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Monthly Archives: June 2017



Component Reclamation Via Thermal Spray Processes

One of the many reasons that people choose to utilise thermal spray processes is thethermal-spraying reclamation and refurbishment of components that are worn or damaged and no longer viable in their current state. However rather than opting for an expensive replacement part, many components can be returned to a state even better than new when treated with one of the many thermal spray coating processes.

So what are thermal spray coatings?

Thermal spray coatings are the process by which one material (the substrate) has a coating applied to it (which can be made up of a number of different materials). This coating is applied by the process of heating the coating material up until it becomes molten and then spraying this onto the substrate. The coating material then solidifies upon impact with the substrate bonding with it on a molecular level and forming a very tough and durable coating.

How can this be used for component reclamation?

Wear and tear of components is a common side effect of many manufacturing (and other) processes. However often these components are expensive and/or difficult to replace. In these instances, many of these components can quickly and easily be returned to full working order by simply applying an strong, tough and durable thermal spray coating. Coatings can be applied to cover the entire component or in some cases may be applied to just the worn area.

In many cases worn or damaged components can actually be made better than their original state by the application of a thermal spray coating. For example, if the component is especially susceptible to wear it may be possible to coat it with a different material that is much stronger and more durable than the original. This would then result in the component lasting for longer and thus significantly reduced downtime for your business.

Even surprisingly delicate components can be reclaimed via the application of a thermal spray coating, as even though the name suggests that the coating is very hot, in some types of thermal spraying the substrate actually stays at an ambient temperature and so any metallurgical changes that could weaken the substrate if it was exposed to too high a heat is avoided.

To find out more about our expert component reclamation services, contact IRS Ltd today.


Published Date: 30th June 2017
Category: Thermal Spray Systems



Arc Spray Coating Systems

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Of the many different type of thermal spray coatings that are available arc spray coatings are one of the most popular. See below for our summary of the arc spray process and then contact us to find out more about our full range of thermal spray coatings.

What is an Arc Spray Coating?

Arc spray coatings are a form of thermal spray coatings. In this process a pair of electronically conductive wires is melted by means of an electric arc which is passed between them. One wire is given a positive electrical charge and the other is given a negative charge. This forms an electric arc between them which causes the wires to become molten. A stream of compressed air is then passed through the molten material, propelling it towards the surface of the material that is to be coated (the substrate). When the tiny particles of molten material hit the substrate they bond with the surface forming a coating.

Advantages of Arc Spray Coatings

  • When carried out correctly this is known as a ‘cold process’ as the temperature of the substrate can be kept relatively cool compared to the temperature of the molten coating material. This means that more delicate substrate materials can be coated whilst avoiding damage, distortion and metallurgical changes This is particularly useful when spraying sensitive substrates such as capacitors and similar electronic components.
  • Arc spray coatings have the highest deposition density of all of the thermal spray processes, with deposition rates of 15kg/hr or higher being able to be achieved.
  • The density of arc spray coatings tends to give them a much higher strength and resilience to wear and other environmental factors.
  • The power input required for arc spray coatings is much lower than other thermal spray processes at around 5-10 kW (compared to up to 50kW for plasma spraying). This makes the process much cheaper to run and these savings can then be passed onto the customer.

Disadvantages of Arc Spray Coatings

  • This process can only be used to spray electronically conductive material that can be sourced in wire form. A different process would be required to create cement or ceramic coatings.
  • Although it is cheaper than many other forms of thermal spray coating, arc spraying can result in a lower quality coating than methods such as plasma or HVOF.
  • This is one of the messier thermal spray processes, producing a large amount of dust and fumes.

To find out more about arc spray coating and how it can be beneficial to your business, contact the experts at IRS Ltd today.


Published Date: 10th June 2017
Category: Thermal Spray Systems