Thermal spraying for durability | Thermal spray coating

what is thermal spraying?

During thermal spraying, a coating material in the form of wire or powder is fused or melted and subsequently accelerated onto the component to be coated. Thermal spray coatings are characterized by a high surface hardness and excellent non-stick properties. Using metals, ceramics and polymers as well as different process variants, our experienced employees create the ideal protection for components subject to heavy loads.

We will cooperate with you in order to find the coating process to match your material. All kinds of surfaces can be coated using thermal spray: aluminum, steel, and other types of metals, but also glass, ceramics, plastics, and more. From initial sampling to series introduction, we will determine the relevant process steps together with you. Upon request, we will complete our technical services by a logistics concept with pick-up and delivery services tailored to your needs.

PlasmaCoat® thermal spraying for excellent non-stick properties

Our PlasmaCoat^® thermal spray process comprises different coatings which are applied to components with varying degrees of roughness and different profiles with the aim of creating surfaces with excellent non-stick and traction properties as well as corrosion protection. In the run-up to the thermal spraying coating process, we clean the material and roughen up its surface. This results in the spray particles’ mechanical adherence to the surface and guarantees coating adhesion strength. An embedded metal or ceramic layer serves as a substrate for the anti-corrosion coating. Depending on the coating type and application, the coating thicknesses customary to thermal spraying range between one-tenth of a millimeter and several millimeters.

properties of thermal spray coatings

Our PlasmaCoat^® spray coating process merges the extreme surface hardness and excellent wear protection of thermally sprayed metal or ceramic coatings with the non-stick and gliding properties of polymers and fluoropolymers. In this way, we prolong the service life of components subject to heavy mechanical loads. When mechanically reworked, PlasmaCoat^® coatings can also replace hard-anodized layers. Precise diamond tools are usually required for reworking the hard surfaces. Thanks to our comprehensive expert knowledge and high-quality tools, the results we achieve are accurate to one-thousandth of a millimeter.

By the targeted thermal coating of different materials, we also create other excellent functionalities, such as:

Non-stick properties
Improved tribological values
Corrosion resistance
Very low porosity
Low degrees of roughness
Resistance to temperatures
FDA approval for food contact

base materials suitable for thermal spraying

PlasmaCoat^® coatings can be applied to almost all metallic materials as well as to CFRP components. Thermal spray coatings are primarily applied to aluminum, steel, stainless steel, cast iron, brass and copper. However, it is also possible to apply this type of coating to ceramics, glass or temperature-sensitive materials, such as (fiber-reinforced) plastics, wood or fabrics. We will find the appropriate procedure for your requirements, be it plasma spraying, electric arc spraying or flame spraying.

fields of application of thermal spraying

PlasmaCoat^® is primarily used as a surface finish in the nonwovens industry. To allow for the safe and trouble-free transport of materials or webs made from plastics, textiles or paper, transport rollers and other relevant components require wear-resistant traction coatings. Depending on the type of application, non-stick and conductive properties might be required as well. Thermal spray coatings by Aalberts surface treatment create precisely these characteristics.

Below you will find a non-exhaustive list of components which can be coated with PlasmaCoat®:

We also offer special repair services: With the help of our processes, worn components can be fully refurbished. When doing so, we restore the required original dimensions along with all the characteristics offered by relatively new protective coatings. As a customer, you will save both costs for new acquisitions and resources.

Due to the wide range of possible materials and the targeted creation of characteristics, thermal spraying is superior to many other coating processes. Apart from metals and metal alloys, it is possible to process hard metals, ceramics and plastics.

WHICH BASE MATERIALS CAN BE COATED WITH THERMAL SPRAYING PROCESSES?

Almost all metallic base materials can be finished with thermal spraying (aluminum, steel, cast iron, brass, copper, etc.). However, it is also possible to coat ceramics, glass or temperature-sensitive materials, such as (fiber-reinforced) plastics, wood or fabrics. Since the coating adhesion is usually based on mechanical interlocking, the surfaces to be coated have to be roughened up by sandblasting.

IS THERMAL SPRAYING ALSO SUITABLE FOR THE REPAIR OF WORN COMPONENTS?

Thermal spraying is an excellent method for repairing worn components, as their original dimensions can be restored while protecting their surfaces against further wear and tear.

WHAT CHARACTERIZES THERMAL SPRAY COATINGS?

Thermal spray coatings have a high surface hardness. Using metals, ceramics and polymers as well as different process variants, our experienced employees create the ideal protection for components subject to heavy loads.