Thermal spraying is a technology that enhances the surfaces of different solid materials. With the help of this process, you can apply coatings to a varied range of solid materials, and act as resistance to abrasion, corrosion, cavitation, heat, and erosion. It is also used to make materials more lubricating, resistant to low and high friction and chemicals. This method is used across different industries and has shown an enormous capacity to extend the life of different solid materials through the techniques that have been tested and tried techniques that are used for re-engineering and repairing.

Getting the facts

All the processes of thermal spraying involve the projection of small particles that have been softened. These particles are sprayed on to surfaces that are cleaned and prepared to form a coating that is consistent. The action of kinetic and thermal energy causes these particles to flatten on the surface on to which it is sprayed to produce a coating which is cohesive. The coating that forms on the material is in the form of different layers. It is a cold process that can be used for spraying on different materials of varied thicknesses.

Combustion wire thermal spray

This is another process involving in which molten metal is sprayed on to a surface to provide a fine coating. The material is melted in the form of a wire in a flame which is oxy-acetylene in most of the cases and then atomized with the help of compressed air to form a fine spray. When carried out appropriately, this is also referred to as the cold process as the temperature of the substrate can be kept low during the processing to avoid metallurgical changes, prevent distortion in the substrate material and other damages.

Spraying materials

When it comes to Thermal Spray Wire related to the process of combustion, the following materials are used for spraying on the surfaces.

• Inconel wire is used for bond coatings, creating resistance, used for piston rings, in journals and synchromesh cones, and other applications that are hard-bearing.
• For cathodic coatings on the surface of the steel, is used for preventing corrosion.
• High-quality chromium steel is used for all those applications that resistance to wear and tear.
• For the bearing applications
• To prevent wear and tear followed by corrosion, stainless steel, monel, and nickel is used.
• For oxidation and heat resistance, aluminum and nickel are sprayed on the surface of the materials.

Advantages of combustion thermal spray wire process

• It requires little capital investment which helps in increasing the profitability in different industries.
• The process is natural and can be operated flexibly.
• The deposition of the coating is rich, and it shows high efficiency.
• The wire form of the combustion spray process is cheaper than the powdered variant.
• With high purity molybdenum coatings, it is undoubtedly one of the best methods for wear resistance.
• It is possible to get the in-built pre-heating facility
• It can be used even in those areas that do not require electric supply.