From an inferior material to optimized quality.
The production between costs and efficiency. In order to achieve a satisfying result, numerous industrial companies often have to manage a balancing act. The example of components and parts makes it particularly obvious. Since elements with an inferior material quality are frequently used due to cost reasons, several losses in terms of resilience, efficiency, and durability have to be accepted. But theres something to be done about that.
The task is evident. The components features have to be improved accordingly. Especially with regard to wear resistance and corrosion protection. The art of transforming a low-price part into a high-class product can be found in a customized surface treatment.
A resistant surface finish
To that end, those parts of the components exposed to wear are partially coated with carbides, ceramics, or metals using professional treatments. The choice of material is precisely adjusted to individual practical requirements. A high-tech finish extremely resistant to different damaging influences is thus developed. This also includes thermal, abrasive, and chemical resistance. Furthermore, some coating systems are biocompatible or electrically insulating.
Convincing cost reasons
Up-to-date coatings have not only proved successful in many sectors due to their application-related advantages. Cost aspects play an important role as well. While the susceptibility to wear of the treated components considerably decreases, performance and durability increase. For the companies, this results in extended service lives, reduced material consumption, higher productivity, improved process dependability, and lower maintenance efforts. Altogether, this leads to significant savings rapidly turning to account.
Perfectly coated in any case
The range of coatings is so huge by now, so that there is always an ideal solution for each application. As for instance reliable sealing systems in the fittings industry. Highly wear-resistant alloys, for example with tungsten carbide, became widely favoured since they attain prime values in terms of strain related to temperature, pressure, abrasion, and flow velocity.
Thermal spraying as preferred procedure
When it comes to optimizing large and heavy components by means of an extremely resilient coating, thermal spraying is an approved and ideal procedure. This process can be explained in a simple way: Small particles of the coating material are heated and accelerated in a sprayer. When temperature and velocity reach a sufficiently high level, the actual spraying process starts. On the surface of the component, the ejected particles create a smooth layer, which firmly unites with the surface and then it exactly features the properties requested by the user.
In contrast to common thermal spraying, the process of high velocity oxygen fuel is conducted in a high-speed mode, in which the accelerated process gas reaches supersonic velocities of more than 2,000 m/s. The velocity of the jet particles increases adequately to up to 800 m/s. By using low thermal but high kinetic energy, high velocity oxygen fuel offers excellent adherence of the coating without any considerable strain of the surface material. So this universal application technique is suited for all market-based materials.ochgeschwindigkeits-Flammspritzen eineH
Due to the virtually unlimited range of additives that may be combined with different basic materials, it is generally possible to find the perfect wear protection without any difficulties. The thickness of the layer ranges from 0.3 to 0.8 mm. Post-processing steps like lathing, honing, or lapping are easily possible. The new surface is convincing in all aspects for all practical purposes. Wear-resistant, thermally stable, diffusing, and thus highly adherent as well as corrosion-resistant against alkaline, acidic, and aqueous solutions.
“For us, thermal spraying techniques belong to the best suited methods for multiply increasing wear protection and for permanently optimizing production processes”, tells Heinz-Achim Kordt, Head of Design at the tungsten carbide manufacturer DURIT from Wuppertal. “We expanded our process technology and we invested in a new laser cladding system. So we are able to use metal or ceramic powders for creating wear-resistant protective coats in a specialized fusing process.”