I understand that the life of a zinc coating on steel depends on its thickness and the relationship is a linear one. So if the thicknees is doubled, the life is doubled. Usually, zinc sprayed coatings are 50-250 microns but how thick could they go - is 1mm or 2mm possible?
Thicker hot dip galvanised coatings can be brittle. You can put down thick coatings by metal spray but they get expensive if you want several mm.
Would Al spray be better for your application.
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