What Is Thermal Spray?

What Are the Steps Included in the Thermal Spray Process?

• Surface Preparation: To guarantee coating adhesion, clean and roughen the surface (typically with abrasive blasting).
• Material Selection: Depending on the application, select the right coating material (alloy, metal, or ceramic).
• Heating the Material: Melt or soften the coating material by heating it with a thermal spray technique (arc, flame, plasma, or HVOF).
• Spraying: To apply the molten substance to the prepared surface, use compressed air or high-speed gas.
• Coating Build-Up: Apply several coats to increase the coating's desired thickness.
• Post-Treatment (Optional): Depending on the application, complete with sealing, polishing, or grinding.

Types of Thermal Spray Coating Methods

• Arc Spray:

It melts metallic wires with an electric arc and atomizes the molten droplets with compressed air before spraying them on a surface. It is suitable for industrial repairs and corrosion protection.

• Flame Spray:

  It uses a fuel gas and oxygen flame to melt coating material, which is subsequently atomized and sprayed to surfaces, making it suitable for automotive and wear-resistant coating applications.

• Plasma Spray:

  It creates a high-temperature plasma jet to melt and accelerate coating powders, resulting in dense and durable coatings suited for aerospace and industrial applications.

• High-Velocity Oxy-Fuel (HVOF):

  This burns oxygen and fuel gas to produce a high-speed flame that melts and propels coating material, offering coatings with exceptional hardness and wear resistance for aerospace and industrial uses.

Benefits of Thermal Spraying

• Thermal spraying protects surfaces from wear, rust, and heat, making parts last longer.
• It reduces the need for frequent repairs or replacements and saves money.
• Thermal spray coatings work on many metals, ceramics, and plastics.
• By using quality thermal spray coatings we can improve surface strength, reduce friction, and increase resistance to heat and electricity.
• You can choose the right coating thickness and material for your needs.
• Thermal spray coating is environmentally friendly as it uses less material and reduces material waste.

Key Features of the Thermal Spray Arc Spray Gun

• Lightweight gun (4.2 lb / 1.9 kg)
• Durable design for harsh industrial environments
• Spray head with interchangeable nozzles, supporting a wide range of atomizing air flows (including a high-velocity option) to meet the required coating structure
• Pull mechanism with a powerful Swiss made DC motor with planetary gear head enclosed in a dust proof protective housing provides smooth feeding of wire stock and ensures a stable arc.
• Streamlined ergonomic design
• Hardened steel wire guides
• Wire feed rollers provide reliable wire grip for slip-free operation with both hard solid and malleable cored wires
• Maintenance free worm gearbox with life expectancy of 10,000-12,000 hours
• Tungsten-copper alloy contact tips