Thermal Spray

 
 

Thermal spray, sometimes called metallizing, is a process of melting a powder or wire in a gas stream and applying the semi-molten material to a substrate. The materials that can be sprayed through this process are almost endless. Ceramics, metals, carbides, alloys and even Teflon materials can be applied in this manner.

The benefits of the thermal spray process is it can be applied to almost any substrate and because of the low temperature application it can be used on finished parts without causing distortion or changing the properties of the base material. We can save you time and money by rebuilding your parts with better materials, less down time and fewer maintenance hours through the life of that part. Below are the standard thermal spray processes, but for more in depth information feel free to call us at any time.

 
 

HVOF

HVOF is short for High Velocity Oxy-Fuel system. This system has been one of the major thermal spray systems in use for many years. It offers hard materials such as carbides but can also spray many different metal-based materials

Typical uses:

  • Anti-fretting

  • High-wear parts

  • Corrosion resistance

  • Anti-Galling

  • Dimensional restoration

Typical Materials:

  • Tungsten Carbide

  • Chrome Carbide

  • Stellite®

  • Stainless steel

 

HVAF

HVAF is short for High Velocity Air Fueled system. This system offers higher densities and bond strength than HVOF on some materials. It also allows for thicker buildups than HVOF without the cracking issues due to its lower spray temperatures and higher velocity. HVAF also offers the ability to spray in smaller ID areas than HVOF.

Typical Uses:

  • Anti-fretting

  • High-wear parts

  • Corrosion resistance

  • Anti-Galling

Typical Materials:

  • Tungsten Carbide

  • Chrome Carbide

  • Hastelloy

  • Inconel

 

Plasma

Plasma spray systems were the original systems used to produce carbide coatings and have high enough process temperatures to spray ceramics also. The system offers lower bond strength and higher porosity than HVOF or HVAF but offers ID capabilities.

Typical uses:

  • High-temperature coatings

  • High-wear parts

  • Corrosion resistance

  • Dielectric

  • Thermal barrier

Typical Materials:

  • Chrome Oxide Ceramic

  • Aluminum Oxide Ceramic

  • T800

  • Chrome Carbide

  • Aluminum polyester abradables

  • Thermal barrier coatings

 

Spray & Fuse

Spray and fuse bridge the gap between standard welding and thermal spray. It has a metallurgical bond like welding but also has thinner layers of pure metal on the base substrate like thermal spray forms. Unlike thermal spray, it will cause the substrate to warp or its properties to change due to the heating of the base to get the coating to fuse to it.

Typical uses:

  • Extreme wear resistance

  • Valve balls

  • Augers

  • Exhaust fans

  • Sucker pumps

  • Pump pistons

Typical Materials:

  • Colmonoy 88

  • Nickle Cobalt

  • Tungsten Carbide

  • Nickle Chrome Alloys

 

Arc Spray

Arc spray operates by taking two wire spools and using electricity to melt the wire and air to spray it onto the part being coated. This system can lay down large amounts of material quickly and achieves good bond strength and hardness during the process. The interesting thing with this process is you can use two different wires and create a new alloy of material to tailor the coating to your needs. Arc can also be used to build up parts that are worn greater than ¼” or more.

Typical uses:

  • Shafts

  • Electrical conductivity

  • Feed rolls

  • No slip coatings

Typical Materials:

  • Stainless steel

  • Bronze

  • Aluminum

  • Zinc

  • Brass

 

Flame Spray

Flame spray is one of the oldest forms of thermal spray. Typically using oxygen and acetylene, these systems melt a wire or a powder in the combustion stream and apply it to the parts. These coatings are great for restoration of old parts. The systems can spray ID and OD components and can be readily brought to a customers site for repairs if needed.

Typical uses:

  • Shafts

  • Bearing housings

  • Casting repairs

  • Mold dyes

Typical Materials:

  • Stainless steel

  • Bronze

  • Babbitt

  • Nickel aluminum

 
 
 

 
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