Thermal spraying is a vital part of keeping a substrate surface in top condition, adding value to the component and ensuring the very best performance. At EP Coatings (EPC), we offer a wide range of thermal spray coating systems including:
All of these thermal spraying systems can coat a wide variety of materials including bronzes, ceramics (chrome oxide, aluminum oxide, zirconia, and titania), steels, stainless steels, nickel alloys, pure metals (like aluminum, zinc, and copper), tungsten carbides, titanium, etc., with minimal heat transfer to the substrate surface. Furthermore, the thickness of the thermal spray coatings and the coating properties can be changed according to specific needs.
Arc wire thermal spraying is a process where an electric arc is formed between the ends of two charged wires, causing them to melt, and compressed air is then used to spray the molten wire feedstock so it coats the substrate surface.
Arc spray systems offer a reliable, versatile, and affordable way of thermal spraying and can be used in a variety of applications, including:
Arc wire spraying enables coatings to be applied quickly and economically, saving the operator time and money. We recommend using the impressive AWS-400 arc wire spray system, which offers high performance and unbeatable power – not to mention it’s highly portable and perfect for use on location. The AWS-400 arc spray system features a patented quick-change wire guide system and wire drive rolls for effortless operation, and its unique capabilities include:
Cold gas spraying is the newest of all spray coating processes and offers special benefits, because the spraying material is not fused or melted during the process. Cold gas spray systems use pressurized cold gas to accelerate coating material particles to extreme velocities (400-1200 m/s), which cold-welds the coating particles to the substrate surface to form a dense, oxide-free coating.
Our Impact Innovations 5/8 and 5/11 cold gas spray systems provide performance pressures up to 725 psi at temperatures up to 1472°F and 2012°F respectively, and the high-performance cold gas spray gun features a proprietary powder injection system and is modularly designed to allow custom configurations during the spray coating process. Conveniently, this spray gun does not require external pre-heating with a hot gas tube.
The Impact Innovations spray systems can either be a stand-alone solution or integrated as part of a turn-key spray coating solution (for example, with multiple powder feed units incorporated alongside).
Convenience, reliability and efficiency are key to these units. Both systems are easy to operate and powerful, reliably offering powder material changes at feed rates of up to 1.8dm3/h, plus they feature automatic data logging of all system variables and values, changelogs and production data, and a 19″ touchscreen with an intuitive interface that allows precise calibration to ensure every spray coating project runs smoothly.
Flame spraying systems, otherwise known as combustion spray systems, can be divided into two categories based on the feedstock used: flame powder spray systems and flame wire spray systems. Both flame spraying processes rely on the chemical reaction between oxygen and the combustion fuel to produce a heat source, which then creates a gas stream with a temperature in excess of 5432°F. The feedstock material (in either wire or powder form) is fed into the flame to melt, and the resulting combustion is then used to atomize and accelerate the particles onto the substrate.
EPC offer spray equipment suitable for both types of process, with high-quality combustion spray systems featuring robust wire or powder spray guns that can be configured for hand-held or machine-mounted/robotic operation. EPC supplies all necessary equipment to optimize the use of a flame spraying system, including:
We stock two types of flame powder spray guns, the 5PII & 6PII, both of which are precision engineered and capable of creating the perfect spray coating. What’s more, these spray guns can use a wide array of coating particles, since the feedstock is in powder form.
Our FWS (flame wire spray) series of spray guns includes the lightweight, manually operated FWS-10 (TSA applications), the manual/semi-automatic FWS-21, and the fully automatic FWS-22 and FWS-30. The FWS-30 is our most powerful FWS gun and is equipped with an electric motor and Metco Gas Head for heavy-duty spray coating work. For increased safety, the FWS-10, -21, and -22 guns can be used with our model-1100 and model-1200 gas control panels for more precise pressure and flow adjustment, less risk of gas leakage and component degradation, and wide access to the couplings, tails, and accessories.
