HVAF technology emerges as the clear frontrunner in sustainable and ethical coating solutions, outpacing traditional Hard Chrome plating.
For decades, the industry has grappled with the environmental and health challenges posed by conventional methods. Traditional processes often rely on toxic chemicals, emit harmful substances and deplete valuable resources. These issues pose risks to worker health, the environment and regulatory compliance, driving the need for cleaner technologies.
Offering a superior and sustainable solution that significantly reduces environmental impact while enhancing worker safety, HVAF is paving the way for a more ethical future in high-performance coating applications.
The Problem with Hard Chrome
In the past, hard chrome plating has been the go-to solution for wear-resistant coatings. However, the environmental and health implications have proven to be severe.
Environmental hazards
Hard chrome plating uses hexavalent chromium, a known carcinogen that can contaminate soil and water. This toxic substance persists in the environment, posing long-term risks to ecosystems and human health through bioaccumulation in the food chain.
Health risks to workers
Workers in hard chrome plating facilities face potential exposure to chromium mist and fumes, which can cause respiratory issues, skin irritation and increased cancer risk. Long-term exposure may lead to chronic health problems, including lung and nasal cancers.
Regulatory pressures and compliance issues
Stringent regulations and compliance requirements, like The National Industrial Chemicals Notification and Assessment Scheme (NICNAS) and Safe Work Australia, are tightening controls with hexavalent chromium use. Companies face increasing pressure to find alternatives, with non-compliance potentially resulting in significant penalties and operational restrictions under the Work Health and Safety (WHS) laws and environmental protection regulations.
The Sustainable Option: HVAF
HVAF technology is becoming the superior solution for sustainability in the coating industry. This advanced thermal spray process uses compressed air and fuel gases to propel chrome carbide particles at high velocities, creating dense, wear-resistant coatings without the environmental baggage of hard chrome.
The environmental advantages
Lower Emissions
HVAF produces significantly fewer emissions compared to hard chrome plating, making it a more environmentally friendly option. Unlike hard chrome plating, which involves hazardous chemicals such as hexavalent chromium, HVAF primarily emits water vapor and carbon dioxide. This reduction in harmful emissions drastically decreases air and water pollution. Additionally, the process results in minimal particulate matter, further contributing to cleaner production practices.
Reduced Waste
The HVAF process is highly efficient due to less overspray and material waste during application. Any waste produced by HVAF is typically non-hazardous and easier to dispose of or recycle compared to the sludge generated by chrome plating. This efficient use of materials not only minimises waste but also supports sustainable manufacturing practices.
Energy Efficiency
HVAF operates at lower temperatures than many other thermal spray processes, leading to significant energy savings. The faster application speed of HVAF means less energy is consumed per coated part. Researchers have found that HVAF can reduce energy consumption by up to 30-50% compared to traditional plating methods. This energy efficiency, combined with its lower emissions and reduced waste, positions HVAF as a more sustainable and environmentally responsible coating technology.
Improved Safety at Work
The benefits of HVAF extend beyond environmental considerations.
Importantly, worker safety is dramatically improved with HVAF. By eliminating the need for hazardous chemicals like chromic acid, the risk of respiratory issues, chemical burns, and long-term health problems is significantly reduced. As a result, this not only creates a safer working environment but also leads to improved job satisfaction and reduced absenteeism.
Ethical Considerations for Business
As industry leaders, we have a responsibility to minimise our environmental impact and prioritise worker health and safety. In essence, adopting HVAF technology isn’t just about compliance or cost-saving – it’s about contributing to a more sustainable industry and safeguarding the well-being of our workforce and communities.
By transitioning to HVAF, companies demonstrate a commitment to ethical business practices and environmental stewardship. Consequently, this can enhance brand reputation, attract environmentally conscious customers and position businesses at the forefront of sustainable innovation in surface engineering.
Performance Considerations
While the environmental and social benefits of HVAF are compelling, the performance advantages are equally impressive. In fact, HVAF chrome carbide coatings outperform traditional hard chrome in several key areas:
1. Superior bond strength: HVAF coatings form a stronger mechanical bond with the substrate, thus reducing the risk of delamination and flaking.
2. Thicker coating capability: HVAF can apply coatings up to 10 times thicker than hard chrome, thereby enhancing durability and allowing for effective restoration of severely worn parts.
3. Faster processing: HVAF achieves deposition rates up to 5 times higher than chrome plating, therefore improving productivity and reducing energy consumption per part.
4. Improved wear and corrosion resistance: The denser structure and lower porosity of HVAF coatings provide superior protection against wear and corrosion, potentially doubling the service life of components.
HVAF technology is a clear winner as a sustainable and ethical coating solution.
Although the initial investment in HVAF equipment may be higher, the long-term benefits – including reduced operational costs, and improved worker safety and compliance – far outweigh the upfront expenses.
For 60 years we have been at the forefront of surface engineering, and we have the power to drive positive change. By embracing HVAF technology, we can lead the charge towards a more sustainable, ethical and high-performance future in surface engineering.
Want to learn more about how HVAF technology can benefit your operations? Reach out to our team of specialists, leaders in surface engineering
