THERMal Spray                  Product overview

ORGANIZED BY COATING FUNCTION

Thermal coatings can fulfill a wide range of functions. Here is a brief overview of our most important products:

Purpose of coating
Protection against diffusion, particularly of carbon

Applications/features
Equipment for thermal treatment, soldering ovens, and plants

Parts made of CFC, C/SiC, graphite, steel mesh, and parts of other metals and alloys
Operating temperatures of over 1,000 °C

 

Coating material Method Applications/components (examples)
Zirkonium oxide, Yttrium oxide Plasma spraying Charging and firing racks, carrier plates, easy-to-clean surfaces in thermal plant engineering

 

 

Purpose of coating
High degree of emission, especially in the infrared range of fast thermal processes.

Applications/features
Industrial and craft ovens
Baking and cooking equipment for personal use
Heating and cooling plates in vacuum systems
Drying systems for technical equipment and food
Hot shaping of thermoplastic parts

Several base materials can be coated, such as steel, copper, aluminum, glass, ceramics. Operating temperature up to approximately 700 °C

 

Coating material Method Applications/components (examples)
Oxides in specific composition Plasma spraying Radiators, tubular heatinge elements, halogen lamp emitters, ceramic heaters, coolers

 

 

Purpose of coating
High coefficient of friction for machine parts such as couplings, shaft-hub connections, transport rollers, locking brakes

Applications/features
Ship propulsions, power engine
Drives in machine and plant engineering
Wind turbines
Conveyor and clamping elements

Ceramic coatings with static friction coefficients of µ > = 0.5
For planar, cylindrical, or conical pairings

 

Coating material Method Applications/components (examples)
Oxide ceramic Plasma spraying

Force-fit shaft-hub connections, releasable couplings for ship drive shafts, wind turbines

Locking brakes for cranes, machinery, wind turbines

Grippers, feed rollers, clamping jaws

 

 

Purpose of coating
Electrical insulation of components

Applications/features
Mechanical and electrical components especially in the drive area in mechanical and plant engineering, rail vehicles, shipbuilding, automotive, aircraft, energy technology, electrical equipment, electronics

Dielectric strength > 2 kV per 0.1 mm layer thickness
High strength, chemical, thermal, and wear resistance

 

Coating Material Method Applications/components (examples)
Aluminum oxide (also in combination with other ceramics) Plasma sprayingHVOF Electrically insulating hubs, bearing seats, antifriction bearing shells, housing, heat sinks, circuit carriers, corona rolls

 

 

 

 

Purpose of coating
Multilayer coatings with at least one electrically isolating ceramic layer and an additional electrically conductive functional layer

Applications/features

Packaging of integrated circuits for power electronics
Heating plates for mechanical and plant engineering, automotive and household appliances
For efficient cooling of power electronics and for rapid heaters

Base body material can be steel, aluminium alloys, AlSiC, other metals and alloys
Functional coating layout can be sprayed in fine pattern – can also carved out of continuous coating

 

Coating Material Method Applications/components (examples)
Isolation: oxides (please see also i-CER) Plasma sprayingHVOF

Heat sinks for power electronics, high voltage heaters for HEV, flow heaters, sensor systems

 

Conduction: copper, aluminum, silver, brass, nickel, oxide Plasma sprayingHVOFArc sprayingCold gas spraying

 

 

Purpose of coating
Thermal insulation of actively cooled components in hot environment

Applications/features
Thermal power generation, thermal plant engineering
Turbines and internal combustion engines

Operating temperatures up to appr. 1,400 °C
High thermal shock resistance
With active cooling the temperature can be increased by up to several hundred degrees Celsius
Combination with oxidation protection coating o-MET possible

 

Coating material Method Applications/components (examples)
Zirconium oxide,
mixed oxides
Plasma spraying

Turbine blades, burner chambers, burner parts, casting dies, foundry tools, motor components, thermal apparatuses

Oxygen-ion conductors (λ probes, fuel cells)

 

 

 

 

Purpose of coating
Protection of component parts from sliding wear, abrasion, erosion, cavitation

Applications/features
Applications in almost all industrial branches

Coating hardness up to 1,400 HV0.3 (w-CER)
Finished surfaces Ra < 0.01 µm (w-CERMET)
Oil pressure-tight: more than 700 MPa (sealed coating)

Combination with good corrosion protection – very good chemical resistance in both acid and neutral media, also in seawater (tungsten carbides) respectively in both acid and alkaline media (chromium carbide, chromium oxide)

Coating material Method Applications/components (examples)
Hard metal:
tungsten carbide
chromium carbide
HVOF Forming tools, gap rings for pumps, hydraulic pistons, valve spindles, shaft bushings, rollers, clutches, ball valves, landing gear parts, brake discs
Hard alloys:
nickel alloys
cobalt alloys
HVOFPowder flame spraying Forming tools, drive shafts, shaft bushings, stirrers, slide bearings
Ceramic:
chromium oxide
aluminium-(titanium-)oxide
Plasma sprayingHVOF Plungers, shaft bushings, seal seats, rollers, rope and wire pulleys, printing machine parts, couplings, thread guides

