thermal spray

Need a special functional layer on your component? Then you’ve come to the right place.

Whether as wear protection, insulation, or friction improvement – GfE has over 25 years of experience in the area of thermal spraying, and performs job coating for nearly every industrial sector. Our expertise in materials, layer, and technology development allows us to find the right coating solution, even for new applications. State of the art thermal spray technology and machinery for mechanical processing guarantee you complete, fast, and reliable handling of your orders.

Certified

Quality and safety are our top priorities.

GTS certificate - thermal spraying

certificate for the following procedures in accordance with GTS-QM guideline GTSPA 003 Personnel and Resources Testing: Flame spraying with powder, flame spraying with wire, high velocity oxygen fuel spraying (HVOF), arc spraying, plasma spraying, vacuum plasma spraying, cold gas spraying

Customer-friendly

We provide you with competent individual consulting on all your questions regarding manufacturing and the use of our products. For the coating, we coordinate technology and material with one another optimally – this allows us to provide you with custom solutions for your requirements.

High-quality functional coatings for many industries and applications

GfE offers a wide range of high-quality coatings for customer-specific components in various industries: 

  • Automobile manufacturing
  • Chemical apparatus engineering and process technology
  • Printing, paper, and packaging machinery industry
  • Energy industry
  • Aviation industry
  • Machine and plant construction

Thermal spraying offers nearly unlimited possibilities for applying various functional layers, repairs, or new production of components. Our layer systems have proven themselves in practice under a wide variety of application conditions.

Thermal coatings are used in the following applications:

Abradables increase operating security and reduce energy consumption and emissions from turbines. They are abraded when they come into contact with counter bodies, without damaging them. This creates a defined gap size on the mating surfaces. The layers often consist of a porous metal matrix with soft ceramic, graphite, or plastic content. This saves fuel, reduces noise, and increases efficiency.

 

Material Procedure Area of application (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 layers with emergency running properties

 

Modern power electronics require reinforced high-performance coatings that can stand up to the requirements of increasing operating voltages and high power density. Electrical insulation, as well as electrical engineering and electronics, is also increasingly needed in modern machine, plant, and vehicle construction. This effectively prevents bearing damage from stray and induced currents with insulating shaft connections. Our ceramic insulation layers provide dielectric strength of more than 2 kV/0.1 mm.

 

Material Data sheet Procedure Area of application (examples)
Aluminum oxide
also combined with other ceramics (titanium oxide, chromium oxide)
Al2O3 Plasma spraying
HVOF
electrically insulating hubs, bearing seats, antifriction bearing shells, housing, heat sinks, circuit carriers, corona rolls

 

See data sheet for more information and technical details.

 

With the developing market of electromobility, the need to shield high-frequency electromagnetic fields from components that would otherwise impact their function is also growing. The lightweight construction used in many vehicles often does not provide this shielding function. Protective EMC coatings guarantee optimum protection for components made from plastic and composite material. 
A number of non-metallic materials can be coated by thermal spraying; thermoplastics with and without fiber reinforcement, SMC and long-fiber GRP and CRP components are primarily coated. Thermally sprayed metallic layers made from plastics have significant advantages compared to alternative EMC solutions, such as metal or foil inserts:

  • bonds to plastic over a large area
  • can be manufactured with almost no dependence on contours (multi-dimensional, rounded shapes)
  • small assembly space
  • low weight

 

Material Data sheet Procedure Area of application (examples)
Zinc, zirconium aluminum, copper Cu Arc spraying
Wire flame spraying
Protective EMC coatings on battery casings, cable channels, connectors, casings

 

See data sheet for more information and technical details.

 

Sliding coatings and guides are produced and installed by the millions. The requirements for operating safety and lifespan are steadily growing. Thermal spraying allows bearing bushes and thrust washers to be manufactured in large sizes at economical costs. Furthermore, selective or thin coatings can be applied on components with sliding surfaces, which conventional bearing technologies do not allow. 
Sliding coating materials can be manufactured using the thermal spraying process with a wide variety of material combinations; these include embedding solid lubricants and hard particles. This allows the desired tribological properties to be set.

 

Material Procedure Area of application (examples)
Tin, aluminum alloys, white metal, bronze, brass Arc spraying
Wire flame spraying
Powder flame spraying
Cold spraying
Bearing shells, thrust rings, bearing bushes, sliding guides, multi-surface sliding bearings
Molybdenum Wire flame spraying
Plasma spraying
Synchronizer rings, bearings subjected to high stress

 

GfE offers coatings under the brand name e-CER® that are able to increase the efficiency of thermal processes significantly through high emissivity in the infrared range. The ceramic layers are used primarily wherever a high amount of infrared radiation is needed for fast heating: for example, in baking oven construction, food drying systems, plastic processing, warming and heat treatment or in cooling technology, especially in vacuum systems. 

It’s easy to test the effectiveness and advantages of e-CER®; we can coat your components with no problem – radiators, emitters, or heaters – up to dimensions of several meters. 

