THERMAL SPRAY                     PRODUCT OVERVIEW

Properties: 

soft, relatively good electrical and thermal conductivity, curable alloys

Applications:

• corrosion protection
• electrical contacts
• shielding layers (EMC protection)
• soft buffer layers
• aluminum component repairs

Properties

• soft, good electrical and thermal conductivity, good soldering characteristics
• Aluminum bronze, hard, good machinability, suitable for thick layers

Applications

• Layers for electronics applications and electrical technology
• soldering foundation on Al heat sinks
• corrosion-resistant layers for printing and paper machinery
• bronze bearing layers

Thermal spray coating with copper (download, PDF)

Properties

hard layers (up to 500 HV), highly adhesive (self-adhering), excellent rubbing/sliding properties (no fretting, microporous, good emergency running characteristics)

Applications

• tribological pairings
• bearing seats
• guides
• shift forks, synchronizer rings
• cannot be used on copper or heavily copper-based alloys

Properties

magnetic, corrosion-resistant to all alkalis, oxidation-resistant up to 800 ºC

Applications

• corrosion prevention
• buffer layer
• textile machinery and apparatus engineering

Properties

thick layers, NiAl self-adhering due to exothermic reaction, oxidation-resistant up to 1000 ºC

Applications

• base adhesion layer
• corrosion barrier
• anti-scaling protection
• NiCr well suited for lining bearing seats, for example, can be turned and sanded

Properties

• wear-resistant, corrosion-resistant due to sintering (“melting down”), completely leakproof, bonded by metallurgy, resistant to shocks and edge pressure
• hardness of 25-60 HRC, can be adjusted with WC addition (75 HRC) for strongest wear resistance
•  layers up to 1 mm thick

Applications

• glass molds, water gauges
• shaft bushings
• feed screws
• drums in wire drawing machines
• valve seat inserts, such as for marine diesel
• bearing journals
• gland nut seats

Properties

• very hard, wear-resistant, low shrinkage, can be sanded
• ferritic chromium steel, 35-50 HRC, can be sanded
• austenitic steel, machinable

Applications

• wear protection
• repairs
• induction layers
• wear protection
• repairs, e.g. bearing seats
• anti-corrosion protection, e.g. on rollers

Thermal spray coating with chromium steel, carbon steel (download, PDF)

Properties

resistant to high temperatures and oxidation

Applications

• protective layer on gas turbine blades
• adhesive primer for insulating layers

Properties

composition similar to Inconel, corrosion-resistant

Applications

repair components made from Inconel

Properties

high strength, high biocompability

Applications

coatings for medical technology

Properties

• high-melting, extremely corrosion-resistant
• ductile cold-sprayed layers are impervious to corrosion

Applications

protective coatings for chem. Apparatus engineering

Properties

anodic corrosion protection, rel. soft, no thermal stress compared to hot-dip galvanizing, purity > 99.9%

Applications

• general anti-corrosion protection
• base layer for plastics for building up more layers
• shielding (EMC protection) on plastics

Properties

soft, solderable, low-melting

Applications

• anti-corrosion protection
• solder layers

Properties

high-quality bearing metal with excellent lubrication properties, harder than cast white metal, cheaper to manufacture

Applications

• bearing shells
• crossheads

Properties

• hardness 900-1100 HV 
• can be used at up to 800 °C 
• better cavitation resistance than WC to particle erosion at high temperatures

Applications

• valve spindels for gas turbines
• guide vanes for turbochargers
• plungers for high-pressure piston pumps

Thermal spray coating with chromium carbide (download, PDF)

Properties

• best wear-resistant material against abrasion, hardness up to 1350 HV, WC-CoCr is tougher, has higher resistance to corrosion than WC-Co
• layers can be polished up to Ra <0.01µm 
• WC-Ni suitable for nuclear applications
• max. operating temperature 550 ºC
• typ. layers are 0.1-0.3 mm thick
• high adhesive strength to steel (> 80 N/mm²)

Applications

• molds for building materials and ceramic industry
• piston rods
• mechanical seals
• pump pistons
• rollers in paper machines
• rough coatings on grippers

Thermal spray coating with tungsten carbide (download, PDF)

Properties

• pure Al₂O₃ is a good insulator, dielectric strength up to 20 kV/mm
• hardness > 1400 HV
• titanium oxide portion increases the toughness/wear resistance, with higher portion the hardness drops
• down 10% TiO₂layers are electrically conductive (prevents stat. charge!)
• non-stick properties on plastics, elastomers
• usable up to 1000 °C
• good resistance to acids, not resistant to alkalis

Applications

• electr. insulating layers for drive shafts, couplings, bearings
• corona rolls
• insulating intermediary layers on heat sinks for power electronics
• thread guides in textile machinery
• ink fountain rollers 
• agitators and mixers for fine ceramics
• shaping and transport rollers in glass processing

Thermal spray coating with aluminum oxide/titanium oxide (download, PDF)

Properties

hardness > 1400 HV, wear-resistant and corrosion-resistant as aluminum oxide Si and Ti additives increase toughness

Applications

• pure chromium oxide for anilox rolls
• shaft bushings
• seal seats
• piston rods
• pump pistons

Thermal spray coating with chromium oxide (download, PDF)

Properties

• low heat conductivity and high resistance to changes in temperature
• excellent chem. resistance 
• not easily wettable by molten metals
• operating temperature up to above 1200 °C

Applications

• heat insulating layers on gas turbine blades
• foundry tools
• burner parts
• oxygen ion conductors (λ probes, fuel cells)

Thermal spray coating with zirconium oxide (download, PDF)

Properties

• adaptation layers in turbomachines for manufacturing a defined gap size
• porous metal matrix with soft ceramic parts
• layers wear down upon contact with mating parts without damaging them
• hardness 35-55 HR 15Y
• can be used at up to 650 °C

Applications

• labyrinth seals in steam and gas turbines
• abradable coatings for turbine blades

Properties

graphite particles coated in nickel, self-lubricating, usable at up to 450 °C

Applications

• compressors in aircraft engines
• special friction linings
• sliding layers with emergency running characteristics