Thermal spraying is a coating process in which a coating material in wire or powder form is melted or fused by applying thermal energy and accelerated by a gas flow in the direction of a component surface to be coated. In contrast to welding, the base material is not melted. Adhesion is mainly achieved by mechanical interlocking in superposition with induced shrinkage stresses. Residual stresses and metallurgical interactions as well as diffusion processes and van der Waals forces also influence the layer adhesion.
The substrate must be roughened in a previous work step so that a form fit can occur between the spray particles and the substrate. The particles then cling to the generated roughness peaks. Roughening is usually done by sandblasting, but can also be done by high-pressure water jets or mechanically (turning, milling, grinding).
Eutalloy RW 12112 metal powder mixture
2.218,50 £ 443,70 £ / kgfor wear-resistant coatings
MetaCeram 28010 Ceramic powder
780,39 £ 650,33 £ / kgCeramic powder for wear- and corrosio...
RotoTec HardTec 19400 metalic powder
306,07 £ 226,72 £ / kgfor adhesion-resistant coatings
MetaCeram 28030 Ceramic powder
292,61 £ 243,84 £ / kgCeramic powder for wear- and corrosio...
RotoTec FrixTec 19850 metal powder
497,04 £ 368,18 £ / kgfor adhesion-resistant coatings
RotoTec LubroTec 19985 Metal powder
397,69 £ 294,59 £ / kgfor machinable coatings
SuperJet -S- Eutalloy powder flame sprayers
1.683,13 £Powder flame spraying
CastoDyn DS 8000 flame spraying system
5.340,85 £Advanced flame spraying system
Eutalloy 15999 Metal powder
322,89 £ 461,27 £ / kgfor wear-resistant coatings
Eutalloy PE 8418 metal powder
347 £ 69,40 £ / kgfor coatings and repairs of glass molds
Eutalloy 10911 Metal powder mixture
1.308,44 £ 261,69 £ / kgfor wear-resistant coatings
Eutalloy BoroTec 10009 metal powder
261,87 £ 374,10 £ / kgfor abrasion-resistant coatings
Eutalloy NiTec 10224 metal powder
268,40 £ 383,43 £ / kgfor cast iron materials
Eutalloy TungTec 10112 Metal powder mixture
320,33 £ 457,61 £ / kgfor extremely wear-resistant coatings
Eutalloy UltrAloy 10611 Metal powder mixture
319,50 £ 456,43 £ / kgfor wear and heat-resistant coatings
Eutalloy RW 12496 Metal powder
1.144,46 £ 286,12 £ / kgfor hot wear resistant coatings
Eutalloy RW 12999 metal powder mixture
722,50 £ 144,50 £ / kgfor highly wear-resistant coatings
ProXon 21021 metal powder
379,61 £ 303,69 £ / kgfor primer coats
ProXon 21031 Metal powder
650,39 £ 260,16 £ / kgfor adhesion-resistant coatings
ProXon 21071 metal powder
331,92 £ 265,54 £ / kgfor adhesion-resistant coatings
MetaCeram 28060 Ceramic powder
201,61 £ 168,01 £ / kgCeramic powder for wear-resistant coa...
MetaCeram 28085 Ceramic powder
600,94 £ 120,19 £ / kgCeramic powder for high-temperature c...
MetaCeram 28095 metal powder
554,19 £for adhesion-resistant coatings
Eutalloy ChromTec 10680 metal powder
247,83 £ 354,04 £ / kgfor wear-resistant coatings
Eutalloy 8426 PE powder
466,66 £ 93,33 £ / kgSelf fluxing nickel-base alloy
Eutalloy PE 8422 Self fluxing nickel-base alloy
375,33 £ 75,07 £ / kgSelf-fluxing nickel-base alloy
Castolin Eutectic products are highly regarded for quality and reliability by experts in various industries worldwide. Our range includes spray guns, welding equipment, wire feeders and accessories for efficient and cost-effective projects.
Thermal spray is a breakthrough technology that is redefining surface coating and refurbishment processes in various sectors. A material is heated at high temperature, melted and sprayed onto a surface. There it solidifies and creates a versatile coating with properties such as wear and corrosion resistance as well as thermal insulation.
This innovative method allows various materials to be applied to a target surface. The result is a robust, protective layer that increases the performance and service life of components. The heat source in thermal spraying melts or softens the coating material, which is then applied via a spray gun.
The heat source can be a flame, an electric arc or a plasma jet, depending on the specific spraying process. As soon as the molten or partially molten particles reach the surface, they harden and form a strongly adhesive protective layer.
Thermal spraying is very flexible and can work with different materials, for example metals, ceramics or plastics. These materials can be tailored to meet specific requirements such as corrosion resistance, wear resistance, thermal insulation, electrical conductivity or even aesthetic improvements.
Thanks to the wide range of coating materials, thermal spraying is suitable for many applications. It is used in industries such as aerospace, automotive, energy and manufacturing.
One of the main advantages of thermal spraying is the ability to create coatings of exceptional thickness. This ability allows for the restoration of worn or damaged components by building up the coating to its original dimensions. In addition, customized coatings can be produced with specific thicknesses that offer enhanced protection and performance characteristics.
Thermal spray coatings are known for their exceptional bond strength and durability. The rapid impact of molten particles ensures strong mechanical adhesion. As a result, the coatings are extremely temperature and environmentally resistant and can withstand demanding conditions. These coatings effectively protect against wear, corrosion and erosion, and increase the service life of components.
Thermal spraying is flexible and offers various methods such as flame spraying, arc spraying, plasma spraying and HVOF (high velocity oxygen fuel spraying).
Each method has its advantages. The choice depends on things like the material of the coating, the type of substrate, the thickness of the coating and the desired result.
This versatility allows precise control of the coating process and ensures optimal results for a wide range of applications.
In addition, thermally sprayed coatings can be post-treated or finished to further improve their properties. Additional treatments such as grinding, polishing or milling can be used for specific surfaces, dimensional accuracy or appearance.
The variety of customization and post-treatment options makes thermal coatings extremely flexible for individual application needs.