Flame Powder Spraying

In this process the spray material is fed in powder form through the gun using a transport gas injecting it centrally into a burning gas/oxygen mixture, where it is melted and delivered onto the substrate.

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Benefits

Micro porous lamellar structure
Relatively high degree of oxidation in the coating
Moderate tensile strength
Good compressive strength
Low elongation properties
Versatile and with a wide choice of materials
Relatively inexpensive thermal spraying process
Transportable process, spraying on location is possible

Features of fused coating

Metallurgical bond with the substrate
Resistant to line and point loads
Low resistance to impact loads
Homogeneous and closed structure

Applications

Sealing moving surfaces to prevent seals from leaking
Improvement of wear resistance and chemical protection of ball valves
Boiler walls of incinerators against high-temperature erosion and chemical degradation
Repairs and dimension corrections of worn drive shafts and bearing seatings with nickel-based alloys

Overview

Because nickel-based and cobalt-based meltable alloys and ceramic materials cannot be produced in wire form powder spraying was developed in 1956. Over the years powder spraying has been enhanced to include many other types of spraying powders. The way the powder spraying system works is similar to that of a wire spraying system.

Process properties

Material Form: Powder
Thermal energy source: by combustion of a fuel and oxygen
Process fuel: propane, hydrogen, acetylene
Process temperature: < 4,000 ºC
Spray particle speed: < 50 m/s

Typical coatings

Fused alloys NiCrBSi (Fusing, Self-fluxing)
Nickel-based alloys
Various stainless steel alloys
Cermets, carbides (hard metals)
Ceramic coatings (oxides)
Abradable coatings (abradables such as nickel graphite, AlSi polyester)