WORLD WIDE THERMAL SPRAY SERVICESTM

 

Empire Metal Spray, Inc.®

 

 

 

 

 

 

 

 

Flame Spray

Arc Spray

Spray & Fuse

Rokide® Ceramic Spray

Plasma Spray

HVOF Spray

Welding

Flame Spray - a Thermal Spray Process

 

This technology uses an oxygen and acetylene flame in conjunction with compressed air to atomize pure or alloyed wire metals into a fine spray of particles.  These sprayed particles are then projected with a flame spray gun/assembly onto a previously prepared object surface which builds up to form a solid metal coating.  Equipment components, gases, compressed air, and wire materials are gaged and monitored to produce optimal coatings.  With the use of this low heat source and compressed air, parts maintain low temperatures and do not warp or distort.

 

The Flame Spray process produces coatings of aluminum, babbitt, bronze, copper, molybdenum, monel, nickel, carbon/stainless steels, and many more materials.

 

-See Coating Materials Section For Additional Information-

 

 

 

Electric Twin Arc Spray - a Thermal Spray Process

 

This technology uses electricity and two material feed wires which intersect to a point forming an electric arc, melting the metal within a gas spray stream of compressed air.  These sprayed particles are then projected with an arc spray gun/assembly onto a previously prepared object surface which builds up to form a solid metal coating.  Equipment components, compressed air, and wire materials are all automatically gaged and monitored to produce optimal coatings.  As is the case with Flame Spraying, relatively low temperatures are maintained and part distortion does not occur unlike other processes such as welding.

 

The Electric Twin Arc Spray process produces coatings of aluminum, bronze, copper, molybdenum, monel, nicked, carbon/stainless steels, and many more materials.

 

-See Coating Materials Section For Additional Information-

 

 

 

Thermal Spray & Fuse  - a Thermal Spray Process

 

This technology uses an oxygen and acetylene flame to atomize self-fluxing alloy metal powders into a fine spray of particles.

 

During the 1st phase , these sprayed particles are projected with a thermal spray powder gun/assembly onto a previously prepared object surface which builds up to form a solid metal coating.

 

The second phase uses an additional heat source such as an oxygen/acetylene torch, induction heating, or furnace fusing to remelt and fuse the coating essentially into a porous free, dense coating.  Equipment components, gases, compressed air, and powder materials are gaged and monitored to produce optimal coatings.  High temperatures achieved during this second phase should be taken into account during part production planning.  Distortion of part sizes and chemistry is possible.  Additional machine or grind finishing may be required.

 

These coatings range in hardness from Rc 30 to Rc 62.  They are highly resistant to wear, abrasion, corrosion, and oxidation, outperforming hardened metals and stainless steels.

 

The Thermal Spray & Fuse process produces alloy coatings of nickel chromium and tungsten carbide in nickel & cobalt based matrix's.

 

-See Coating Materials Section For Additional Information-

Rokide® Ceramic Spray - a Thermal Spray Process

 

This technology uses an oxygen and acetylene flame in conjunction with compressed air to melt all types of ceramic rods into fine droplet particles.  These sprayed particles are then projected with a Rokide® gun/assembly onto a previously prepared object surface which builds up to form a solid ceramic coating.  Equipment components, gases, compressed air, and rod materials are gaged and monitored to produce optimal coatings.  With the use of this low heat source and compressed air, parts maintain relatively low temperatures and do not warp or distort.

 

The Rokide® Spray process produces coatings of aluminum oxide, chromium oxide, zirconium oxide, and many more ceramic materials.

 

-See Coating Materials Section For Additional Information-

Metco®  9M

 

High Energy Plasma Spray - a Thermal Spray Process

 

This technology uses an electric arc and a high temperature plasma flame controllable to a range well above the melting point of any known substance.  As the plasma gas passes through the arc in the gun it disassociates, then partially ionizes, absorbing high temperature heat from the arc.  This is then passed onto the powder material that is introduced into the plasma stream.  These sprayed particles are projected with a high energy plasma spray gun/assembly at high velocities onto a previously prepared object surface which builds up to form a solid coating.  Equipment components, gases, compressed air, and powder materials are automatically gaged and monitored to produce optimal coatings.  Even though high temperatures result for material melting to occur, this heat dissipates during the particle projection process.  As a result, part distortion is minimized and essentially non existent.

 

The High Energy Plasma Spray process produces coatings of metals, stainless steels, carbides, ceramics, and cermets.

 

-See Coating Materials Section For Additional Information-

 

 

 

Praxair®  JP-8000

 

High Pressure HVOF Spray (Hyper Velocity Oxygen Fuel)

-a Thermal Spray Process

 

This technology uses a combination of liquid kerosene and oxygen to produce a supersonic (Mach 2+) flame jet.  Using a high pressure HVOF spray gun/assembly (fully automated), digitally metered powder materials are introduced, heated, and accelerated at very high velocities onto a previously prepared object surface.  This material builds up to form a solid coating on the substrate.  Equipment components, gases, compressed air, and powder materials are automatically gaged and digitally monitored to produce optimal coatings.  Higher pressures (up to 120 psi) can be achieved producing higher velocities, hardnesses, densities, and better overall coating integrity.

 

Multi-axis manipulators and robotic technology used in conjunction with HVOF allow precise programed control of all the elements and equipment in this coating process.  Superior uniformity and quality with less waste and time result in better coating products at lower costs and prices.

 

The High Pressure HVOF Spray process produces coatings of metals and carbides.

 

-See Coating Materials Section For Additional Information-

 

Welding

 

Empire Metal Spray, Inc.® uses three different welding processes to produce hard, dense, and porous free coatings.

 

1.

MIG (Metal Inert Gas) also known as

GMAW (Gas metal Arc Welding) also known as

MAG (Metal Active Gas)

 

2.

TIG (Tungsten Inert Gas) also known as

GTAW (Gas Tungsten Arc Welding)

 

3.

Stick Welding also known as

SMAW (Shielded Metal Arc Welding) also known as

MMA or MMAW (Manual Metal Arc Welding) or

Flux Shielded Arc Welding

A complete range of thermal spray and weld processes with related coatings

 are available  for selection, dependent on the application and service requirements.

 

 

Coatings

 

Machining - Grinding - Manufacturing - Thermal Spray Coatings

 

Empire Metal Spray, Inc.®

3755 S. Jason St.  Englewood, Colorado  80110  USA

Phone:  303 762 8744    800 397 8746    Fax:  303 762 8505

sales@empire-spray.com    www.empiremetalspray.com

 

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