Classification of the different metallising processes

Metallising by electrical discharge or gas

Arc spraying (AS)

This process consists of introducing two electrically conductive wires as like zinc or zinc-aluminium alloy into an electric arc spray gun. When these two wires come into contact, an electric arc forms which melts the wire. The melted wire is then sprayed using compressed air onto the surface to be metallised. Wires with finer diameter, generally 2.50mm max, are used for this type of spray gun.

Materials used:

  • Electricity conducting wires.

Fields of application:

  • steel structures as anti-corrosion protection: bridges, wind turbines, etc.;
  • power plants as anti-corrosion protection or protection against wear;
  • machine manufacture as protection against wear and repair of machine elements.

For more details: method and equipment

Plasma (APS, VPS, APSS)

A plasma torch is an apparatus where a gas is forced through a choked electric arc. This electric arc is established between an anode and a cathode which are cooled by water circulation. The cylindrical anode is pierced at its centre for receiving the cathode and letting the gas flow through. The gas injected this way around the cathode will flow across the electric arc where it is ionised and then sprayed as a plasma. This plasma has ultra-high temperature (up to 20,000 K) and ultra-high speed. The coating material introduced into this plasma will be sprayed at ultra-high speed onto the substrate.

Materials used in powder form:

  • pure metals;
  • alloys;
  • ceramic oxides;
  • materials containing nickel;
  • materials containing cobalt.

Fields of application:

  • aviation: turbine blades;
  • waste incineration plants: high-temperature piping;
  • medicine: implants;
  • machine manufacturing: pistons.

For more details: method and equipment

ISO 2063 Standard

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