Metallising Services
Thermal Spray Metallising: Restoring, Protecting and Extending Life
Extend component life, restore worn parts to fully operational, and get unmatched protection from the harshest environments.
For over 60 years, our customers have relied on our thermal spray metallising services to increase productivity and reduce their costs. We’re happy to oblige.
High-Velocity Coatings
Advanced, high-performance solution
- Superior protection against wear, erosion, and corrosive environments
- Long-term reliability due to exceptional bond strength
- Uses a high-velocity flame to create dense, 99% porosity-free coatings
- Utilises quality materials, including composite carbides
Applications: Slurry pump shafts, conveyor rolls, hydraulic rams, turbine components, valve stems, bearing journals
Electric Arc Spray Systems
Fast, cost-effective dimensional restoration
- Economical solution for large surface areas
- Versatile material options: steel, stainless steel, aluminium, aluminium bronze, high chrome steel
- Excellent corrosion protection and wear resistance from harsh environments
Applications: Gearbox bores, track rollers, pump housings, valve bodies, shaft journals, wear plates
Gas Metallising
Proven technology for controlled coating applications
- Precise control for intricate geometries
- Lower heat input protects heat-sensitive substrates
- Wide material compatibility: wire or powder feedstock
Applications: Propeller shafts, rudder posts, bearing surfaces, seal faces, pump components
Ceramic Spraying
Extreme abrasion and wear protection
- Excellent performance and durability in abrasive environments
- High-temperature stability: up to 1000°C+ without losing structural integrity
- Fully oxidised materials protect parts from acidic and corrosive environments
- Electrical insulation properties to withstand high voltages and temperatures
Applications: Boiler tubes, heat exchangers, chute liners, classifier components, turbine blade erosion protection
Rokide™ Ceramic Coatings
Premium ceramic protection for harsh environments
- High density and minimal porosity protect from corrosion and routine wear.
- Provide a strong thermal barrier coating beating temperatures of up to 927°C
- Exceptional kinetic energy and thermal mass provide a precise application
- Utilises ceramic oxide rods melted into our patented spray unit
Applications: Combustion chambers, flame paths, thermal barriers, reactor vessels, heat exchangers
Typical Applications of Metallising
Our metallising services are used by a wide range of industries that need extended life for their machinery with minimal downtime, including:
Mining Equipment
Water Treatment
Heavy Machinery
Power Generation Turbine Components
Frequently Asked Questions
Thermal spray metallising is a surface coating process that uses heat to melt materials (metals, ceramics, or composites) and propel them onto a component’s surface at high velocity. The molten particles bond to the substrate, creating a protective or restorative coating that extends component life and enhances performance.
The optimal process depends on your specific requirements:
- HVAF offers exceptionally dense, high-hardness, and low-porosity protective coatings, providing superior wear and corrosion resistance.
- Twin Arc Electric Spray provides a cost-effective coating for durability against wear and corrosion.
- Gas Metallising is a versatile, cost-effective and long-lasting solution for superior protection while maintaining the substrate’s integrity.
- Ceramic Rokide™ coatings are dense, hard and highly cohesive, ideal for protection against extreme temperatures, friction and abrasions.
Our surface engineers can analyse your application and recommend you the best solution.
We work with a wide range of base materials, including steel, stainless steel, cast iron, aluminium, and many alloys. Our coating materials include various metals (steel, stainless steel, aluminium, and zinc), composite carbides, and high-performance ceramics. Each material is carefully selected to match your operating conditions.
Project duration varies based on component size, preparation requirements, and coating specifications. Simple shaft repairs might be completed in 8 – 10 working days, whilst larger or more complex projects may take 2 – 4 weeks. We’ll provide a specific timeline when reviewing your project requirements.
Thermal spray is ideal for dimensional restoration because we can apply coatings in controlled thicknesses, typically from 0.1 mm to several millimetres depending on the repair process used. Components are then precision-machined or grounded to your exact specifications, restoring original dimensions or compensating for wear.
Most worn components with erosion, corrosion, or dimensional wear are excellent candidates for metallising. Our team can assess your specific situation based on the component’s material, wear pattern and operating conditions and determine the best solution.
We stand behind the quality of our work with comprehensive quality assurance processes and appropriate warranties based on your application. Specific warranty terms are discussed during project consultation, as they depend on operating conditions and maintenance practices.
Find out more about Australia’s most experienced Metallising operation
Our metallising specialists will analyse your specific challenges, recommend the optimal metallising solution and provide a detailed cost-benefit analysis.