Thermal Spray Technology

Thermal Spray Services, Electric Arc Spray

Twin Wire Arc Spray

Plasma Electric Arc, Ceramics, Steel Industry

Ceramic Surfacing Using Plasma Electric Arc Process

What is Thermal Spray Technology?

Thermal spray technology involves different processes and techniques of applying a protective coating to the surface of parts and equipment exposed to harsh operating environments. Various materials including ceramics and metals are used in thermal spray technology and they can be applied to almost any type of metal.  These coatings are ideal for rebuilding worn parts and for providing protection against high temperatures, corrosion, wear, abrasion and chemicals.

Thermal spray coating companies work with a wide range of industries including power generation, steel, aerospace and paper. Thermal spray technology is highly versatile and is a cost-effective way to increase part life, save on costly repairs, and prevent loss of productivity resulting from equipment downtime.

How Are Thermal Spray Coatings Applied?

Materials including metals and ceramics are used to create a protective coating. They can appear in a variety of feed stock including powder and wire depending on the material and application process.

Most thermal spray processes involve the same equipment: a spray gun, spray materials and a carrier gas. To apply the coating, the material, either in wire or powder form, is transformed to a semi-molten state. Particles are then accelerated towards the surface through various gas velocity. As the micro particles hit the surface, the particles solidify to form the coating. For thermal spray coating materials that cannot withstand heat, cold spraying is an alternative that utilizes powder mixed with a carrier gas to form coatings on a substrate.

Thermal Spray Services Thermal Spray Capabilities Machining, Grinding & Finishing


What Processes Are Included in Thermal Spray Technology?

Thermal spray technology covers several different processes, each offering their own benefits. All can be used to rebuild worn parts or on new components to create a protective layer, but the methods used to apply the coatings produce different results.

Plasma Arc Spraying

Plasma electric arc spraying involves introducing powder into a heated plasma gas stream to create a high-density coating using a large array of materials. It provides a full range of protection and is commonly used for a large cross-section of industrial applications. Plasma electric arc spraying is a versatile solution for materials, including ceramics, where components require high temperature resistance, extreme wear resistance and inert chemical resistance.

High Velocity Processes (HVOF)

High velocity processes (HVOF) involve combining fuel and oxygen in a combustion chamber. The spray materials are then introduced to the powder and fed through a nozzle where it is accelerated onto the workpiece surface. HVOF creates a consistent, hard-particle surface with low porosity to provide high resistance against wear, corrosion and abrasion. 

Electric Wire Arc Spraying

Electric wire arc spraying is an economically efficient process that uses an arc to produce heat and provides one of the fastest coating rates. Instead of using an external heat source, two electrically opposed charged wires are fed together, creating an arc strike at the intersection and melting the wire. Compressed gas is then used to propel and spray the molten metal onto the part surface. The capability to produce thick build-up and higher bond strengths makes this thermal spray process ideal for dimensional repair.  Because of its cost-efficiency, electric wire arc spraying is also commonly used for high-volume application of coatings.

Cold Spraying

Cold spraying is a non-heated, high kinetic process that requires minimal surface preparation and provides high density oxide-free coatings. The low gas preheat temperatures and low nozzle exit temperatures significantly reduce the occurrence of high-temperature oxidation and other concerns associated with other thermal spray technology processes. The low temperatures make cold spraying suitable for heat-sensitive materials.

Thermal Spray Coating Provides Effective Solutions for Various Applications

The addition of thermal spray coating can be used for a range of materials including ceramics, metals, alloys and composites. ASB's thermal spray coating technology has been proven effective in a broad range of industries and applications including:

  • Power generation
  • Aerospace
  • Steel industry applications
  • Paper mill products
  • And more

Thermal spray technology is a versatile solution for protecting parts and equipment against high temperatures, corrosion and wear. When correctly applied by a thermal spray coating company, it can help reduce the frequency of maintenance and extend the life of your equipment.

  • Refurbishing worn components
  • Adding anti-corrosive properties to metal surfaces
  • Providing protection from oxidation
  • Preventing wear and abrasion on mechanical parts
  • Protecting components from heat and chemical exposure

We Provide Turnkey Solutions Using Thermal Spray Technology

ASB Industries Inc. is your number one source for complete, turnkey thermal spray coating solutions. We offer a thermal spray technology that is customizable to the needs of your unique application. We will work with you to develop the ideal thermal spray coating solution for your project’s unique challenges.

Our thermal spray coating services help extend the life of treated parts and components by shielding them from all types of wear and tear. No matter what physical, chemical, or environmental factors you’re up against, our thermal spray technology provides the protection your machinery and equipment need.

Whatever your thermal spray coating application may require, we have the experience, technology, and the know-how to deliver the ideal thermal spray coating solution. Our connections to material and equipment suppliers give us an understanding of both material composition advancements and equipment enhancements. This knowledge, in turn, enables us to improve production efficiencies for our thermal spray coating and cold spray processes.

Delivering Results Through Custom Spray Coating Solutions

For OEMs, second-tier parts manufacturers, and other industrial manufacturing businesses, we can create custom thermal spray coating solutions that improve the efficiency and extend the working life of the equipment these companies use every day.

Working within your requirements and observations, ASB Industries offers a comprehensive cost and benefit analysis for your thermal spray coating project. If we believe your current specification can be improved through our thermal spray technology, material, or process advancements, we will mutually discuss the potential improvement options.

Thermal Spray Technology & Specialized Sealing Treatments

To complement our thermal spray coating solutions, ASB offers a range of sealing treatments that are proven to enhance performance in molten metal, ultra-corrosive, and high temperature applications. These specialized sealers require distinct chemistries as well as advanced, closely controlled, post-coating heat treatments developed by our internal R&D team, and our international partners.

A prime example of a thermal spray technology that specializes in sealing expertise is our proprietary KarGen coatings.

  • KarGen coating thermal spray technology - Applied after thermal spray coating services and processing, these sealers are specifically engineered for treating furnace rolls for pickup resistant surfaces used in steel strip processing. As steel producers develop new high-strength steel chemistries, increased processing temperatures require better surface finishes. The nano-based sealers in our KarGen coatings offer superior flexibility for continuous processing demands.

Contact ASB Today to Learn More About Our Thermal Spray Coating Services 

Contact ASB Industries for more information on our thermal spray coating services or customizable thermal spray technology that will improve your equipment’s performance. Or, submit your project today for a free price quote.