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Thermal Spray Coating


MWC Advanced Coatings Enhance the Performance of Your Parts
With Complete Thermal Spraying and Machine Shop capabilities we ProviHouse Coating Facilities, Thermal Spray Coatings, Abrasion Resistant Coating, Plasma Coating and Thermal Spray Coating Services On-Site Worldwide.

Coatings for Soft Bearing Surfaces
Coatings of a soft bearing material allow the embedding of abrasive particles and permit deformation to accommodate some misalignment of the bearing surfaces. These surfaces require adequate lubrication and should be low in cost as they wear in preference to the mating surface (usually very much harder). Some of these coatings are quite porous with the advantage that they act as reservoirs for lubricants.
  • Common Coatings
    • Aluminium bronze
    • Phosphor bronze
    • White metal or babbitt
    • Aluminium bronze/polymer composites



Coatings for Hard Bearing Surfaces
Coatings of a bearing material which are hard and have high wear resistance. Hard bearing materials are used where the embedding of abrasive particles and self-alignment are not required and where lubrication may be marginal. The inherent nature of thermal spray coatings seems to provide additional benefits over comparable wrought or cast materials due to the porosity acting as a lubricant reservoir and the composite nature of included oxides and amorphous phases increasing wear resistance. Some coatings show relatively low macro hardness compared to their relative wrought or cast materials, but very often show improved wear resistance.
  • Common Coatings
    • Cermets coatings like tungsten carbide/cobalt and chromium carbide/nickel chromium
    • Oxide ceramics like chromium oxide and alumina
    • Molybdenum
    • Various hard alloys of iron, nickel, chromium or cobalt



Coatings for Resistance to Abrasion
Ideally, the material should have a hardness that is in excess of that of the mating surface or abrasive particles.
  • Common Coatings
  • Cermet coatings like tungsten carbide/cobalt
  • Chromium carbide/nickel chromium (particularly for high temperatures above 540 C)
  • Oxide ceramics like chromium oxide and alumina
  • Fused self fluxing alloys (NiCrSiB)
  • Various hard alloys of iron, nickel, chromium or cobalt



Coatings for Resistance to Fretting and Surface Fatigue
Coatings resistant to wear caused by repeated sliding, rolling, impacting or vibration. Generally coatings with good toughness and low residual tensile stress are best.
  • Common Coatings
    • Cermets coatings like tungsten carbide/cobalt
    • Chromium carbide/nickel chromium (particularly for high temperatures above 540 C)
    • Fused self fluxing alloys
    • Aluminium bronze
    • Copper nickel indium
    • Various alloys of iron, nickel, chromium or cobalt

Coatings for Resistance to Erosion
The selection of coating for erosive wear is dependant on the severity and type of erosion. For solid impingement erosion at a shallow angle of attack where the wear is similar to that of abrasion, high hardness coatings are required. For solid impingement angles near 90 coating toughness becomes more important. For cavitation and liquid impingement generally, a coating with good surface fatigue resistance is needed.
  • Common Coatings
    • Cermets coatings like tungsten carbide/cobalt
    • Chromium carbide/nickel chromium (particularly for high temperatures above 540 C)
    • Fused self fluxing alloys
    • Non ferrous alloys, aluminium bronze, monel
    • Oxide ceramics like chromium oxide and alumina
    • Various alloys of iron, nickel, chromium or cobalt

Thermal Barrier Coatings for High Temperature Resistance
  • Application
    • Burner cans/baskets (gas turbines), exhaust ducts, Exhaust mufflers, heat treating fixtures, exhaust valve stems
  • Common Coatings
    • Partially Stabilized Zirconium
    • Aluminum, Nickel/Chrome Alloy, Hastelloy

Corrosion Resistant Coatings
Typically used to protect surfaces from atmospheric corrosion, chemical attack. Pump parts, storage tanks, food handling equipment.
  • Common Coatings
    • Stainless Steel (316), Aluminum, Inconel, Hastelloy

Carbide Hard Coatings for Wear Resistance
Typically used to reduce abrasion, fretting, erosion, surface fatigue, and cavitations. Applied by HVOF (preferred) or Plasma Spray.
  • Common Coatings
    • Tungsten Carbide (WC/Co)
    • Chrome Carbide (Cr3C2/NiCr)

Ceramic Thermal Spray Coatings
Ceramics applied by thermal spray are used for Dielectric strength, Sliding wear ,Thermal barriers, Corrosion protection .
  • Common Coatings
    • Alumina (Aluminum Oxide, Al2O3)
    • Zirconia (Zirconium Oxide, ZrO2)
    • Chromium Oxide (Cr2O3)
    • Titania (TiO2)
    • Yttria stabilized Zirconia (YSZ thermal barrier coatings, ZrO2-Y2O3)

Abradable Thermal Spray Coatings
These coatings are used in gas turbine engines for clearance control.
  • Common Coatings
    • Ni-graphite, NiAl-Bentonite, Nickel-Aluminum, Aluminum Silicon-Graphite, AlSi-Polyimide, AlSi-Polyester are common abradable coating materials

Metal and Metal Alloy Thermal Spray Coatings
  • Common Coatings
    • MCrAlY’s (NiCrAlY, CoCrAlY, NiCoCrAlY, CoNiCrAlY)
    • Nickel Aluminum alloys (NiAl)
    • Nichrome (NiCr)
    • Molybdenum (Mo)
    • Titanium (Ti)
    • Stellite
    • Triballoy