Frequently Ask Questions

Thermal spraying is used in a wide range of industries and applications, including aerospace, automotive, power generation, and medical devices. Common uses include coating aircraft parts for Oxidation and Wear Resistance, applying Thermal Barriers to engine components, protecting industrial machinery from corrosion, and enhancing the biocompatibility of medical implants.

The Wire flame spraying process involves feeding a consumable wire into a Spray Gun, where it is melted by a combustible Gas Flame. The molten material is then atomized by compressed air, creating a fine spray of molten droplets. These droplets are propelled toward the prepared surface, where they solidify to form a coating. This process is widely used for its versatility and ability to apply various materials, such as metals, alloys, and ceramics.

Wire arc spraying is a Thermal spray process where two consumable wire electrodes are melted by an electric arc. The molten material is then atomized by a stream of compressed air and propelled onto the surface to be coated. This process is commonly used to apply metallic coatings for Corrosion Protection, Wear Resistance, and Dimensional Restoration.

Flame spraying is a Thermal spray coating process where a feedstock material, typically in powder or wire form, is heated to a molten or semi-molten state and then propelled onto a surface to create a coating. This method uses an oxy-fuel gas flame as the primary heat source to melt the feedstock material. The molten particles are then accelerated towards the substrate using a carrier gas, forming a protective or functional layer.

Atmospheric plasma spraying (APS) is a Thermal spray coating process used to deposit materials onto a surface. In this process, a high-energy plasma jet is generated by an electric arc between two electrodes, which is then used to melt powder particles and propel them onto the substrate. This creates a durable, high-quality coating that enhances the surface properties of the material.

The High velocity oxygen fuel (HVOF) spray method is an advanced Thermal spray technique used to apply protective coatings to surfaces. This process involves injecting a powdered coating material into a high-temperature, High-Velocity Gas Stream, created by the combustion of a fuel gas and oxygen. The powder particles are heated and accelerated towards the substrate, forming a dense, hard coating with excellent adhesion and wear resistance.

Detonation spray coating is a Thermal spray process used to apply protective coatings to surfaces. This method utilizes a mixture of Gases (such as oxygen and acetylene) that are Detonated in a controlled chamber. The resulting high-energy shock wave propels powdered coating materials at supersonic speeds, creating a dense, well-adhered coating on the target surface. Detonation Spray Coatings are known for their Exceptional Hardness, Wear Resistance, and Bond Strength, making them ideal for high-stress industrial applications.

The Weld overlay method involves applying a layer of material onto the surface of a base metal to enhance its properties, such as wear and corrosion resistance. This is achieved through various Welding Processes that deposit the Overlay Material by melting it onto the Substrate, Creating a Metallurgical Bond. This technique is commonly used in industries where equipment faces harsh operational conditions.

GTA welding involves creating an arc between a Non-consumable tungsten electrode and the workpiece. The weld area is protected from atmospheric contamination by a shielding gas, usually argon or helium. This process can be used with or without filler metal, depending on the requirements of the weld.

The Spray and fuse process is a surface coating method used to apply a protective or functional layer onto a substrate. This technique involves two primary steps:

1. Spraying : A Coating Material, often in powder form, is sprayed onto the workpiece's surface using specialized equipment.
2. Fusing : The Sprayed Coating is then heated (often using a torch or furnace) until it melts and fuses with the substrate, creating a strong, wear-resistant bond.

The Microstructure of a coating refers to the arrangement of its Microscopic Components, including grain size, phase distribution, and the presence of any defects or inclusions. Understanding the Microstructure is Crucial for determining the Coating’s performance characteristics such as Durability, Hardness, and Resistance to Wear and Corrosion.

The Microhardness test method is a technique used to measure the hardness of a material on a small scale. It involves pressing a diamond indenter into the material's surface with a specific load and then measuring the size of the indentation. This test is particularly useful for evaluating the hardness of thin Films, Coatings, and Microstructures, where traditional hardness tests may not be applicable.

Microindentation involves using a diamond indenter to create a small impression on the surface of the material under a controlled force. The process typically includes:

1. Preparation : The sample surface must be polished to a mirror finish to ensure accurate measurements.
2. Indentation : An indenter, usually made of diamond, is pressed into the material with a defined load for a specified time.
3. Measurement : The dimensions of the indentation are measured using a microscope. These dimensions are then used to calculate the material's hardness.

