In the thermal spray process, molten coating particles are propelled at a prepared substrate. The particles form an overlayed coating as they adhere to the substrate. Most commonly, metallic alloys are used in thermal spray repair, such as stainless steel, tungsten carbide, nickel, copper, or brass. In some cases, ceramic coatings may be applied using thermal spray techniques. At our facility in Portland, we use two-wire electric arc and flame spray application processes to repair machine parts such as shafts, rolls, or journals.
The Thermal Spray Process
Thermal Spraying is a proven effective industrial process used to repair worn out or damaged equipment by building up a layer of coating on a prepared surface and machining it according to technical specifications. A combined kinetic and thermal energy is used to bond the coating to the workpiece. This mechanical bonding process feeds a wire or powdered coating through an electric arc or high-powered flame to liquify the coating for application. Thermal spray coatings can be applied at various thicknesses, typically 100-750 microns. For restoration and repair of worn or damaged components., thermal spray is a reliable way to restoring a component back to its OEM specifications or better.
Applications of thermal spray
- Dimensional restoration
- Main shaft repair or refurbishing
- Bearing housing repair
- Seal fit repair
- Bearing fit repair
- Wear resistance
- Corrosion protection
- Galling and fretting protection
Common Types of Coating Materials Used
- Stainless steel
- Tungsten carbide
- Nickel alloys
Benefits of Thermal Spray Coatings
- Cost-efficient vs replacement. Compared to manufacturing or ordering a new component, refurbishing a large shaft or component saves money and extends the lifespan of the part.
- Component protection. Thermal spray coatings can be used to increase resistance to wear, corrosion, temperature, oxidation, fretting, and conductivity. Components can be set to OEM specifications and made “like new”.
- Quicker lead times. Ordering a new bearing housing, shaft, or other component may take longer than enhancing via thermal spray metallization.
- Base characteristics are not altered. Applying thermal spray coatings to a worn equipment component will not alter the characteristics of the base material.
- Reduced downtime. By using thermal coatings to build a critical component back to OEM specs will help prevent unexpected equipment failure.
- Coating thickness can be controlled at a granular level. Our engineering and machining team can polish tungsten carbide coatings down to a tolerance of 6 Ra.
- No substrate heat distortion. Thermal spray repair is a good alternative to welding for many components.
- Optimized coating. Our team measures the final coating using precision equipment. Your equipment component is polished to a tight tolerance, inspected for tensile strength bonding, hardness, surface finish, and thickness. Each shaft is dynamically balanced for an even balanced load.
thermal spray Repair in the Pacific Northwest
Worn components, eroded shafts, and other damaged machine parts can be restored with thermal spray coatings.
Industrial machine parts frequently undergo erosion, friction, high temperatures, and corrosion. If left untreated, the components may need to be replaced or re-manufactured. Refurbishment using thermal spray coatings can restore the components to their original dimensions, oftentimes with better mechanical or structural properties than before.
If you have a question, our engineering team can help inspect your industrial equipment and propose the most cost-efficient and appropriate repair solution. Our 34,000 square foot facility is conveniently located in Portland to service customers in Oregon, Washington, Idaho, California, Wyoming, Nevada, Montana, Alaska, and the rest of the country.
Thermal Spray repair Projects
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thermal spray repair is proven effective for these industries:
- Pulp & Paper
- Wind Power
- Oil & Gas
Let’s talk about your project.