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Thermal Spray

WHEN DO WE APPLY?

When worn, when a more wear-resistant surface is needed, when a well-sliding surface is needed, when corrosion is a problem, when a thermal insulation layer is needed, when an electrically insulating or conductive layer is needed, when plastic shielding is needed, when melt does not stick, when it should be stainless when…

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WHEN DO NOT USE IT?

If the surface is subjected to significant and regular edge or line-like pressure (bearing basket, crane wheel). Significant heat on a component subjected to shock. In case of strong vibration (air hammer). If you need a reflective surface (reflector mirror). Production of sharp corners (cutting tools).

WHY US?

- Because there is no significant heat input during the process (no deformation, cracking, component burnout, warping, hardening, softening) as opposed to overlay welding.

- Because there is no limit on layer thickness and material choice against galvanizing (stainless steel for iron, bearing metal for steel, zinc for plastic, molybdenum for aluminum, everything for everything).

- Because it is cheap, fast and can achieve the same or better properties as the original surface property (easy to remanufacture, it does not always pay off for small pieces).

- Because layers can be formed from which it is not possible or worthwhile to manufacture. (molybdenum, silver, metal oxides, metal carbides, metals mixed with plastics).

- Because, in addition to sliding abrasion, the flame is excellent against chemical abrasion.

- Because by increasing the layer thickness we can determine the duration of the cathodic corrosion protection and by choosing the metal we can adapt to the corrosive material (aluminum in a salt environment).

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WHAT MATERIAL DO WE CHOOSE?

- Molybdenum (Excellent slip properties with high wear resistance)
- Bronze (Wearable surface with good sliding properties)
- Carbon steel (Highly machinable with different carbon contents)
- Stainless steel (food industry, chemical resistance, etc.)
- Aluminum (Corrosion protection, food industry, saline environment, etc.)
- Zinc (Corrosion protection, alkaline environment, shielding)
- Silver (Electrical conductivity)
- Copper (Electrical conductivity, paint uptake, chemical resistance)
- Tin (Chemical resistance, solderability)
- Bearing metal (Slip property)
- Tungsten (Chemical properties, high heat resistance)
- Alumina (Thermal and electrically insulating)
- Zirconium oxide (Thermal corrosion, chemical protection, anti-adhesion)
- Tungsten carbide (Extreme wear resistance)
- 382 types of metal, metal alloy, metal and oxide combinations are available to achieve different optimal effects.

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WHAT IS THERMAIL SPRAYING?

Thermal spraying is when a layer is formed on a surface by stacking molten metal particles of microscopic size at high speed. In most cases, the particles bind to the parent metal by micro-welding under the influence of heat and kinetic energy and then form into the porosity between the particles, thus forming a layer. The metal particles, passing through the air, form an oxide shell that surrounds them in a shell-like manner. After machining, the surface is formed by “cut-in” grains, which means that a three-dimensional oxide grid is located in the metal coating. This oxide grid gives the metal sprayed layers a higher wear resistance. The sprayed layer is microporous, which is advantageous in some cases (oil retention, paint base), in other cases it is disadvantageous to use an impregnation seal which makes the surface 100% compact (hydraulic shafts, chemical mixers).

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WHAT ARE THE THERMAL SPRAYING PROCEDURES?

One grouping of metal spraying processes can be based on the generation of melting heat.
- Flame spraying of powder or wire (combustion gas and oxygen)
- Electrical scattering from wire only (high voltage electric arc between two wires)
- Plasma arc with powder only (heat generation in plasma gas)
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Another grouping of thermal spraying processes can be done according to the types of materials applied:

- Cold spraying (the workpiece can be kept below 50-60C ° during application)
- Two-stage (primer and coating material) - cheaper
- One-step (primer included in the coating material) - more expensive, better quality, also good for broken surfaces.

- Hot spraying (the applied layer must be heated to 1050C °) Due to the silicon and boron in the material, the oxides in the layer precipitate and a homogeneous porosity-free layer is formed.
Our company has all the technology and material groups!

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How did it start?

The first metal spray gun from 1910.

Where are we now?

Eight-axis moving robot + two-axis rotary table with high-performance computerized plasma equipment during “training” to spray the gas turbine heat shield.