Abstract: [Problem] To provide a corrosion-resistant coating that exhibits greater corrosion protection in saltwater environments and the like than was conventional, a method for forming the same, and a device for forming the same. [Solution] A corrosion-resistant alloy coating is formed on a substrate surface by: a) using a thermal spray gun, having a function wherein a flame including melted material particles is jetted toward a substrate, and the flame is partitioned from the open air in an upstream region on said jet path (which is to say the region in which the material particles are melted), and a function wherein, in a downstream region (the area continuing from the upstream region), the material particles and the flame are forcibly cooled by a jet-gas or jet-mist before reaching the substrate; and b) using a corrosion-resistant alloy material comprising aluminum, for the material particles.

Abstract: [Problem] To provide a corrosion-resistant coating that exhibits greater corrosion protection in saltwater environments and the like than was conventional, a method for forming the same, and a device for forming the same. [Solution] A corrosion-resistant alloy coating is formed on a substrate surface by: a) using a thermal spray gun, having a function wherein a flame including melted material particles is jetted toward a substrate, and the flame is partitioned from the open air in an upstream region on said jet path (which is to say the region in which the material particles are melted), and a function wherein, in a downstream region (the area continuing from the upstream region), the material particles and the flame are forcibly cooled by a jet-gas or jet-mist before reaching the substrate; and b) using a corrosion-resistant alloy material comprising aluminum, for the material particles.

Abstract: A highly corrosion-resistant, rust-prevention coating material comprising: an inorganic binder; and Zn metal particles comprised of Zn and unavoidable impurities and dispersed in the binder at the rate of 30 mass % or greater based on a dry coating film, wherein (i) the Zn metal particles include (i-1) fine-grain Zn metal particles of 0.05 to 5 ?m peak grain diameter whose grain-diameter distribution has a grain-diameter frequency distribution with a single peak and a tail on either side of the peak and (i-2) coarse-grain Zn metal particles of 6 to 100 ?m peak grain diameter whose grain-diameter distribution has a grain-diameter frequency distribution with another single peak and a tail on either side of the peak, and wherein (ii) the percentage of all Zn metal particles accounted for by Zn metal particles of 0.05 to 5 ?m grain diameter expressed in volume percentage is 5 to 99%.

Abstract: Zn alloy particles for high corrosion resistance rust prevention paint containing, by mass %, Mg: 0.01 to 30% and having a balance of Zn and unavoidable impurities, having physical fracture facets and/or cracks of a length of 0.01 ?m or more or cracks of a depth of 0.01 ?m or more, having an average particle size of 0.05 to 200 ?m, and having an aspect ratio of maximum size and minimum size (maximum size/minimum size) of an average value of 1 to 1.5. Also, a high corrosion resistance rust prevention paint containing these Zn alloy particles and a high corrosion resistance steel material and steel structure coated with that paint.

Abstract: Zn alloy particles for high corrosion resistance rust prevention paint containing, by mass %, Mg: 0.01 to 30% and having a balance of Zn and unavoidable impurities, having physical fracture facets and/or cracks of a length of 0.01 ?m or more or cracks of a depth of 0.01 ?m or more, having an average particle size of 0.05 to 200 ?m, and having an aspect ratio of maximum size and minimum size (maximum size/minimum size) of an average value of 1 to 1.5. Also, a high corrosion resistance rust prevention paint containing these Zn alloy particles and a high corrosion resistance steel material and steel structure coated with that paint.

Abstract: A highly corrosion-resistant, rust-prevention coating material comprising: an inorganic binder; and Zn metal particles comprised of Zn and unavoidable impurities and dispersed in the binder at the rate of 30 mass % or greater based on a dry coating film, wherein (i) the Zn metal particles include (i-1) fine-grain Zn metal particles of 0.05 to 5 ?m peak grain diameter whose grain-diameter distribution has a grain-diameter frequency distribution with a single peak and a tail on either side of the peak and (i-2) coarse-grain Zn metal particles of 6 to 100 ?m peak grain diameter whose grain-diameter distribution has a grain-diameter frequency distribution with another single peak and a tail on either side of the peak, and wherein (ii) the percentage of all Zn metal particles accounted for by Zn metal particles of 0.05 to 5 ?m grain diameter expressed in volume percentage is 5 to 99%.