Thermal Spraying Process
In applications, different individual thermal spraying processes do not compete directly with each other. Their specific process and coating properties complement each other well.
“Thermal spraying" is a term used to describe a variety of spraying methods. They are sub-divided according to:
• The type of spray material (wire, powder, rod, etc.),
• The mode of application (semi-mechanical, fully mechanical or automated), and
• The type of energy source (thermal or kinetic).
The exact classification is defined by DIN EN ISO 14917. It differentiates between:
• Thermal spraying using gaseous or liquid fuels,
• Thermal spraying by expansion of high pressure gases without combustion, and
• Thermal spraying by means of arc or gas discharge.
What it can do
On materials, thermal spraying can ...
• ... optimise, via protection against wear, fatigue and loss of creep strength, corrosion, ageing, abrasion, heat, electrical effects, and leaks,
• ... enable electrical conductivity, and
• ... support biocompatibility.
Where it is applied
Thermal spraying is used in a wide variety of industries. Some examples are:
• Aerospace,
• Construction,
• the automotive sector,
• Energy supply,
• Medical technology,
• the printing industry,
• Water, waste water and waste disposal,
• Textile and clothing manufacture,
• Food processing,
• Mining, and many others
Thermal spraying is a thermomechanical coating method used for new construction as well as repair work. Thermal spraying is flexible, which facilitates a range of possible solutions. Its low repair costs and relatively short downtimes provide serious advantages compared to other maintenance alternatives.
Cladding Processes
Conventional methods of cladding are:
- Gas welding,
- Manual metal arc welding,
- Gas-shielded metal-arc welding,
- Tungsten inert gas welding,
- Plasma arc welding,
- Submerged arc welding,
- Electroslag welding, and
- Laser cladding.
There are three basic types of welding coatings:
- Armouring (against abrasion)
- Plating (against corrosion)
- Buffer layer (for joining two components).
What it can do
Cladding can ...
• ... protect by coating against wear or corrosion and as a result, optimise a material.
• ... perfect or repair the geometry or contour of a part.
Cladding works for new constructs as well as repairs.
Where it is applied
Cladding is used in a wide variety of industries. As examples:
• The construction industry (power plant construction),
• The automotive sector,
• Structural and civil engineering,
• Power generation,
• Mining, etc.
Good examples of successfully welded protective layers can be found on excavator buckets or the impact-shielded areas of stone crushers that, thanks to cladding, can be protected against wear and corrosion in appropriate locations. In addition, potential "attackers" can also arise with crude oil and natural gas extraction in the form of sour gas or rock fragments passed along from the source, or else occur as corrosive chemicals generated in the primary circulation flow of a nuclear reactor.
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