 

 

Purpose of coating
Abradable coatings are used to create a defined clearance on mating surfaces during running-in

Applications/features
Turbines, compressors

Fuel consumption and noise emission will be reduced by autonomous adjustment of clearance during running-in

Coating material Method Applications/components (examples)
Nickel-bentonite

Powder flame spraying

Labyrinth seals for shafts in steam and gas turbines, abradable coatings for turbine blades
Nickel-graphite Powder flame spraying Compressors in aircraft engines, sliding contact bearings with emergency running properties
Further coating materials: aluminum-, cobalt-, copper-,and ceramics

Powder flame sprayingPlasma spraying

 

Compressors and HP compressors in turbines, counterparts of titanium blades, turbines in hot gas path

 

 

Purpose of coating
Bonding of surplus and undesirable coating material on vacuum coating equipment

Applications/features
Vacuum systems

Protect the vaccum equipment from straying particles or tinsels
Reduction of pollution with particles
More easy maintenance of facilities
Longer availability of equipment and maintenance intervals

 

Coating material Method Applications/components (examples)
Metal alloys

Wire flame sprayingArc spraying

Shields, liners, equipment in vacuum coaters

 

 

 

 

Purpose of coating
Contact coating with good solderability and high thermal and electrical conductivity

Applications/features
Joining technology in power electronics
Conductor tracks, busbars, switching devices
Apparatus engineering, cooling systems

Sharp contours of selective coatings support autonomous positioning for soldering process
Coating thickness adjustable – from several micrometers up to millimeters
Best electrical and thermal conductivity, best heat dissipation of all thermal sprayed coatings
High bonding strength and resistance to thermo-cycling loads and thermo-shocks

 

Coating Material Method Applications/components (examples)
Copper, nickel, silver

Cold gas spraying

Heatsinks for light engineering and power electronics, base plates, circuit carriers, busbars, conducter tracks, power connectors

 

 

 

Purpose of coating
Shielding of high-frequency electromagnetic fields

Application/features
Vehicle construction (HEV/BEV)
Aircraft construction

Numerous light-weight materials can be coated: thermoplastics with or without reinforcement, sheet moulding components, fibre-reinforced plastics
Small coating thickness – little constructed space, limited weight

Coating Material Method Applications/components (examples)
Zinc, tin, aluminium, copper Arc sprayingWire flame spraying Battery housings, cable tunnels, connectors, enclosures for electronics, power electronics, high frequency technology

 

 

Purpose of coating
Protection of components from corrosion and oxidation in different atmospheres

Applications/features

Steel construction, automotive engineering, shipbuilding, mechanical engineering, plant and apparatus construction,
Power plant technology, waste-to-energy plants, thermal facilities, metallurgy

Proved range of coating materials
Additionally adapted solutions for specific applications possible - depending on kind of stressing and requirements

 

Coating Material Method Applications/components (examples)
Zinc, aluminum Arc spraying Steel construction, automotive engineering, housings
Nickel, nickel alloys HVOFPlasma spraying Mechanical + apparatus engineering, paper industry
Chromium-aluminum Plasma spraying Protection against the effects of sulfur and carburization, burner parts, high-temperature reactors
Aluminum oxide, titanium oxide, mix oxide Plasma spraying

Protection against damage by molten metals (e. g. hot galvanization)

Protection in combination with organic sealer

Protection against chemical corrosion combined with abrasion (e. g. flue gas treatment equipment)

 

Purpose of coating
Microporous coating for guide, deflection, clamping of flexible material and stiff parts with over- or underpressure

Applications/features
Contact-free deflection by a uniformly distributed air or gas cushion

For guidance and clamping of paper web, film web or other materials and parts with low pressure during processing

 

Coating Material Method Applications/components (examples)
Steel, aluminium, copper, other alloys Wire flame sprayingHVOFArc spraying Cylinders, pulleys, support plates, fixing plates
Oxides Plasma spraying

 

 

Purpose of coating
Protection sliding surfaces from severe wear and ensuring a good sliding behavior

Applications/features

Sliding bearings in machines, constructions, equipment and vehicles

Sliding coating of variable material compositions possible - e. g. mixtures of sliding metals, inclusions of hard particles and/or solid lubricants
Sliding material can deposited straight on to machine parts
Coating thickness up to several millimeters

 

Coating Material Method Applications/components (examples)
Tin, aluminium alloys, white metal, bronze, brass

Arc sprayingHVOFWire flame sprayingPowder flame sprayingCold gas spraying

Bearing shells, thrust rings, bearing bushes, sliding guides, multi-surface sliding bearings
Molybdenum Wire flame sprayingPlasma spraying Synchronizer rings, bearings subjected to high stress
Cobalt alloys
(similar to stellite, Triballoy)

Plasma sprayingHVOF

Valves

 

Further applications can be:

 

  • Rough surfaces on machine parts
  • Resistance to slipping of sole on paving elements
  • Dimensional or structural repair of engine parts

Your contact partner

Dr. Marcel Roth

Product Manager Component Coating

Phone: +49 (0)37322 472 - 536
marcel.roth@gfe.com

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