Thermal Spray Coating Service in Indonesia

Thermal spray coating is a general term for a group of processes that use a torch or gun to heat metals, ceramics, cermet, and some polymeric materials in the form of powders, wires, or rods to near or slightly above their melting point. 

The resulting droplets of molten or near-molten material are accelerated in the gas stream and projected onto the surface to be coated. It is affected and attached to the surface of the surface, clinging to coagulation, obsessed together and stuck together. The total thickness is usually achieved in several passes of the coating unit. The thermal injection method is a cold injection method with much less thermal stress, residual stress and other defects.

Thermal spray coatings are widely used in industries. Surface treatment can improve the performance of materials used by adding properties such as abrasion and heat resistance, conductivity, insulation, and heat shielding and dissipation. A variety of applications include thermal resistors, thermal and electrical conductors or resistors, electromagnetic shielding, and dimensional restoration for radiation amplification or retardation. 

Thermal spray coatings are used in a wide range of applications in industries such as aerospace, agriculture, automotive, precious metals, mining, paper, oil and gas, chemical and plastics, and biomedical. Indonesia as developing country has cooperated with foreign manufactures in industrial production, and some thermal spray coating technique is applied in Indonesia.

1. Wire spray coating

The Firewire system is the oldest form of warrior application. The basic principle of operation is that the system uses oxygen and a fuel gas (such as acetylene, propane, MAP or natural gas) to generate the heat needed to melt the raw wire. Wires are usually fixed on wire holders and spools or separate spools. 

Oxygen and fuel gases are passed through the gun via an air or electric mechanism, where they combine and ignite to create a heated area. A heated zone is used to melt the wire and propel the molten droplet using a limited flow of compressed air. The heated zone operates in 4600-4800 degrees Fahrenheit and the particle velocity is approximately 800 feet per second.

2. HVOF (arc spray and plasma)

HVOF is a thermal injection system using the combustion of a gas such as hydrogen or kerosene. Fuel and oxygen are mixed and consumed in the combustion zone if the proper combustion regime and pressure are observed. This process produces a very fast speed used to track particles at a supersonic speed until it collides with the substrate. One of the basic rules of the spray is that the higher the firing pressure, the higher the gas speed, the higher the particle speed and the higher the quality of the coverage.

One main advantage of the high speed of the system is the density of very high coating and low oxide content. The low oxide is partially due to the particle velocity spending less time in the heat source and partially due to the lower flame temperature of the heat source compared to the alternative process.

The resulting layer of material will have mechanical properties that exceed the base metal material. Thermal Spray Coating is commonly used to repair engine components to make them resistant to abrasive wear, fretting and galling, sliding wear and particle erosion. Can be used on compressor machines, pumps, steel rollers, bearing bores, engines, drive shafts, dies and others. 

Thermal Spray Coating is the best choice to save on machine maintenance costs because it extends component life. 

The types of Coating Materials are: - Aluminum - Zinc - Cooper - Stainless - Ceramic Oxide - Tungsten Carbide - Chrome Steel - Babbit - Nickel Scope of metal spray - Pree Inspection for visual and dimension and run out check - Welding scratch area - Machining ( under cutting) area to be coated - Cleaning & grid blasting process, - Metal Spray Process, - Machining to standard size - Final inspections submit report.

3. powder flame spray

The principle of polymer flame spray (FSA) usage was originally derived from metal flame spraying technology. Coatings have a greater impact on decorative properties and are limited by the type of polymer which is used. Spray is a general definition emphasizing the function of a coating. The method which is most commonly used in industry is the polymer powder material method, such as:

  • Fluidized bed
  • Electrostatic application
  • Jet thermal application

There are unique advantages and disadvantages that these methods are effective. Based on the geometric parameters, the design, the technological characteristics and the future working environment of the parts and closed products. 

The only thing that holds all these elements together is the heat treatment required to form a permanent adhesive bond between the primer and the polymer. Fluidized bed and electrostatic application have complex operations and special cabins, baths and ovens. 

Therefore, the main limitations of their use relate to durability and oversized products. In this case, thermal spraying, the only cheap and simple method, can simultaneously form a polymer coating.

4. Electric arc spray

Electric arc spraying is one of the oldest and most effective thermal spray coating processes. Developed in the early 20th century, electric arc spraying uses a rectifier to ignite two wires that produce a heat/energy source that uses nitrogen as fuel. This arc creates an economically efficient spray process to produce effective results with little heat transfer to the workpiece. Electric arc wire spraying also produces a spray at a higher spray rate than other thermal spray processes, producing one of the fastest coating rates of all coating methods.

Arc spray coating is very cost effective and is commonly used for the application of metal alloys such as pure aluminium, carbon steel, copper and stainless steel along with high temperature alloys. Arc spraying also allows adjustments to achieve different coating textures. Coating service and machinery companies in Indonesia apply for repair and surface protection (Surface Repair & Protection) for materials Chrome Steel, Stainless Steel, Titanium, Zinc, Ultra Copper, Aluminium, Babit. Examples of components:
  • Heavy Equipment Components such as: Spindle, Wheel, Hub, Final drive housing, Final drive shaft etc.
  • Light Vehicle Components (LV) such as: Blanking piece, Clutch Housing, Cage bearing, etc.
  • Rotating Equipment such as: Pump shaft, Casing pump

5. Plasma Arc Thermal Spraying

Plasma guns consist of a water-cooled copper anode and a tungsten cathode. A plasma gas, usually argon, nitrogen, hydrogen or helium, flows around the cathode and through a narrow nozzle, the anode. Plasma is initiated by a high voltage discharge that creates localized ionization and a conduction path that forms a direct current arc between the cathode and anode. The resistive heat of the arc causes the gas to reach extreme temperatures and dissociate to form a plasma. Plasma puts vinemhemia as free or neutral plasma or neutral plasma. Unlike the plasma arc cover, it extends to the location of the arc surface. 

After the plasma has stabilized and is ready for atomization, an electric arc is passed through the nozzle without blocking the anode at the nearest end of the nozzle. This spring stretch is caused by thermal pinching. The cold gas around the nozzle surface of the non-conductive water-cooled anode narrows the plasma arc, increasing its temperature and velocity. The powder is usually transmitted to a sealed outdoor powder gate and is generally installed near the release of Anodoah.

All in all Thermal spray coating service has already served in Indonesia. Many coating service and machinery companies offer coating service that can be used in metal based production manufacture for broad sector industry. 

For instance PT TOCALO SURFACE TEHCNOLOGY INDONESIA served thermal spray coating in any fields such as semiconductor, steel, medical care, energy, transport equipment, industrial machinery, paper making, petrochemistry, resin or film, building, food, and cutting tools. 

TOCALO always develops thermal spray coating technology for manufacture and machinery services.