Thermal Spray Equipment: A Guide to Advanced Coating Technology

Linde Advanced Material Technologies (Linde AMT), a global leader in innovative thermal spray coating equipment technologies, is dedicated to improving industrial productivity and component performance. Thermal spray equipment represents many of our advancements, offering diverse industries high-performance coating solutions that boost efficiency and durability, from manufacturing, applications, and optimizations of thermal spray technology, reflecting our expertise in facilitating better coatings through our thermal spray equipment.

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Understanding Thermal Spray Equipment Fundamentals

As a global leader in the thermal spray industry, Linde's TAFA® thermal spray coating systems are designed to apply high-performance coatings.

Thermal spray involves spraying heated or melted materials onto surfaces such as metals, ceramics, or carbides. It's an integral part of manufacturing and enhances component performance and durability in operating environments subject to wear, corrosion, and high temperatures.

While each process is unique in how it produces a thermal spray coating, each method has five main components in the thermal spray system:

1. A control console to manage gases, liquids, and electrical current
2. A spray torch that generates a hot gas stream to heat and propel coating materials
3. A feeding mechanism to deliver coating materials to the spray gun
4. Proper feedstock delivery speed for optimal melting (available in powder, wire, rod, or cord form)
5. A controlled atmospheric environment in the coating application area

Related: What is Thermal Spray?

Advanced Applications and Technology Solutions

Industrial Coating Applications

Thermal spray coating equipment is widely used across various industries. These systems enhance the surface properties of components, making them resistant to wear, corrosion, and temperature fluctuations. Our thermal spray systems use innovative materials and proprietary advanced coating technologies to boost industrial productivity and component performance.

Aerospace and Automotive

Thermal spray coatings are an essential resource for the aerospace and automotive sectors, demanding industries where reliability and durability are paramount. These sectors benefit from our high-end coating equipment and rely on our innovative thermal spray systems to enhance productivity, reduce downtime, and extend component life.

Energy

Thermal spray technology has also been significantly adopted in the energy sector. Our advanced coatings protect components against extreme heat, corrosion, and wear, ensuring reliable operation and sustainability in harsh environments.

Linde's TAFA® Thermal Spray Systems

We design and build thermal spray coating systems that deliver consistent results using your choice of materials and application methods. Our systems incorporate advanced control and monitoring technology to enhance, restore, and protect surfaces according to your specifications, backed by our ongoing support.

• Arc Spray Systems: TAFA® arc spray technology provides an optimal balance of dependability, flexibility, and cost-effectiveness. Our range of arc spray systems features customized solutions to your coating requirements. Whether you need push, pull, or advanced process modifications, we can configure the ideal system for your most challenging projects.
• High-Velocity Oxy Fuel (HVOF) Systems: Linde's TAFA® HVOF product line features two types of systems: liquid-fueled high-pressure/high velocity oxygen fuel (HP/HVOF®) and gaseous-fueled HVOF. The liquid-fueled systems create superior, highly compact coatings with outstanding production efficiency. In contrast, the gaseous-fueled systems combine user-friendly controls with proven safety features to deliver consistent, high-quality HVOF coatings.
• Plasma Spray Systems: Plasma spray operations demand reliable performance across all energy levels. Our TAFA® plasma spray systems deliver this consistency, from basic manual models with critical orifice control to advanced computerized systems featuring mass-flow control.
• Powder Feeders: Our TAFA® pressurized volumetric powder feeders precisely and consistently transfer powder material to thermal spray guns. These reliable units offer highly controlled results, ranging from simple open-loop RPM-controlled systems to sophisticated closed-loop weight-loss controlled feeders, meeting all your operational needs.
• Comprehensive Thermal Spray Cells: We provide all the necessary ancillary equipment for thermal spraying, such as acoustical enclosures, dust collection systems, part handling equipment, and suitable automation and integration.

Components of Thermal Spray Coating Equipment

Robust and efficient thermal spray systems comprise various key components. These include spray wires and a wide array of thermal spray equipment and spares. The compatibility of these components contributes to the optimality of the entire thermal spray system.

Spray Wires

Without the right coating material, even the highest-quality spray equipment can deliver low-quality coatings. Spray wires form a crucial component of our thermal spray systems, particularly in the arc spray process. Made of diverse materials suited for various applications, these wires are melted and atomized to create the desired coating on a substrate. Linde provides a wide variety of TAFA® wires, from traditional metal and metal alloy to complex cored wire compositions, for every arc spray application. Our wires are tested and analyzed to make sure they offer the proper tensile strength, hardness, and surface finish properties for thermal spraying. We also offer several sizes of level-layer wound spools and large dispensing containers for high-volume applications.

Thermal Spray Equipment: Spare Parts

Thermal spray systems include vital components like powder feeders, control systems, turnkey solutions, and replacement torch parts. These elements work together to ensure optimal coating performance. Linde supplies both TAFA® and GENIE™ brand thermal spray components, manufactured using cutting-edge technology and expert craftsmanship. With our extensive inventory of crucial spare parts, we help minimize downtime and maximize your operational productivity and profitability.

Maintenance and System Longevity

Effective maintenance is vital for optimizing the life and operation of thermal spray systems. Linde offers comprehensive maintenance services that ensure preventive upkeep, timely replacement of spare parts, and continuous system calibration. Thermal spray system longevity is our primary focus.

Learn about our thermal spray equipment maintenance services

FAQs

What are the key considerations when selecting thermal spray equipment for specific coating applications?
Selecting the appropriate equipment for a specific coating application requires careful consideration of several factors. These include the type of material to be coated, the operation's environmental conditions, the spray material itself, and the desired thickness and texture of the coating.

How can operators ensure optimum performance and quality in thermal spray processes through proper equipment maintenance?
Proper maintenance of spray equipment is essential for optimum performance and quality. Regular check-ups, cleaning, and replacing vital components when necessary are important to keep the machine in top shape. Appropriate protective equipment, such as welding safety equipment, abrasives, and other accessories, is also crucial in ensuring safety during routine maintenance.

What materials can be used in thermal spray?
Various materials, including metals, ceramics, polymers, and composites, can be used in thermal spray processes. Each offers unique properties like wear resistance, corrosion protection, and thermal insulation. Selection depends on the desired coating characteristics and application requirements.

What thicknesses are thermal spray coatings?
Thermal spray coatings can vary in thickness based on the application requirements. Typically, coatings range from a few microns to several millimeters. The coating material, process parameters, and desired performance characteristics determine the thickness. Coating thickness is vital in providing the coated components with the required protection and functional properties.