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Flame Spray

When to be used?

When it weared and when more wear resistant surface to be requested, when a good sliding surface to be required, when corrosion is a problem, when a thermal barrier coating needs, when electrical conductivity or isolation is requested, when electrical sheelding is the aim on plastic surfaces, when moulded particle sticking is not requires, when surface must be inox, when etc…

When not to be used?

When the surface is under regular and heavy point-or line loading(bearing cage, crane wheels, etc…).When the surface is under heavy heat-shock. In case of vibration (pneumatic caulker). When need mirror-like surfaces (Reflector house) Repairing sharp edges (cutting tools).

Why shall we apply for?

- There is no significant heat up by the process comparing to the welding technology. (There is no deformation , cracking, components burn out, distortion, hard up, etc…)

- There is no limit of coating thickness or choice of material (stainless steel to steel, babbitt to steel, zinc to plastic, molybdenum to aluminium, anything to everything).

- Because of the process is cheap and quick and produce equivalent or even better surface to the original. (It is not economical in case very cheap parts)

- Because you can reach such a surfaces which is not been reached by other technologies. (molybdenum, silver, oxides, carbides, metaplast, etc…)

- Because it sufficient against flame, chemical, abrasive wearing beside of slide loss.

- Because you can influence the lifetime of corrosion protection to providing coating thickness or choosing the proper catodic material. (aluminium in salty surrounding)

What kind of material to choose?

- Molybdenum (High wear resistance under the excellent sliding property)
- Bronze (Good sliding property and wear surface)
- Carbon steel (Workable, different carbon content)
- Stainless steel (Food industry, chemical resistance, etc…)
- Aluminium (Corrosion prevention, food industry, salty surrounding, etc…)
- Zinc (Corrosion prevention, base surrounding, shielding)
- Silver (Electrical conductivity)
- Cooper (Electrical conductivity, paint keeping, chemical resistance)
- Tin (Chemical resistance, solderability)
- Babbitt (Sliding feature)
- Tungsten (Chemical attributes, high heat-tolerance)
- Aluminium oxide (Thermal and electrical insulation)
- Zirconium oxide (Thermal corrosion, chemical protection, adhesion inhibition)
- Tungsten carbide (Extremely high abrasion resistance)
- Still available 382 kinds of metal, metal alloy and metal oxide, to reach various combination optimal effects.

What is Flame/ Thermal Spray Coating?

In the simplest terms possible, thermal spray coating involves heating a material, in powder or wire form, to a molten or semi-molten state. The material is propelled using a stream of gas, or compressed air, to deposit it, creating a surface structure on a given substrate. The coating material may consist of a single element, but is often an alloy or composite with unique physical properties that are only achievable through the thermal spray process. Generally speaking, thermal coatings are a highly cost-effective way to add superior performance qualities to a given substrate. The variations on this technical theme are virtually limitless. Coatings can be metallic, plastic, or any combination desired to meet a broad range of physical criteria. The coating materials can be applied using several different processes. Thermal coating methods utilize fuel combustion, plasma spray, and electric arc delivery systems. Coatings can be applied under standard atmospheric conditions, or in specialized, highly controlled atmospheric environments – even under water. Coating can be applied by hand, or with the automated precision of software-driven robotics. Many industries use our coatings to extend product life, increase performance, and reduce production and maintenance costs. Thermal coatings can be the most cost-effective means of protecting substrate surfaces from wear or corrosion. Other primary uses of thermal coatings include restoring dimensionality, maintaining precise clearances, and modifying thermal and electrical properties.

What kind of technologies are in flame spraying?

One type of flame spraying process group basis on the formation of the smelting heat:
- Flame spray with powder or wire (burning gas and oxygen)
- Electric spray with wire only (two high-voltage electrical arc between the wires)
- Plasma arc with powder only (in the gas of plasma taking place in heat-development)
Our company can provide all equipment!

The other types of flame spraying processes can be classified by apply different kind of materials:

- Cold process (during of the application the workpiece can be maintained below 50-60C°).
- Two-steps process (bonding and coating material) - cheaper.
- One-step process (coating includes the bonding material) - more costly, better quality, for disrupted surfaces too.

- Thermal/Hot process (the applied coating must be heated on 1050C°). The silicium and the Boron in the material is creates a homogeneous porosity-free coating.
Our company can provide all technologies and all type of materials!

How did it start?

First flame spray gun from 1910.

Where are we now?