Thermal Sprayed Surface Coatings
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COATING TYPE AND/OR COMPOSITION | BOND STRENGTH (psi)* | HARDNESS ** | POROSITY (average % volume) | COATING TEXTURE AND/OR SURFACE | MAXIMUM COATING THICKNES S | MAXIMUM OPERATING TEMPERATURE | COATING CHARACTERISTICS | TYPICAL APPLICATIONS |
HVOF (High Velocity Oxygen Fuel) Applied Coatings |
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TUNSTEN CARBIDE COBALT NICK | 12000 | 65 Rc | <1% | As Sprayed: 225-
300 Ground: 2-4 |
.025″ | 1000 F
540 C |
Highly resistant to abrasion, particle erosion, fretting, and corrosion with good impact resistance. Excellent surface finish. Hard Chrome Replacement. | Ball Valves, Pump Parts, Compressor Rods, Valve Parts, Screw Conveyors, Cutting Dies, Fan Blades, Cams, Hard Chrome Replacement on Hydraulic Cylinder Rods, Rudder Posts, for Marine, Pulp & Paper, Oil & Gas, Tobacco Industries, etc. |
TUNSTEN CARBIDE COBALT CHRO | 10000 | 68 Rc | <1% | As Sprayed: 325 Ground: 2-4 | .015″ | 850 F
440C |
Dense, hard, tough coating suited for sliding wear, erosion, impingement, abrasion and fretting wear. | Valve Components, Hig Wear Areas On Down Hole Equipment, Compressor Rods, Hydraulic Rods, ID Fans, Rolls Fof A Variety Of Industries. |
HIGH GRADE STAINLESS STEEL | >7900 | 29 Rc | <1% | Ground & Polished <2 | .060″ | 1000 F
540 C |
High bond strength, 316 stainless steel Ductile, machinable, low porosity, with good corrosion and wear resistance. | Exhaust Fans, Boiler Tubes, Food Processing Industry, Tobacco Industry, Corrosion and Wear Resistance for Rollers, Cylinders, etc. in Printing, Glass, Textile Industries, etc. |
CHROME CARBIDE NICKEL CHROM | >10000 | 55-65 Rc | <1.5% | As Sprayed: 225-
300 Ground: 2-4 |
.020″ | 1800 F
950 C |
Replacement coating for hard chrome. Resistant to abrasion, solid particle erosion, cavitation The NiCr matrix provides excellent corrosion resistance. | Nuclear Power Components, Compressor and Turbine Blade Coating for High Temperature Oxidation, Feed Screws, Pump Casings, Impellers, Plungers, Hydraulic Rods |
TUNSTEN CARBIDE CHROME | >10000 | 55-65 Rc | <1% | As Sprayed: 225-
300 Ground: 2-4 |
.020″ | 1000 F
540 C |
Replacement coating for hard chrome. Resistant to abrasion, solid particle erosion, cavitation, and fretting. Provides excellent corrosion resistance. | Marine Industry Components, Seal Liners, Hydraulic Rods, Steering Gear Rams, Rudder Posts, etc. |
CHROME CARBIDE TUNGSTEN CA | 7000 | 50 Rc | 5% | As Sprayed: 250-
325 Ground: 2-4 |
.020″ | 1500 F
815C |
Spheroidal, agglomerated and sintered powder wich generates coatings that provide high abrasion, sliding wear, and fretting protection. | Hard Chrome Replacement, Hydraulic Rods, Boiler Tubes, Pump Parts, etc. |
NICKEL CHROME BORON | >10000 | 55-60 Rc | <1% | As Sprayed: 300- 400 Ground: 2-4 | .020″ | 1000 F
540 C |
Coatings are dense, metallurgically hard and essentially devoid of oxides which are characteristic of most coatings. Wear resistant. Hard Chrome Replacement. | Piston Rings, Exhaust Fans, Forging Tools, Hydraulic Rods |
NICKEL CHROME BORON (Sprayed & Fused) |
Metalurgical | 55-60 Rc | 0% | Ground: 2-4 | .050″ | 1000 F
540 C |
Resistant to abrasion, solid particle erosion, cavitation, and fretting. Provides excellent corrosion resistance. | Metalurgical Bonding Provides Excellent Wear Resistance For Pump Components, Rotors & Shafts Operating In Extremely Harsh Environments. |
Twin Electric Arc-Wire Applied Coatings |
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ALUMINUM CHROME IRON WIRE | >7000 | 35-40 Rc | <1% | Machined: Excellent Ground: Good | .150″ | >1000 F
540 C |
General purpose wire used to restore parts having most common steels as the substrate. | Mis-Machined Parts, Shafts, Bearing Fit Areas, Rolls, Journals, And Build-Up In Areas Of Deep Wear Prior To The HVOF Application Of A Carbide Topcoat. |
HIGH GRADE STAINLESS STEEL WIRE | 4000 | 40 Rc | NA | Machined: Excellent Ground: Good | .0200″ | >1000 F
540 C |
General Purpose Austhenitic Stainless Steel Wire. | Bearing Seats, Pistons, Rams, Mishmachined Parts, etc. |
COATING TYPE AND/OR COMPOSITION | BOND STRENGTH (psi)* | HARDNESS ** | POROSITY (average % volume) | COATING TEXTURE AND/OR SURFACE TEXTURE | MAXIMUM COATING THICKNES S | MAXIMUM OPERATING TEMPERATURE | COATING CHARACTERISTICS | TYPICAL APPLICATIONS |
