Flame Spray - Spray & Fuse

The Spray and Fuse method begins with the deposition of a powder coating material onto the substrate using a Thermal Spray gun (typically Combustion Spray or HVOF). The gun propels the powder at high velocity onto the surface, where it forms a dense, adherent layer. This initial coating provides excellent adhesion and coverage.

After the thermal spraying stage, the coated substrate undergoes a controlled heating process known as fusion. Heat is carefully applied to the surface with a vacuum heat treatment or acetylene heat gun, causing the coating particles to melt and fuse together. This fusion stage improves the density, integrity and mechanical properties of the coating, providing exceptional bond strength and resistance to wear and corrosion.p>

The resulting coating exhibits excellent resistance to abrasion, erosion and chemical attack, making it ideal for demanding environments such as power generation and oil and gas. Additionally, the Spray and Fuse technique can be used to repair damaged or worn components, extending their life and reducing downtime.

1. Coatings for Corrosion Protection: Spray and Fuse coatings are ideal for protecting components exposed to harsh operating conditions, such as those found in the petrochemical and renewable energy industries. Post-spray fusion ensures that the coating is free of porosity, providing an impenetrable barrier against chemical and atmospheric corrosion.
2. Anti-Wear Coatings: These coatings are designed to withstand high mechanical stresses, such as erosion and abrasion, which often cause damage to metal components. The density and structural integrity of the cast coating provide long-lasting protection, reducing mechanical deterioration.
3. Coatings for Repair and Recovery: The Spray and Fuse process can be used to repair and regenerate components that have already been worn or damaged, restoring their original functionality without having to replace the entire piece. This not only extends the useful life of the components, but significantly reduces maintenance and replacement costs.

1. Improved Bond Strength: The fusion process significantly improves the bond strength between the coating and the substrate. The molten particles fuse together, creating a metallurgical bond that improves adhesion and minimizes the risk of delamination or chipping of the coating.
2. Superior Coating Integrity: The fusion stage ensures that the coating material is fully fused, resulting in a dense and homogeneous coating structure. This leads to improved coating integrity, reducing the chances of porosity or voids in the coating.
3. Increased Wear and Corrosion Resistance: Dense, fully fused coatings exhibit excellent resistance to wear, erosion and corrosion. This makes them highly effective in protecting surfaces subjected to harsh operating conditions, extending component life and reducing maintenance costs.
4. Application Versatility: Spray and Fuse can be applied to components of various sizes and geometries, ensuring high performance even on complex and difficult-to-coate surfaces.