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Ceramic Coatings and Coated Components

What is Thermal Spray Coating?

A coating is produced by a process in which molten or semi-molten particles are applied by impact onto a substrate. The impacting molten particles rapidly solidify on the substrate to form a coating.  This process is called a “cold process” (relative to the substrate material being coated) as the substrate temperature can be kept low during processing avoiding damage, metallurgical changes and distortion to the substrate material.

Process:

        Schematic View of Detonation Process

Thermal spray coating involves heating a material, in powder or wire form, to a molten or semi-molten state.  The material is propelled using a stream of gas or compressed air to deposit it, creating a surface structure on a given substrate.  The coating material may consist of a single element, but is often an alloy or composite ceramic with unique physical properties that are only achievable through the thermal spray process.

Thermal spray coatings can be the most cost-effective means of protecting substrate surfaces from wear or corrosion.  Other primary uses of thermally sprayed coatings include dimensional restoration, maintaining precise clearances, and modifying thermal and electrical properties.

Commonly Used Ceramic Coating Materials

• Grey Alumina
• Titanium Dioxide
• White Alumina
• Chromium Oxide
• Alumina – Titania Composite
• Chromium Oxide Silica Composite
• Zirconia
• Zirconium Oxide Composite
• Magnesium Zirconate
• Yttria Stabilized Zirconia

Properties Of Thermal Spray Coatings

COATING TYPE MAX. COATING THICKNESS POSSIBLE MAX. COATING HARDNESS POSSIBLE
Metals & Alloys 20 microns to a few mm 60 HRC
Ceramics 50 microns to 1000 microns 72 HRC
Carbides 20 to 500 microns 72 HRC

Features and Benefits:

• Excellent bond strength of the coatings
• Very dense coatings. Porosity less than 1%
• Higher thickness coatings easily possible
• Higher productivity
• Better coating characteristics in terms of hardness, wear & corrosion resistance
• Versatile process, ensuring wide range of coatings
• Can be easily automated
• Low substrate temperature enables spraying of precision components
• Less downtime

Special Properties Provided By Thermally Sprayed Coatings:

• Enhances Tribological (Wear Resistant) Characteristics
• Increases Corrosion Resistance
• Boosts Heat & Oxidation Resistance
• Alters Electrical Conductivity or Resistivity
• Make the material Abradable or Abrasive, depending on the need

Apart from coatings, we can provide coated components, designed to your specifications or prints. Please contact us for more information.

Click Here to Download our Product Catalogue for Ceramic Coatings
(PDF Format)