ALUMINUM BRONZE ALLOY WIRE | NA
3500 w/Bond Coat |
35 Rc | 5% | Machined: Good | .100″ | Low | Produces dense, low-shrink, high tensile strength coatings which are easy to machine. Excellent general purpose, wearresistant coating. | Pump Impellers, Bronze Castings, etc. |
MOLYBDENUM COMPOSITE BOND WIRE | 2500 | 40 Rc | Fair | Ground: Fair | .030″ | 650 F
340 C |
Self-bonding, High Bond Strength. Produce hard, long wearing coatings. Excellent load bearing capacity when subjected to low temp conditions. |
Ideal For Building Up Journals For Use With Bronze Bearings, etc. |
NICKEL ALUMINUM COMPOSITE BOND WIRE | 4000 | 22 Rc | NA | As-Sprayed: Course Ground: Fair | .007″ | 1380F
750 C |
Self-bonding composite only used as bond coat prior to application of further coating layers. Produces dense coating of high bond strength. | Underlay bond coat forcarbon steels, hardened alloy steels, stainless steels, aluminum, nickel, cast iron, titanium, etc. Not self-bonding to copper based allys or tungsten. |
PURE ALUMINUM WIRE | 1000 | 60 Rb | 5-15% | Machined: Good | .200″ | 1100 F
590 C |
Excellent resistance to corrosion therefore used extensively in marine applications. Also resistant to sulfur dioxide. | Pump Casings, Boiler Tubes, Structural Components such as Water Tanks, Bridges, Communication Towers, Wind Turnbine Towers, and Offshore Oil Platforms, etc. Shipboard U.S. Navy Applications Aare Extensive. |
BABBITT WIRE | NA | 58 Rc | 2-5% | Machined: Excellent | .200″ | Low | High grade tin-based babbitt | Babbitt Bearing Applications |
MONEL WIRE | NA | 50 Rc | 3-5% | Machined: Good | .050″ | 1000 F
540 C |
Copper Nickel alloy wire, producing dense coatings suitable for machine element components subject to corrosion. | Gland Casings, Tailshafts, Hydraulic Pump Parts, Shafts, Seat Rings, etc. |
Plasma Applied Coatings |
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ALUMINA TITANIA COMPOSITE | 2250 | 63 Rc | <1% | As-Sprayed: 250- 300
Ground: 10-20 |
.025″ | 1000 F
540 C |
Very dense, hard, low porosity coating with good corrosion resistance to alkalies. Good non-conductive electrical properties. | Bearing Surfaces On Rolls, Shafts, And Rotors. Pump Components, Exhaust Fans, Non-Conductive Coating On Submarine Cable Connectors |
CHROME OXIDE | 5500 | 60-70 Rc | <4% | As-Sprayed: 200- 400
Ground: 20-50 Superfinished: 4 |
.030″ | 1000 F
540 C |
Excellent self-mating and anti-galling properties. Dense, hard, and insoluble in acids, alkalis, and alcohol. Low temp abrasion resistance (<1000 F). | Rolls Coatings For Textile, Printing, Pulp & Paper Industries, etc. Pump Seals, Exhaust Fans, Wear Rings, Pump Sleeves, Ball Valves, Seal Liners, etc. |
ZIRCONIUM OXIDE | 5500 | 49 Rc | 3-6% | As-Sprayed: 250- 400
Ground: 15 |
.050″ | 3000 F
1850 C |
Dense coating resistant to thermal shock and partical erosion at high temps. Useful as thermal barrier coating. | High Temperature Turbine Parts, Engine Parts, etc. |
YTTRIA STABILIZED ZIRCONIUM | 5000 | 60-70 Rc | Varies greatly depending on
production method |
As-Sprayed: 250- 400
Ground: 15 |
.080″ | 3000 F
1850 C |
Dense coating resistant to thermal shock and partical erosion at high temps. Useful as thermal barrier coating. |
Reacing Engine Components, Fuel Cells, Jet Engine Components, Gas Turbines, Mssile Diffusers, etc. |
*BOND STRENGTH Bond Strength Values indicate stress required to break bond (in PSI) between the coating and the substrate
HARDNESS VALUES** Hardness Values indicated are shown in the Rockwell Scale. NOTE: There are literally hundreds of thermal spray coating materials available on the market today. We work with many of the major coating material suppliers and the coatings included here are a sample of the ones we most commonly use. In addition to the standard coatings available, we also have proprietary coating materials manufactured for us for specific Customer applications. Give us a call today to discuss your coating application! COATING TEXTURE/SURFACE FINISH Texture / Surface Finish Values may vary depending on the surface finishing equipment available. Thermal Spray Solutions, Inc. 1105 International Plaza, Suite B Chesapeake, VA 23323 Phone: (757) 673-2468 Fax: (757) 673-3128 26d.fd4.myftpupload.com |