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 Thermal diffusion galvanizing vs. powder coating

Thermal diffusion galvanizing vs. powder coating

Before ArmorGalv® was brought to Australia, powder coating was a suitable option for industrial metal corrosion protection. Ten years after entering the local market, ArmorGalv® is now Australia’s superior choice for metal corrosion protection over powder coating.

Much like hot-dip galvanizing, coating offers less protection than ArmorGalv®. Read on to discover the differences between powder coating and thermal diffusion galvanizing, and why ArmorGalv® is the better option.

Powder coating

Powder coating is a form of metal corrosion protection. According to Dulux, it’s a solids thermoset coating that is electrostatically charged and applied as a dry powder to a base metal. It then passes through an oven where the powder particles melt and coat the metal to form a protective film.

Powder coating was first invented in the late 1940s by a German scientist named Dr. Edwin Gemmer. But interest in coating in the galvanizing industry did not start until the late 1960s and 1970s.

As powder coating is not a galvanizing technique, it offers different metal protection to thermal diffusion galvanizing.

However, powder coating does offer a vast range of colours and can be used as a nice topcoat over ArmorGalv®.

Thermal diffusion galvanizing

ArmorGalv® is a trademark name for ArmorGalv Australia’s thermal diffusion galvanizing process. The technology was borne out of the traditional sherardising process, which involves heating up metal components in a rotating drum.

ArmorGalv Australia’s thermal diffusion galvanizing technology uses a metallurgical vapour diffusion process to apply a uniform, sacrificial, zinc-iron coating to ferrous and certain non-ferrous materials. The corrosion-resistant and abrasion-resistant coating help increase part life in harsh environments.

In contrast to other galvanizing methods, ArmorGalv® does not leave any areas of the product ungalvanized. This is because the formation of a zinc coating by means of diffusion is not hampered by the product’s geometry.

You can learn more about ArmorGalv Australia and our thermal diffusion galvanizing technique here.

Why ArmorGalv® is the superior choice over powder coating

It offers stronger, more durable protection

Powder coating creates an external protective layer around the metal. Alternatively, ArmorGalv® coats and penetrates the metal, offering stronger, deeper protection.

It has a geographic topcoat

Powder coating finishes with a hard, smooth surface, making it difficult for a top coat to cover and adhere to the surface. This means the metal would require further preparation before applying a topcoat.

ArmorGalv® has a ‘geographic’ surface, meaning any type of topcoat can be applied to the surface without prior preparation and will stick.

It can be applied to various types of metal

There are limitations on the type of metal powder coating can be applied to. Powder coating is usually applied to thin, flat metal products like sheet metal for roofing or fencing.

The ArmorGalv® process has been designed to suit almost all types of ferrous and non-ferrous materials. It can coat steel, cast iron, stainless steel, powdered metal parts and aluminium. It can even be applied to springs and other specialty metals.

It can be used across a range of industries

Coating limitations on the type of metal it can be used on also limits the industries it can be used in. ArmorGalv® is used across a variety of industries including:

  • Mining

Thermal diffusion galvanized components have been used in the mining industry worldwide for decades due to the reliable and multifunctional zinc-iron alloy. ArmorGalv is used to coat roof support rock bolts in hard rock, underground mines.

  • Construction

ArmorGalv provides a uniform, even coating on products with complicated shapes. High impact and wear resistance mean thermal diffusion galvanized products can be used for longer, despite repeated assembly and dismantling.

  • Transport

Suitable applications include components for spring and dampening systems, container seals and lashing eyes. Rivets are thermal diffusion galvanized because the unique properties of the zinc-iron alloy are preserved after distortion.

  • Rail

Pressure springs, snap fasteners and rail clips retain their properties during thermal diffusion galvanizing. They are impact and wear-resistant, but still malleable enough to ensure that no cracks appear when they move to provide elasticity.


Is your industry looking for a metal corrosion protection alternative to powder coating? Get in contact with ArmorGalv® today.

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