More technical information can be found in our white papers

e-CER® - Ceramic functional layers for infrared radiation applications (PDF)

e-CER®- Baking plates: Ceramic-coated metal plates for industrial and craft ovens (PDF)

Components can be effectively protected from corrosion and its consequences with specific coatings. In addition to a proven selection of coating materials, GfE also offers custom solutions.

 

Material Procedure Area of application (examples)
Zinc, aluminum Arc spraying Construction parts, automobile, housing
Nickel, nickel alloys HVOF
Plasma spraying
Textile machine building, apparatus engineering, paper industry
MCrAlY HVOF
Plasma spraying
high-temperature oxidation protection, turbine blades, burner parts
Chromium aluminum Plasma spraying Protection against the effects of sulfur, carburization, burner parts, high-temperature reactors
Aluminum oxide, titanium oxide, mixed oxide Plasma spraying Protection against molten metals (e.g. galvanizing baths), protection combined with organic sealers, protection against chemical corrosion combined with abrasion (e.g. flue gas treatment systems)

Paper, film, and fabrics are processed in high-performance machines. Wear-resistant rough coatings on grippers and rollers guarantee that production processes will run smoothly, even at high speeds. By selecting procedures, parameters, and materials, we can set the exact roughness you need to guide or transport the product precisely.

 

Material Data sheet Procedure Area of application (examples)
Tungsten carbide WC HVOF Gripper rails, grab tips, transport rollers, embossing rollers
Tungsten carbide + nickel-alloys WC HVOF
Powder flame spraying
Arc spraying
Grippers, support rollers, pulleys, embossing rollers, emery rollers
Molybdenum   Wire flame spraying Feed rollers, grippers
Ceramics   Plasma spraying Embossing rollers

 

See data sheet for more information and technical details.

 

As they do for rough coatings on transport components, thermally sprayed layers can also increase the friction coefficient for machine element pairings. 
GfE offers coatings under the brand namef-CER®to provide especially high coefficients of friction in comparison to steel and other building materials. The ceramic layers produced by GfE for are used in ship and vehicle construction, in printing machinery construction, and in the textile industry, among other things. While a steel-steel pairing usually demonstrates a static friction coefficient (µ) of 0.10–0.12, systems using f-CER® coating achieve values far higher than 0.5. This includes the following advantages:

  • more compact construction 
  • lower production costs
  • higher operating safety
  • energy saved due to smaller masses moved

For friction systems under dynamic stress, such as brake discs and clutch elements, metallic and hard metallic coatings in particular have proven successful. They offer a friction coefficient that remains consistent across a wide temperature range, in addition to excellent wear resistance and adhesive strength.

 

Material Procedure Area of application (examples)
Ceramic Plasma spraying General friction shaft-hub connections, detachable couplings for ship shaft drives, wind turbines; parking brakes for cranes, machinery, wind turbines; transport rollers, clamping jaws
Tungsten carbide or chromium carbide HVOF Brake discs for vehicles, cranes, machinery, conveyor systems, etc., couplings
Tungsten carbide and nickel-alloy HVOFPowder flame spraying Arc spraying Brake discs for vehicles, cranes, machinery, conveyor systems, etc., couplings

 

Wear reduces the lifespan of machinery and tools. Thermally sprayed coatings help keep costs down, because cheaper base materials can often be used for the components thanks to the coating. Longer lifetimes for protected components increase the operating safety of systems. 

 

Material Data sheet Procedure Area of application (examples)
Hard metals
Tungsten carbide
Chromium carbide
WC
Cr3C2
HVOF Molds, pump parts, hydraulic pistons (hard chromium replacement), valve spindles, shaft bushings, rollers, grippers
Hard alloys
Nickel alloys
Cobalt alloys
  HVOF
Powder flame spraying
Molds, spindles, shaft bushings, mixing blades, bearings
Ceramics
Chromium oxide
Aluminum (titanium) oxide
Cr2O3
Al2O3
Plasma spraying
HVOF
Pump pistons, shaft bushings, sealing seats, rollers, thread guides, printing press engineering
Molybdenum   Plasma spraying
Wire flame spraying
tribological pairings, synchronizer rings, shift forks

 

See respective data sheet for more information and technical details.

Ceramic thermal insulating layers expand the range of application for system components exposed to thermal stress. With actively cooled components, thermally sprayed insulating layers can increase the threshold temperature for use (process temperature) by up to several hundred degrees Celsius. Along with the application in turbine construction, there are a number of other possibilities for using protective layers as thermal insulation.

 

Material Procedure Area of application (examples)
Zirconium oxide,
mixed oxide
Plasma spraying insulating layers on turbine blades, foundry tools, burner parts, motor components, thermal apparatuses, oxygen-ion conductors (λ probes, fuel cells)

 

 

More technical information about our products can be found in our brochure Thermal Spray (PDF).

YOUR CONTACT 

Dr. Steffen Marx

Product Manager Component Coating

Phone: +49 (0)37322 472 - 548
steffen.marx@gfe.com

Menu