Thermal spraying

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Comparison of Thermal Spray Process Characteristics

Property		Flame Powder Spray	HVOF	Arc	Plasma (APS)	Cold spray	Detonation
Gase		Acetylene, propane, H₂, ethene	Propane, H₂, ethene	Air, N₂, Ar	Ar, N₂, H₂, He	Ar, He, N₂	Acetylene, O₂, N₂
Coating Materials		All	Metals Carbides	Metals	Oxides Metals	Ductile metals	All
Flame Temperature	[°C]	3160	2950	4000	< 20000	< 300	3160
Deposition Rate	[kg/h]	3 – 6	2 – 8	8 – 20	4 – 8	2 – 15	3 – 6
Particle velocity	[m/s]	< 50	< 700	ca. 150	< 450	< 1200	< 1000
Porosity	[%]	3 – 10	< 2	3 – 10	2 – 5	< 1	< 1
Adhesive tensile strength	[MPa]	14 – 21	48 – 62	28 – 41	21 – 34	50 – 70	70 – 100
Coating thickness range	[mm]	0.05 – 2.0	0.05 – 2.5	0.1 – 2.5	0.4 – 2.5	0,05 – 10	0.05 – 0.5
Hardness	[HRC]	< 35	< 45	< 40	< 40	< 70	< 70

Detonation Spraying

Advantages

Materials processed

Metals: copper, nickel, molybdenum, iron, others
Alloys: steels, nichrome, bronze, others
Oxides: aluminum oxide, chromium oxide, zirconium oxide, titanium oxide, others
Cermets: metal–ceramic composites with tungsten, chromium, and titanium carbides

The system coats complex geometries, including non‑standard shapes. The process is fully computer‑controlled for high process reliability and quality control.

Process cycle

– Gasgemisch wird ins Geschoß zugeführt (1,2,3)
– Beschichtungsmaterial (Pulver) wird ins Rohr eingebracht (4)
– Gasgemisch wird gezündet (5)
– Explosionsenergie schleudert das Gas Pulver Gemisch mit hoher Geschwindigkeit aus dem Rohr (6)
– Die Pulverteilchen werden beim Aufprall auf das Werkstück mit der Materialoberfläche verschmolzen und es entsteht eine Beschichtung mit einer Stärke bis 10 Mikron (7)
– Beschichtungsdicke wird je nach Anzahl der Schüsse entsprechend erhöht.

Typical applications

Aerospace
Medical devices
Mechanical engineering

Atmospheric Plasma Spraying (APS)

We apply APS coatings to production parts.

How it works

A non-transferred DC arc in a water-cooled cathode–anode torch generates the plasma jet; process gases form the plume.
Powder feedstock is injected, melted in the jet, and propelled to the substrate to build dense, adherent layers.
Jet temperatures reach tens of thousands of °C, enabling ceramics and high-melting alloys.

Typical applications

Aerospace
Medical devices
Mechanical engineering

High Velocity Oxygen Fuel (HVOF)

We apply HVOF to extend component life. Fuel and oxygen combust in a chamber and expand through a converging–diverging nozzle to form a high-velocity jet.

Powder feedstock is injected, heated, and driven at supersonic particle velocities to build dense, low-porosity coatings with high bond strength.

Talk to our engineers about material selection and finish requirements.

Flame Spraying

Builds wear- and corrosion-resistant coatings or restores dimensions on steel and non-ferrous parts.

Wire or powder feedstock is melted in an oxy-fuel flame; compressed air and combustion gases atomize and propel molten droplets onto a prepared surface, where they solidify into a lamellar coating. Fuels include acetylene, propane, or hydrogen.