Flame spraying is a thermal spray process that creates quality coatings using heat to melt materials that are usually in powder, ceramic rod or wire form. This type of thermal spray method is cost effective and one of the simplest ways to deposit coatings onto a substrate to provide impact resistance and protection from wear and tear.
The flame spraying process is fueled by a heat source that is created by a chemical reaction between a fuel of combustion and oxygen to create a stream of gas. The thermal spray material is then put into the flame in the form of a wire and compressed air is used to atomise the molten particles before propelling them onto the substrate. If you use a powder flame spray, the powder particles are softened by the flame before they are coated by the flame gases and accelerated through the nozzle.
Widely used as a cost effective method of protecting components and structures from damage and corrosion, flame spraying is used on a variety of different substrates. When equipment or a structure is required to have a high resistance, flame spraying is used to apply metallic and ceramic coatings so they are suitable for the environment they are being used in.
Flame spraying will is not as costly as many other forms of spraying due to the nature of the process and the finished quality of the coating.
With lower dust and fume levels than plasma and HVOF spraying, flame spraying can be used without a spray booth and also has lower noise levels.
Due to the nature of manual flame spraying, it is easier to coat equipment and components with complex geometry.
Compared to other thermal spray processes, flame spraying is made from a more simple design making it easier to use and it is suitable for manual use without the need for mechanised manipulators.
The coatings achieved by flame spraying are of a lower quality than those by other thermal spraying processes, however this is fine for environments which are less demanding. The coatings may have higher oxide levels for metal deposits, higher porosity and a lower bond strength.
Like most thermal spraying processes, flame spraying requires line of sight to the surface to coat. This means it is difficult to coat restructured surface areas or inner surfaces with a smaller diameter.
If you would like to find out more about flame spraying or the other quality coatings we provide for you and your business operations, please don’t hesitate to get in touch. Here at IRS, we are fully committed to providing durability and high performance through our range of applications.
Precision grinding is a precise manufacturing process used across a diverse range of sectors, providing an efficient way to complete the fabrication and finishing of metal parts with very close and tight tolerances.
There are a number of different precision grinding techniques that can be adopted in order to achieve desired affects including cylindrical grinding and surface grinding. And, although this process is mostly carried out in factories, many companies are also happy to perform precision grinding off site too for added convenience.
These processes use a specialist spinning wheel that has been made of bonded abrasive particles in order to successfully remove a vast range of materials from the object that is being re-surfaced. The technique, which is right for the part that you are working on, will depend on its individual specification requirements.
With this in mind, it is also crucial that the technician also uses the correct tools in order to optimise results at every stage of the process. This is because there are a number of different tools that should be used based on the shape, size and texture of the part being worked on.
It’s mostly tiny metal parts such as the components found in many modern electronic devices that require precision grinding.
However, there are also a number of larger parts that also require precision grinding and these include parts that are commonly used within aerospace instruments, medical devices, bladed implements, as well as a number of different scientific instruments.
The majority of precision grinding projects can be adapted to accommodate the exact specification of a wide range of different parts.
Of course, there are also a number alternatives to precision grinding, which can also be used to accommodate the needs of the applications mentioned above however, these tend not to be as cost effective or precise.
Offering a virtually unrivalled service in overhaul, reclamation, specialist overlay and reverses engineering ﬁelds, here at IRS Surfacing Technologies Ltd, we specialise in providing a complete range of in-house thermal fringe technology.
We provide high quality, cost-effective solutions to premature and severe wear problems in the Aerospace, Offshore, Chemical and Manufacturing Industries.
For further information about any of our services, please do not hesitate to contact us using our website or calling directly. Our professional and helpful team is always on hand to answer any of your questions.
For more detail regarding our Precision Grinding Services please Contact Us.
This time last week our college Paul Molland married the love of his life, Debbie!
All of the IRS team would like to congratulate them both and wish them both many happy years together as husband and wife !!!
IRS have had a great start to 2018, signing some major contracts with both our regular customers and also new.
One being an UK specialist train’s operator who use good old classic steam trains to tour the UK.
IRS has a long standing history of helping to restore parts for historic locomotives, classic cars and vintage vehicle enthusiasts.
IRS is always happy to help in keeping these beauties up and running!
Everyone at IRS would like to welcome and introduce, our new Office Administrator Lisa Jones.
I have recently joined the workshop administrative team here at IRS Surfacing Technologies and I am looking forward to contributing my part and effort to continue with the excellent services all the staff at IRS offer to their customers. I will also be delighted to welcome new customers and help with any queries, so don’t hesitate to get in touch!
I come to IRS with 10 years of administrative experience through working alongside a huge team at HM Revenue and Customs, so hopefully through the knowledge and skills I have gained over the years, I will become an asset to the company….I am sure Mr Rob Berry will let me know if not!!
I look forward to speaking and meeting all IRS customers and would just like to thank everyone for being so welcoming!”
Thermal Spray Systems is a popular technology used to improve and enhance the surface of a solid material, restoring it to its best or improving it. The process is designed to add many benefits and it can help protect against: wear, cavitation, corrosion, abrasion, heat and erosion. It is used in many industries to further enhance the quality of finished work and can extend the life of components of many different machines from vehicles to factory equipment.
The process of thermal spraying involves the spread of a thermal spray coating onto the chosen surface. It involves the projection of particles onto the fully clean and prepare surface and a combination of thermal and kinetic energies leads to these particles flattening and spreading on the surface, joining together and creating the full, cover-all coating.
Thermal spray coatings are used for a variety of applications in industry. They provide a wide range of functions and are often used to treat aeroplanes to protect them from extremes of temperature and the elements. They are also used to protect buildings from environmental conditions such as rain and humidity. Thermal spray coatings are also widely used in the automotive industry, to enhance longevity of vehicles and bring them back to their best.
From a more technical perspective thermal coatings may be used specifically for:
This type of coating provides excellent corrosion protection and involves applying a metal coating which is cathodic to the base. For example, applying a nickel alloy coating to a steel base would be considered a cathodic coating. It provides a strong, protective barrier and is recommended as a thicker coating.
Thermal spaying is an established choice for surfacing metal parts in industry and in vehicles. It can increase the lifespan of a component or improve its engineering performance. Thermal spray coatings are usually applied to elements which have been worn or corroded such as bearings or printing rolls.
In industries such as electronic packaging and the automotive and aerospace industries ceramic dielectric coating is a common choice. Dieletric coatings are usually pure aluminium oxide and they are sprayed at an extremely high density, allowing them to withstand thousands of volts, as is necessary in industries which involve significant volumes of live electricity.
Thermal spray coatings are a commonplace industrial technology which many businesses can benefit from, enhancing the quality of their equipment and ensuring their end products are finished to the highest standard.
For further details of our services please contact us.
PTA (Plasma Transferred Arc ) Process that can produce welds using powders instead of just wires. This give you limitless opportunity’s for picking something that will work instead of that’s all you can have!!! I haven’t said anything about the amazing delusion in this post. Give us a call and we will be happy to discuss more in-depth!!!!!!!!!!!!!