We provide a variety of customized coating solutions tailored to meet specific requirements and applications. This includes :
1) Complete manufacturing of Thermal spray and Weld overlayed Components
2) Thermal spray coating and Weld overlays on new Components
3) Repair & Recoating of worn-out Components
4) Development of customized coating solutions
Our goal is to enhance the performance and longevity of your parts based on their intended use.

Our re-coating and re-conditioning service helps you save on capital by refurbishing worn-out tools and components. We use advanced refurbishment techniques to restore your tools to their original functionality, extending their service life and reducing replacement costs. However, the feasibility of reconditioning will depend on the condition of the tools which will have to be evaluated at the review stage.

We stay at the forefront of technology through continual research and development. Our in-house testing and validation setup helps us explore and develop new coating applications to meet evolving industry standards and customer needs. Further, our strategic cross border partnerships and prominent position in the Thermal spray community keeps us abreast with the latest technology in the market.

Thermal spray coatings involve applying a layer of material onto a surface through a thermal process. These coatings are used in the aerospace industry to enhance the performance and longevity of components subjected to harsh operating conditions, such as high temperature wear and corrosion. They are critical for maintaining the reliability and safety of aerospace parts, including airframes, propulsion systems, and landing gears. In aerospace applications, several types of coatings are used, including :

• TBC Coatings : Provide high-temperature resistance and thermal insulation.
• Ceramic & Carbide Coatings : Offer corrosion resistance and improved wear characteristics.
• Cermet Coatings : Combine metal and ceramic properties to enhance durability and resistance to extreme conditions.
• Composite Coatings : Utilize a mix of materials to achieve specific performance attributes

Thermal spray coatings offer several benefits, including :

• Increased Durability : Coatings protect against metal-to-metal wear, fretting, hot corrosion, and particle erosion.
• Enhanced Reliability : They help maintain optimal engine performance under extreme temperatures.
• Extended Component Life : Coatings improve the lifespan of critical engine components, ensuring more efficient operation.

Quality management is crucial because any failure in coatings can lead to significant safety issues or operational failures. Aerospace components must meet stringent quality and performance standards. Implementing a robust Quality Management System, such as AS 9100 Rev D, ensures that the coating process is controlled and consistent, reducing the risk of failures and ensuring reliability.

Thermal spray coatings are applied to various sections of an aircraft engine, including :

• Combustion Section : Where high temperatures and corrosive gases are present.
• Turbine Section : Subjected to high wear and thermal stress.
• Compressor Section : Requires protection against wear and corrosion.

The power generation sector is under constant pressure to produce clean and sustainable energy in an efficient and cost-effective manner. However, it faces challenges like high-temperature corrosion and erosion of critical components, especially due to aggressive gases produced during fuel combustion.

Critical components in the steel production process are subjected to extreme operating conditions such as high-temperature wear, abrasion, erosion, and galvanic corrosion, which can significantly impact their operational life.

The materials used in thermal spray coatings include ceramic, carbide, cermet, and composites, each selected based on the specific operating conditions they need to withstand.

Thermal Spray Coatings often outperform alternative surface treatments like Nitriding, Hard chrome plating, and PU coating, offering better protection against wear, corrosion, and high temperatures, thereby extending the life of the components.

Pump components can experience several types of wear, including abrasion, erosion, cavitation, and sliding wear. Abrasion and erosion are typically caused by abrasive particles in the medium being pumped. Sliding wear can occur even without abrasive particles due to unintended contact between rotating and stationary components.

The wear rates in pumps are often higher than expected because wear and corrosion can exacerbate each other. As pump components wear down, clearances between sealing surfaces increase and vane angles can change, leading to more vibration, potential leakage, and a decrease in pump efficiency over time.

Thermal spray coatings can be applied to various pump and valve components to improve wear and corrosion resistance. These coatings help increase the operational life of the equipment and reduce downtime costs by protecting components from the harsh conditions they face during operation.

Components that are most exposed to abrasive and corrosive media, such as impellers, shafts, and sealing surfaces, benefit the most from thermal spray coatings. These coatings help maintain the integrity and efficiency of the pump or valve assembly.

