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To make industrial moving parts last longer and work better, it’s crucial to focus on remanufacturing the equipment so they are effective and durable. A keyway to do this is by applying advanced coatings to these important components of the machine.

For over 60 years, we have been at the forefront of this innovative field, employing the very latest surface engineering technologies to refurbish and protect industrial parts.

Our team of Surface Engineers considers various coating technologies for each project, such as High Velocity (HVAF/ HVOF), Arc and Flame Sprayed Thermal Coatings, Precision Laser Cladding, and more. Selecting the best process takes experience and know-how.

Over time, heavy industry machinery components wear out, corrode or faults appear. Our remanufacturing processes result in a repaired component that is as good or better than the original specifications. Not only does this deliver notable reductions in future downtime, thereby reducing ongoing maintenance costs; this approach is far more cost-effective than buying new replacement parts and eliminates the waste of throwing worn parts away

What is the Role of Coatings in Machinery Maintenance?

High-tolerance coatings are applied to components that are subjected to wear – usually because they are rotating often at high speed or under high loads, against other parts. These engineered layers serve as a formidable defence against wear, corrosion, and fatigue, ensuring machinery components can endure the stress of their operational environment.

What Coating Technologies Do We Consider and Why?

Arc Sprayed Thermal Coatings

Process: Utilises an electric arc to melt feedstock material, which is then atomised and sprayed onto the substrate.

Benefits: Offers excellent bond strength and corrosion resistance, making it ideal for components that are exposed to harsh environments. It’s particularly effective for restoring worn surfaces or providing enhanced wear resistance.

Flame Sprayed Thermal Coatings

Process: Involves the melting of coating material in a flame, which is then propelled onto the surface to be coated. 

Benefits: Flame spraying is versatile and cost-effective, suitable for a wide range of materials and applications. It provides good corrosion and wear resistance, making it a popular choice for refurbishing and enhancing the durability of machinery parts. 

Precision Power Laser Coatings 

Process: A high-precision technique where a laser beam is used to melt the coating material as it is fed onto the substrate, resulting in a coating that is metallurgically bonded to the surface. 

Benefits: Laser cladding is renowned for its ability to produce coatings with minimal dilution and exceptional bond strength. It’s ideal for high-value components requiring superior wear and corrosion resistance, as well as for parts needing precise dimensional restoration. 

High-Velocity Oxygen Fuel (HVOF) Coating

Process: The HVOF coating technique involves propelling a mixture of fuel and oxygen to create a high-velocity flame. Powdered coating material is fed into this flame, where it melts and is sprayed onto the surface at high speeds. This process produces coatings that are extremely dense and well-bonded to the substrate. 

Benefits: HVOF coatings are renowned for their extremely dense, hard, and well-bonded coatings, which significantly enhance wear and corrosion resistance of the treated components. This process is particularly beneficial for extending the life of parts exposed to severe service conditions, including those in the aerospace, marine, and energy sectors. The high velocity of the particle impact results in coatings with low porosity and high adhesion to the substrate, leading to improved performance and durability of machinery parts. 

High-Velocity Air Fuel (HVAF) Coating

Process: Similar to HVOF, the HVAF coating method uses a high-velocity stream of air and fuel to melt and accelerate the coating material towards the substrate. However, HVAF operates at lower temperatures, reducing the risk of oxidizing the coating material during application. 

Benefits: HVAF technology offers the ability to produce coatings with exceptional bond strength and hardness while minimizing oxidation and retaining the purity of the feedstock material. This method is highly effective for applying coatings that require superior wear and corrosion resistance without the higher heat input associated with HVOF, making it suitable for temperature-sensitive materials. HVAF coatings are ideal for a wide range of applications, including protection against erosion, corrosion, and wear in environments where maintaining the base material’s properties is critical. 

The Science Behind Coatings

At their core, coatings act as a protective shield for machinery parts, safeguarding them against the elements they face, such as extreme temperatures, corrosive substances, and physical abrasion.

The selection of a coating process is guided by the specific operational challenges of each part, ensuring that the chosen method provides the most effective protection and performance enhancement.

Customised Coating Solutions for Specific Machinery Needs

Recognising the diverse demands of industrial machinery, A1 Metallising Services specialises in customising coating solutions to meet the unique requirements of each application.  

Whether it’s tailoring the properties of a thermal spray coating or optimising laser cladding parameters, the goal is to deliver optimised protection and efficiency. 

Embracing advanced coatings is a strategic investment that yields significant returns.   

At A1 Metallising Services, we continually innovate and invest in the coatings, processes and the tools we use so that we can provide tailored solutions that ensure machinery operates at peak efficiency across a wide range of industries including defence, mining, earthmoving and power generation.

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