News & Insights

The Australian Mining Review Feature

Insights and advantages of our process

We have wide range of coating facilities at Arc Spray Engineering which includes Arc Spray, HVOF, APS and Laser Cladding. The coating process can be selected based on the application, service environment and materials.

Please see the tables below for insights and advantages of the various processes from our years of experience in this field

Arc SprayHVOFAPSLaser Cladding
Low energy consumption reduces the cost of the process: Arc spray only uses compressed air and electricityHigher splat flattening ratio and better lamella packingMost versatile and flexible thermal spray systemLow dilution and high purity cladding can be achieved due to highly concentrated and focused laser beam on a small area
Low heating of the substrate leads to low material distortionReduces porosity level with low degree of fragmentationWide range of materials such as most metals, ceramics and alloys onto many different substrate materials such as plastics, glass, metals, ceramics and composite materialsSingle pass cladding is sufficient to achieve a desired chemistry, microstructure and hardness due to low dilution
Porosity can be minimized with optimized process parametersLess carbide decomposition and minimal oxidation due to high droplet impact velocity and relatively colder particle stream Broad range of powder particle sizes can be used 5-100µmHighly concentrated and focused laser beam leads to low heat affected zone which retains the substrate microstructure and mechanical properties after cladding process
Custom coating alloy can be produced easily through feeding different wire materialsFormation of mixed columnar and equiaxed grains in the microstructure reduce the propagation of cracksThe high temperature of a plasma jet makes it particularly suitable for spraying coatings of refractory metals and ceramics, including ZrO2, B4C and tungstenMinimal risk of dimensional deviation or distortion after cladding makes this process promising to achieve finish dimensions of the components with the close tolerance
Sacrificial corrosion coating can be made uniformly on the surface of steel Low fraction of defects (porosity/cracks/ fragmentation), less carbide decomposition and better interlamellar cohesion leads to high hardnessMetallurgical bonding between substrate and laser clad layer improves the bond strength, abrasion resistance and withstands high direct impact load
Fewer health and safety risks due to simple process - No harmful gas, no high energy and no fine powderUnlikely to tear off, fracture and spalling of laser clad layer by any external physical load or stress due the complete metallurgical bonding
Significantly low porosity prevents the penetration of highly reactive corrosive liquids/gases and protect the substrate materials from any catastrophic failure
As-mixed elemental powders (rather than pre-alloyed) can be used in laser cladding to achieve desired chemical composition of any desired alloys (in-situ alloying)

Properties of Arc Spray coating materials from our experience

Coating MaterialsBond typePorosity (%)Bond Strength (MPa)Suitable Service Environment
95Ni-5AlMechanical Bond0.367Bond coating
420SSMechanical Bond0.366High strength, high elongation, low shrinkage, and little tendency to crack on the material
CopperMechanical Bond0.518Antibacterial copper coating on Stainless Steel
AluminiumMechanical Bond6.330Protection of steels from aqueous corrosion
Aluminium-BronzeMechanical Bond547Reduce deterioration, wear, and marine corrosion on ship propellers, pumps, shafts, pipes, and bushings
Pure ZincMechanical Bond526Galvanizing iron and steel against corrosion

Properties of HVOF and Plasma Spray coating materials from our experience

Costing MaterialsBond TypePorosity (%)Hardness (HV)Suitable Service Environment
Cr3C2-NiCrMechanical bond1.501000Wear and oxidation resistance at high temperatures. Excellent sliding and abrasion resistance, Erosion / Corrosion and good cavitation corrosion resistance
Cr2O3Mechanical Bond6.61200When corrosion resistance is required in addition to abrasion resistance
Cr2O3-TiO2Mechanical Bond3.7950High Corrosion, Abrasion and Galling resistance
88WC-12CoMechanical Bond11200Wear, cavitation erosion (CE), and corrosion
88WC-12NiMechanical Bond11200Excellent corrosion, abrasion and sliding wear resistance

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