaces, holes, mating seats, sealing surfaces, and tolerance areas, preventing unwanted deposits and preserving required dimensions and finishes.

The masking products for thermal spraying/flame spraying must ensure stable performance during surface preparation (often involving machining or cleaning treatments), spraying, and possible finishing steps; therefore, thermal resistance and dimensional stability are essential.
A high level of mechanical resistance to impact and erosion from projected particles and overspray is also required, to maintain effective protection until the cycle is complete.
Masking must ensure sealing and shielding in critical areas (reducing leaks and underspray) and, where tapes/adhesives are used, controlled adhesion that withstands heat but allows removal without tearing.
Another key requirement is clean removal without residues and without contaminating the surface, to avoid coating defects and reduce restoration times; where applicable, the reusability of plugs and caps improves cost efficiency and repeatability.

An efficient masking solution is crucial for the reliability and final quality of the surface treatment.

Industrial masking makes it possible to protect threads, holes, functional surfaces, and mating areas.
Masking products for surface treatments include masking plugs, protective caps, adhesive dots, technical adhesive tapes, and masking tubing.
These devices must ensure high resistance to high temperatures.
Dimensional stability is essential during curing and drying cycles.
High chemical resistance to surface pre-treatments, such as degreasing and pickling, is also required.
The elasticity of the materials allows perfect adhesion even on complex geometries.
A key requirement is residue-free removal, in order to preserve the quality of the treatment.
The reusability of masking systems contributes to optimizing production costs.

Industrial surface treatments are essential processes for improving the protection, functionality, and durability of metal components.
Among the main surface treatment processes are powder coating, liquid coating, galvanizing, anodizing, cathodic electrodeposition (e-coating), sandblasting, and flame treatment.
These treatments provide corrosion resistance, electrical insulation, or surface conductivity, depending on the application.
During each industrial treatment, it is essential to define the areas that must not be treated.