High-velocity oxygen fuel, or HVOF, is a thermal spray process that utilizes the combustion of gases (e.g., acetylene, hydrogen, methane, propane, etc.) or liquid fuels (such as ethanol or kerosene) to coat surfaces, increasing erosion and wear resistance as well as protecting the coated equipment from corrosion.
The fuel and oxygen atomize and mix within the combustion area, and are then ignited at controlled temperatures and pressures resulting in a flame with supersonic velocity. The coating material is injected into the flame and propelled towards the substrate to form a durable coating.
The HV-50 Digital Series has been carefully engineered and built with safety and efficiency in mind, reliably offering a continuous and consistent thermal coating process. The series is made up of stand-alone, single-process, mass flow controlled (MFC) HVOF coating systems – namely:
• HV-50 GF (Gas Fuel) HVOF
This system relies on gas as fuel, and is compatible with the following spray guns:
• HV-50 LF (Liquid Fuel) HVOF
This system relies on liquid as fuel, and is compatible with the following spray guns:
Built using only state-of-the-art components and thermal spraying technologies, the HV-50 series is designed to be both reliable and functional and can be used in every type of HVOF application, ranging from R&D, single-piece production to high volume production. Key facts regarding the HV-50 series:
Last but not least, there is the MP-50 (Multi Process), a stand-alone multi-process, mass flow controlled (MFC) HVOF, APS, and combustion spray coating system. Designed with state-of-the-art components and advanced thermal coating technology in mind, the MP-50 system performs reliable and effective HVOF, combustion, and plasma spray coating processes using just one unit and can be used for both single-piece production and high-volume production. Compatible with HVOF spray guns like the eGun™ and the JP-5000 gun, the MP-50 offers users unsurpassed process control and thermal spray operation flexibility.
Laser cladding is a deposit overlay coating technology. This kind of thermal spraying is based on a highly controllable and efficient process that uses a powerful industrial laser to weld material onto a substrate, creating an overlay with true metallurgical bonding.
EPC offers professional expertise on the laser cladding process through our specialist subsidiary company Laser Cladding Technologies (LCT). LCT offers a wide range of laser source options to suit any requirement, such as direct diode, fibre coupled diode, and fibre laser.
A formal partnership exists with Coherent, a leading manufacturer offering a complete line of industrial laser cladding equipment and products. These innovative laser products go hand in hand with LCT integration, part-handling solutions and expert application knowledge, meaning we can deliver complete laser cladding solutions as OEM system integrators.
If you would like to find out more about laser cladding and discover how it could work for you, we invite you to get in touch.
The plasma spray process, also known as air or atmospheric plasma spray (APS), is versatile and flexible thermal spray coating that can be used for a wide range of applications across different industries. APS is capable of spraying a wide range of coating materials such as most metals, ceramics, and alloys onto many different substrate materials such as plastics, glass, metals, ceramics, and composite materials.
The AP-50 Digital Series plasma spray system is a stand-alone single process, mass flow controlled (MFC) APS coating system. The AP-50 has been engineered to be reliable, safe to operate, and able to deliver consistent thermal spray coatings in a variety of APS applications ranging from R&D, single-piece production to high-volume production. Spray guns compatible with the AP-50 Digital Series include:
The AP-50 system is one of the safest on the market today because of its modular design that separates gasses and fuels from the electrical parts, the use of only first-class materials, closed-loop control of all relevant process parameters (such as gas pressures and flows, voltage on the gun, water temperatures), and combustible gas monitoring. What’s more, every unit comes with safety interlock integration and e-stops with external equipment units as standard. Key facts regarding the AP-50 series:
The MP-50 is a stand-alone, multi-process, mass flow controlled (MFC) HVOF, APS, and combustion spray coating system. Designed with state-of-the-art components and advanced thermal spray technology in mind, the MP-50 system performs reliable and effective plasma spray coating, HVOF, and combustion spray processes using just one unit and can be used for both single-piece production and high-volume production. The MP-50 is compatible with the 9MB, 3MB, F4, F1, SG-100, 2700 and 2086 plasma spray guns, and offers users a highly controlled yet flexible thermal spray coating process.