Surface characteristics of materials play a vital role in determining the performance of the component. Metallizing is the process of applying any metal on to virtually any base metal. A metal in the form of wire is pulled into the rear of the gun by an automatic feed mechanism powered by a self contained compressed air driven turbine.
The wire is fed through the gun into a fuel/oxygen frame.
A stream of compressed air restricts the flame and blasts the molten tip of the wire producing a fine metal spray.
The correct ratio of gas pressure & flow parameters with controlled rate of spraying and maintaining optimum distances from the work piece ensures highly atomized metal spray resulting in perfect homogenous fine spray. The thickness achievable is upto a few mm.
Advantages
- Compared to traditional surface modification processes, thermal spraying offers greater thickness capability, no part size restrictions and it produces minimal noxious waste.
- High processing temperatures allow deposition of many high melting point materials onto a relatively cold substrate.
- On site application is possible.
- Metallizing is relevant to any size.
- Apart from building material metallizing also act as a thermal protection.
Application areas
- Printing Industries: Inking Rollers, Printing Roll.
- Automotive Parts: Crankshaft, camshaft, connecting rod, reclamation worn out parts.
- Chemical / Petrochemical: Screw rods
Some of our proved applications of metallizing
| Component | Coating Material | Coating Thickness | Purpose |
| Printing Roller | Copper | 1 mm | Inking Roller |
| Printing Roller | Copper & Stainless Steel | 1 mm | Inking & Process Roller |
| 5 start threading | Copper | Upto 2mm | Ink transfer |
| Crank Shaft | SS | 2 mm | |
| Screw Shaft | Phosphor Bronze | Upto 2 mm | Wear resistance |
Types of Coating Materials
Types of coating powders which are used in D-Gun Coating*
| Oxide based | Carbide based | Metals and alloys |
| Alumina Titania 13% | Tungsten carbide-Cobalt | Iron Boron |
| Alumina Titania 40% | Tungsten Carbide - Cobalt Chromium | Iron Alumina |
| Alumina Titania 3% | Tungsten Carbide - Nickel | Nickel Chromium |
| Alumina (99%) | Chromium carbide - Nickel Chromium | Nickel Aluminium |
| Stainless steel, Copper etc | ||
| Colmonoy |
Types of coating wires by metallizing
Copper, Bronze, Brass, Aluminium, Stainless steel 304, Stainless Steel 316
Coating Thickness Achievable
| Powder | Thickness acheivable |
| Oxides & Ceramics | 20 to 500 microns |
| Carbides | 50 to 1000 microns |
| Metals & Alloys | Upto few mm |
The industries that use thermal spraying
| Aerospace | Machine shops | Power plants |
| Agriculture | Marine | Pulp and paper |
| Automative | Medical | Printing |
| Computers | Military | Steel mills |
| Electronics | Oil gas and exploration | Textile |