Diffusion Alloys Aluminised Burner Plate’s Case Study: Doubling Life Expectancy Under Metal Dusting Conditions

A more than doubling of life expectancy for burner plates operating under metal dusting type conditions has been confirmed by the application of Diffusion Alloys aluminide diffusion coating.

Burner plates, used in the burner systems for steam reformer units, operate in high temperature reducing hydro-carbon atmospheres and unprotected can have an average life expectancy of 3-5 years resulting in a potential for significant replacement of burner plates at each major outage.

For over 10 years Diffusion Alloys has been applying a high temperature aluminide diffusion coating to more than 5,000 burner plates for Lanemark Combustion Engineering Ltd., a leader in the supply of technically advanced burners.

During this period Diffusion Alloys and Lanemark have worked closely together to define the coating process for Lanemark burner plates to ensure uniform coverage, adequate coating thickness and coating consistency which enables high quality post processing welding by Lanemark coded welders resulting in a high quality durable burner head.

Over this period burner plate material selection has changed (Incoloy 800, Inconel 600, RA 330) and in all cases the Diffusion Alloys diffusion coating has proven to provide the same level of protection and increased serviceable life.

Burner plates that had undergone 10 years in operation were recently returned to Lanemark for analysis. Metallurgical analysis showed that after 10 years, the aluminised coating of the Incoloy 800 plates was still in good condition and only the top plate outer face presented an early warning indicator of a limit in remaining life through reduced weight percentage aluminium content.

The analysis vindicated Lanemark’s confidence in the aluminide coating as a highly economical solution for their customers to extend the serviceable life of the burner plates as well as providing real data on which customers could plan their purchasing forecast of replacement stocks.

“Lanemark have been using the Diffusion Alloys aluminde coating on our burner plates since 1998 and are extremely satisfied with the effectiveness of the tried and tested Diffusion Alloys process of aluminide coating combined with the excellent customer service we have received from all areas of their business”.

For more information, please click here to contact Diffusion Alloys.

We are at the forefront of applications for clean energy and the hydrogen industry.

Large-scale hydrogen generation

Hydrogen electrolysers (SOE)

Fuel cells (SOFC)

Energy storage


Other specialist life extension

With over 60 years of industry experience, we’re a global specialist in the application of a range of protective coatings against metal degradation.

We have been supplying diffusion coating services for over 60 years. In 1955 the Company became the first company world-wide to launch chromising as a commercial industrial diffusion coating.


We have decades of experience in coatings for the industrial gas turbine market and the oil, gas and process industries and have developed a leading position in diffusion coating for clean technology applications.


We consider the Health & Safety of its employees, customers, visitors and the general public to be of prime importance. We take an ethical approach to our environmental responsibility & waste management.


We pride ourselves on consistently scoring as best coating supplier for quality with a number of our major and long term customers which is testimony to our quality management system.