How Surface Treatments Protect from Heat & Corrosion

sparks from industrial machine

How Surface Treatments Protect from Heat & Corrosion

Industrial environments are demanding and often require metal components to be constantly exposed to extreme conditions. High heat and corrosive elements can weaken or destroy unprotected metals, leading to equipment failure, safety hazards, and costly downtime. 

For instance, metals like steel, aluminum, and copper are essential in aerospace, automotive, medical, and defense applications. However, they are vulnerable to:

  • Oxidation at High Temperatures: Heat accelerates oxidation, forming brittle scales or weakening metal over time. 
  • Moisture and Chemical Exposure: In corrosive environments (such as saltwater or chemical processing plants), metals can pit, rust, or corrode, compromising structural integrity. 
  • Thermal Cycling: Repeated heating and cooling can cause expansion and contraction, leading to cracks or delamination if the metal is unprotected. 

Without proper protection, these factors drastically shorten the service life of critical components. Fortunately, there are plenty of surface treatments that create corrosion-resistant coatings to protect against these threats, enhancing the durability and performance of metal parts across different industries. 

How Surface Treatments Provide Protection

Surface finishing creates a barrier that shields metals from both environmental and thermal stressors. Some of the most effective treatments include:

1. Anodizing

Predominantly used on aluminum, anodizing thickens the substrate’s natural oxide layer. This makes the surface more resistant to wear and corrosion, while also helping to dissipate heat. As a result, anodizing is a top choice for aerospace and electronics applications. 

2. Electroplating

Electroplating deposits a thin layer of metal—such as nickel, chromium, silver, or cadmium—onto the surface of a part using an electric current. This enhances corrosion and wear resistance while also improving heat performance. Electroplating is widely used in aerospace, electronics, and automotive applications for both functional and aesthetic benefits. 

3. Chemical Conversion Coating (Chem-Film)

Chem-film coatings (such as MIL-DTL-5541) offer corrosion resistance without adding significant thickness. These coatings are ideal for applications where electrical conductivity must be maintained while still protecting the metal from environmental damage. 

4. Electroless Nickel Plating

Electroless nickel provides a uniform, highly corrosion-resistant coating even on complex geometries. High-phosphorus variants offer excellent chemical and heat resistance, making them popular in oil and gas, defense, and chemical processing industries. 

5. Passivation

The passivation process removes contaminants and enhances the natural oxide layer on stainless steel, improving corrosion resistance without altering the dimension or appearance of the part. 

Industry Applications of Heat and Corrosion Protection

  • Aerospace: Engine components and airframe parts face extreme heat and corrosive elements.
  • Automotive: Exhaust systems, turbochargers, and high-performance components require thermal protection.  
  • Medical Devices: Corrosion resistance ensures medical implants and surgical tools remain safe and reliable. 
  • Defense & Marine: Saltwater and harsh weather conditions demand advanced coatings for durability. 

Surface Treatments Provide Benefits Beyond Protection

In addition to heat and corrosion defense, many surface treatments provide added advantages like improved wear resistance, reduced friction, and enhanced aesthetics to further performance and efficiency. For example, hard chrome plating and electroless nickel can dramatically reduce friction and extend the lifespan of gears, bearings, and moving components. Silver and copper electroplating ensure reliable conductivity for connectors and circuit components in aerospace and electronics. 

Ready to Protect Your Metal Parts?

Partnering with an experienced metal finishing provider ensures that your components receive the most effective solution for maximum durability and reliability. At CRC Surface Technologies in Phoenix, we can help you select the right surface treatment for your project. We offer a wide variety of expert metal finishing services for regional and national machine shops, including anodizing, electroplating, passivation, and more.

Request a quote today—send a message to rfq@chemresearchco.com, or give us a call at 602-253-4175 to learn more.

 

Images used under creative commons license – commercial use (9/23/2025). Photo by Christopher Burns on Unsplash