The long-term benefit is an extended operational life for the components, which translates into reduced maintenance needs, less frequent downtime, and lower overall operational costs. This is especially valuable in industries where continuous operation is critical.

The surfaces of Ball and Gate Valves, especially the sealing areas, wear out due to the abrasive, erosive, and corrosive nature of the media they control. Repeated valve operation and the presence of particles in the media contribute to this wear, leading to leakage and decreased efficiency.

Worn valves can compromise sealing, resulting in leaks and uncontrolled media flow. This can lead to sub-standard process quality, safety hazards, and increased maintenance costs due to frequent valve failures.

Thermal Spray Coatings enhance the wear and corrosion resistance of Ball and Gate Valves, increasing their operational life and performance. Coatings like tungsten carbide applied using robotic HP-HVOF processes create a dense, strong layer that protects against abrasion, erosion, and corrosion.

We offer coatings such as tungsten carbide for extreme wear resistance and Inconel or satellite weld overlays for high-temperature and corrosive conditions. These coatings are applied using advanced processes like HP-HVOF and PTAW, ensuring strong adhesion and optimal surface finish. Our coated valves are widely used in industries such as Oil & Gas (for subsea pipelines), Mining (handling metals like gold and copper), Paper and Pulp (managing slurries and steam), and Steam applications (in turbine drain systems).

Yes, we have in-house capabilities to provide custom-coated and finished Ball and Gate Valves according to your design and requirements, ensuring they meet the specific needs of your application.

The operational life of piston rods can be significantly improved by applying HVOF (High Velocity Oxy-Fuel) sprayed carbide and cermet coatings. These coatings provide excellent wear and corrosion resistance. When the coated piston rods are ground and super-finished to achieve a low coefficient of friction, they perform better under harsh conditions, extending their operational life.

Piston rods in air and gas compressors are constantly exposed to corrosive gases such as chlorine, hydrogen chloride, and hydrogen sulphide. Continuous operation under these harsh conditions leads to wear and corrosion, especially in the packaging seal areas, which can result in premature failures and unexpected breakdowns. In industries like Oil & Gas, Steel, and Chemicals, where compressors are critical to production, premature failure of piston rods can cause significant downtime. This unexpected downtime can lead to substantial financial losses due to halted production processes.

HVOF sprayed carbide and cermet coated piston rods offer several benefits, including superior wear and corrosion resistance. These coatings help reduce the friction on piston rods, leading to a longer operational life and reduced maintenance needs, which minimizes unexpected downtimes and associated financial losses.

Hydraulic Piston Rods are critical components in hydraulic cylinders, which are employed in various industrial applications such as dam gates, large valves, marine barges, dredger hulls, mining equipment, cranes, and excavators. They play a vital role in the operation of hydraulic systems by transferring the hydraulic pressure to mechanical energy.

Thermal Sprayed Hydraulic Piston Rods, especially those coated with KERADEX B02, are commonly used in industries such as mining, cranes, excavators, dams, and sluice doors, where high resistance to wear and corrosion is essential for maintaining system integrity and longevity.

Precision finishing of KERADEX B02 coatings is crucial as it ensures a smooth and hard surface on the outer diameter of the piston rod. This is important for proper sealing and minimizing friction with seal elements, which in turn enhances the operational life and performance of the hydraulic system.

Plastic extrusion is a continuous manufacturing process where raw thermoplastic material is melted and formed into a specific shape by forcing it through a die. The extrusion screw is crucial because it conveys the plastic, melts it, and forces it through the die. The screw's efficient operation is vital for consistent product quality and productivity. TRIBODEX™ coatings enhance the wear and corrosion resistance of extrusion screws. By applying advanced cermet-based coatings, these solutions extend the screw's operational life, reduce downtime, and improve overall productivity. The coatings provide superior hardness and durability compared to traditional Hard Chrome plating.

TRIBODEX™ DC coatings offer 6 to 10 times higher operational life compared to Hard Chrome plating. The finely distributed carbides in the metal matrix of TRIBODEX™ coatings provide excellent abrasion and corrosion resistance, ensuring better performance and longevity.