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Thermal Spray Coating

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Thermal Spray Coating Specification

Power
5-15 kW

Feature
Corrosion and wear resistance

Voltage
220-240 V

Type
Thermal Spray Coating

Raw Material
Metallic Alloys

Size
Customizable

Length
Up to 6 meters

Width
Custom as per requirement

Thickness
50-500 microns

Density
7.8 Gram per cubic centimeter(g/cm3)

Thermal Conductivity
0.3-0.8 W/mK

Water Absorption
Low

Water Content
Nil

About Thermal Spray Coating

Hightemperature corrosion and erosion of heat transfer pipes in coal fired boilers,such as tubes for super heaters and water walls, are recognized as a severeproblem, resulting in tube thinning and premature failure. In the applicationof a thermal spray coating, a metal powder is heated to a high temperature andpropelled toward the boiler tube surface with a high velocity gas (HVOF) orplasma jet. Once at the surface, the particles form a coating.

Thermal spray coatings have the advantage ofbeing applied in-situ in the boiler and as a consequence, they are more easilyrepaired after exposure. Coating Requirement HighHardness (To prevent erosion because of ash and silica) Hot corrosionresistance (that will react with the environment to produce a slow growingprotection oxide scale, which should not allow the corrosion species to diffuseinto the coating) Low porosity (Less area for erodent particle to impact and abrade) Smallgrain size (small grains tend to be stronger) Absenceof cracks (Ductile structure, thermal stability, cracking lead to spalling) Uniformcoating structure (Homogenous distribution of hard constituents & ductilebehavior) Smooth Surface

Highchromium content nickel based alloy Cr3C2-NiCr & In presence of sulfur andvanadium atmosphere NiCrTi & amorphous alloy of FeCrBSi as a widely usedcorrosion & wear resistant coating material, possesses good ability againstoxidation, sulfur induced corrosion and hot corrosion.

Chromium Carbide (Cr3C2) Due to hardchromium Carbide content, it offers more erosion resistance.

Nickle Chromium (NiCr) a) Chromium is acorrosion resistance alloy that binds the continuous skeleton of erosion resistantchromium carbide constituents. b) Due to high binding energy and ductility,nickel exhibit enhance erosion resistance by their ability to dissipate theimpact force to particles by plastic deformation. Feric Chromium Boron Silicon(FeCrBSi) A FeCrBSi amorphous alloy producing a partially amorphous, hardabrasive and corrosion resistance coating, with a service environment upto920C. Typical grinding and lapping techniques can be used to obtain highchrome like finishing. It can be used in a wide variety of high wearapplications, anti skid surfacing applications and corrosion environment.

Advanced Performance Coating

This thermal spray coating delivers high levels of wear and corrosion resistance, meeting edge-of-industry requirements. It is customized for diverse client needs, with excellent hardness, low water ingress, and a resilient matte or satin appearance. Ideal for applications facing abrasive or extreme environments, it assures long-term protection and functional integrity of critical components.

Wide Industry Applications

Engineered for use in sectors such as automotive, aerospace, oil & gas, and power generation, this coating safeguards essential parts against degradation. It is particularly suited for steel, aluminum, and a range of alloy substrates. The flexibility in dimensions and thicknesses ensures compatibility across various machinery and manufacturing components.

Efficient Application Process

The coating is expertly applied using plasma or flame spraying techniques, ensuring strong metallurgical adhesion. Each solution is available with customizable widths and lengths up to 6 meters, allowing a tailored fit for unique industrial requirements. Low thermal conductivity further enhances protection against thermal shocks and stresses.

FAQs of Thermal Spray Coating:

Q: How is the thermal spray coating applied to substrates?

A: The coating is applied using advanced plasma or flame spraying methods, which project molten or semi-molten metallic alloy particles onto the prepared surface. This process forms a dense, metallurgically bonded layer with strong adhesion, typically ranging from 50 to 500 microns in thickness.

Q: What industries benefit most from this thermal spray coating?

A: Industries such as automotive, aerospace, oil & gas, and power generation benefit greatly due to the coatings excellent abrasion, corrosion resistance, and ability to withstand service temperatures up to 700C. Its adaptability makes it ideal for protecting components exposed to harsh operational environments.

Q: When should thermal spray coating be considered over other surface treatments?

A: Consider this coating when high abrasion and corrosion resistance, minimal water absorption, and the need for durable matte or satin finishes are required. It is particularly suitable when service conditions demand reliable protection at elevated temperatures or under continuous mechanical stress.

Q: Where can thermal spray coatings be applied?

A: These coatings are suitable for a wide variety of steel, aluminum, and metallic alloy components. Common examples include shafts, rollers, valves, turbine parts, and any machinery part requiring enhanced wear or corrosion resistance.

Q: What is the process for customizing the coating size and thickness?

A: Coating thickness, width, and length are all customizable per client requirements. Our services accommodate pieces up to 6 meters in length and up to 500 microns in thickness, ensuring compatibility with specific equipment or system dimensions.

Q: What are the primary benefits of using this thermal spray coating?

A: The primary advantages include increased component lifespan, reduced downtime, enhanced resistance to wear and corrosion, strong bonding strength, and low water absorption. Its customizable nature also allows precise fit to application demands, supporting reliable, long-term performance.

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