In the case of thermal spraying, no adhesive joining is made, as is normally common during welding. At a process distance of several centimetres from the surface of the workpiece, the spray gun is situated. In it, melting drops are generated by means of a sprayer using energy and are then accelerated via kinetic energy onto the workpiece surface. There, rapid cooling occurs and the droplets solidify. With proper surface pre-treatment, the individual droplets can interlock and form a continuous layer structure.
There are different spraying methods, and both arc spraying and flame spraying use wire as the consumable. These methods operate at relatively low particle velocities and with high deposition rates and easy handling, so investment costs are much cheaper than is the case with powder processing methods, such as HVOF spraying.
Through the design and optimised powder composition, there is the possibility of influencing coating properties through the consumable. To this end, we have established an application centre where cored wires can be optimised for the specific requirements of thermal spraying. The technical features of the application centre also enables the execution of sample coatings and technology testing.