Thermal-sprayed aluminum has been applied to many components in offshore pr
ojects. Vinyl etch primer and aluminum-pigmented silicone, <25-mu m (1-mil)
thick, are the traditional coatings used to seal the porosity inherent in
the thermal-spraying process. At this low film thickness, aluminum silicon
sealer is difficult to see, causing problems both for the sprayer and inspe
ctors. Two-pack epoxy sealers are alternatives. Development testing current
ly is aimed at comparing solvent-based and water-based epoxies for this use
.