Metal Spray & Specialty Coatings

HVOF Metal Spraying & Specialty Coatings

“Metalizing” or metal spray:   HVOF metal spraying will yield higher bond strengths and denser coatings which means better coatings.  Each procedure for metal spraying has unique advantages over the others.  Let us guide you in choosing a metal sprayed coating.

Babbit Spraying Compressor Cross Head
babbitt metal spray can be used in bearings

babbitt spraying engine piston

Prime Machine utilizes the three major types of spray methods, including the recently- developed high-velocity oxy-fuel (HVOF) process.

The three types are; Flame or Arc Spray-and-Fuse, Plasma Spray, and HVOF metal spraying.

Wear Coating Compressor Rods Spraying Of Inside Diameters
HVOF metal spraying coatings of seal surface repair

High Velocity Oxygen Fueled HVOF metal spraying coating of tungsten carbide on shaft seal surface to restore the fit and function of shaft. The hard surface improves the life of seals by maintaining smooth surface for seal to ride.

wheel spindle HVOF sprayed using robot.

High velocity oxygen fueled HVOF metal spraying mine truck wheel spindle repair of bearing fit. Robot controls spraying parameters for coating

Sprayed materials include:

HVOF Metal spraying- Carbide Coatings

Materials/
Chemistry
Hardness Bond
Strength
Application Data
Tungsten
Carbide
Cobalt
WCCO
63-66 RC >10,000 PSI •Pump seals
•Rolls
•Jet engine parts
•Machinery wear parts
Chrome
Carbide
Nickel
Chrome
Cr3C2NiCr
 65 RC >10,000 PSI •Turbine inner nozzle supports
•Turbine exhaust struts
•Fuel rod mandrels
•Exhaust valves
Tungsten
Carbide
Chrome
WcCoCr
 64 RC >10,000 PSI •Pump shafts with corrosion

HVOF –  Metal & Alloy Coatings

Materials/
Chemistry
Hardness Bond
Strength
Application Data
Cobalt
Molybdenum
Chromium
CoMoCr
50-55 RC 9500 PSI •Very dense and well bonded
•Good for pump components, valve shafts and exhaust fan blades
•Excellent fretting wear
Iron
Chrome
Molybdenum
FeCrMo
53 Rb 7500 PSI •Excellent for corrosive and sliding wear below 1200°F
Nickel
Aluminum
NiAl
45 Rb 6000 PSI •Bond-coat for carbides and ceramics
•Coating offers wear and oxidation protection
Copper
Cu
60 Rb 4000 PSI •Exceptionally dense and machinable
•Restoration of worn and mis-machined copper and copper-alloy parts

HVOF – Ceramic Coatings

Materials/
Chemistry
Hardness Bond
Strength
Application Data
Aluminum
Oxide
AL203
68 RC 5000 PSI •Very Smooth, with high dielectric (600-900 V/Mil)

Plasma Spray – Ceramic Coatings

Materials/
Chemistry
Hardness Bond
Strength
Application Data
Aluminum
Oxide
Al2O3
RC-71 5000 PSI •Dielectric covering, textile parts
•Pump shaft (seal areas)
Chromium
Oxide
Cr2O3
RC-74 5000 PSI •Very hard, very high corrosion protection
•Sliding wear for chemical pump shaft wear
Aluminum
Oxide
Titanium
Dioxide
Al2O 3TiO2
RC-69 5000 PSI •Anti-static, cylinder liners
•Molds, sliding wear from fibers
•Resistant to acids and alkalis
•Many textile applications

Plasma Spray – Carbide Coatings

Materials/
Chemistry
Hardness Bond
Strength
Application  Data
Tungsten
Carbide
WCCo
60 RC 7,500 PSI •Machine wear
•Jet engine parts
•Sliding wear (metal parts)
Chrome
Carbide
Cr3C2NiCr
46 RC 5,000 PSI •Promotes extreme resistance to wear at high temperatures
•Good for hot gas and corrosion resistance
•Useful up to 1600°F
Tungsten
Carbide
Chrome
WCCoCr
50 RC  7,500 PSI •Improved oxidation and corrosion protection over WCCO
•Excellent low-temperature wear properties up to 900°F

Plasma Spray – Metal & Alloy Coatings

Materials/
Chemistry
Hardness Bond
Strength
Application  Data
Nickel
Aluminum
NiAl
45-55 RC 8,000 PSI •Highly resistant to oxidation and corrosion
•Very machinable
•Excellent bond-coat for ceramics
Copper
Nickel
Indium
CuNiIn
 75 Rb 3,500 PSI •Indium is renowned for its lubricating properties
•Outstanding resistance to motion wear such as fretting and galling
Molybdenum
Chromium
Silicon
Cobalt
MoCrSiCo
 45 RC 6,500 PSI •Coating exhibits outstanding resistance to wear and galling
•Very suitable for applications where lubrication is a problem

Plasma Spray – Thermal Barrier Coatings

Materials/
Chemistry
Hardness Bond
Strength
Application  Data
Magnesium
Zirconia
MgO2ZrO2
RC 31 2,600 PSI •Thermal barrier coatings for combustion applications
•Abrasive wear up to 1600°F
Zirconia
Titania
Yttria
ZrO2TiO2Y2O3
RC 55 5,000 PSI •Thermal barrier coating
•High temperature hardness
•Resitance to sulfidation, chlorinization and sodium hot corrosion

Arc Spray – Metal Coatings

Materials/
Chemistry
Hardness Bond
Strength
Application  Data
Aluminum
Al
Rb 35-75 4,350 PSI •Chemical and corrosion resistance
•Electrical conductivity •Aircraft approved
Copper
Cu
Rb 37 7,200 PSI •Extreme conductivity
•Copper reclamation
•Alternate to copper plating
•Decorative coatings
Nickel
Ni
Rb 58 4,100 PSI •Corrosion protection at high temperatures
•Excellent machined surfaces
•Aircraft approved
Tin
Sn
Rb 70 2,500 PSI •Sputtering targets
•Electrical contacts
•EMI/RFI shielding
Zinc
Zn
Rb 61-72 1,300 PSI •Excellent bonding to non-metallic surfaces
•Corrosion
•EMI/RFI Shielding

Arc Spray – Alloy Coatings

Materials/
Chemistry
Hardness Bond
Strength
Application  Data
Inconel
718
NiCrMo
RC 30 9,000 PSI •Aircraft engine dimensional restoration
•Acidic and hot gas corrosion resistant
Iron
Chrome
Aluminum
FeCrAl
Rb 88 7,000 PSI •Good for build-up
•Good machinability
•Excellent wear resistance
Nickel
AluminumNiAl
Rb 78 9,800 PSI •Bond Coat
•Oxidation/abrasion resistance at high temperatures
•Aircraft approved
420 SS
FeCrNiSi
Rb 40-45 8,000 PSI •Corrosion protection
•Dimensional restoration