Thermal Spray Coatings & Materials

Thermal Sprayed Surface Coatings
Technical Specifications and Applications
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
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
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
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