Arc Spraying

Metal Spraying has been utilized throughout the world in all forms of industry for over a century. Since the introduction of 'Electric Arc' metal spraying, coatings are now much stronger due to the higher temperatures. The temperature of the wire fusing point is in the range of 4,000 degree C. With these temperatures involved the particles are much hotter when deposited thus forming a more dense interlocking coating with good cohesive strength. It is now possible to obtain a diffusion of sprayed metal particles with excellent adhesion to the base metal which is stronger than the tensile strength of the coating itself and therefore makes the process of reclamation a far more reliable proposition.
Metal Spraying is to some extent related to the welding process although without some of the adverse effects caused by the high temperature directly at the interface causing distortion, metal inclusion and other related problems. Arc Spraying is known also as Cold Spraying whereby no flame is used and very little heat is imparted to the substrate. This means that large items can be built up with even, dense and uniform coatings to virtually any thickness.
Flame Coatings Pty Ltd has successfully reclaimed literally hundreds of thousands of industrial components in the last 50 years for virtually every industry in Australia with extremely good outcomes in virtually every case.

HVOF Coatings

Flame Coatings Pty Ltd were the first to introduce HVOF [High Velocity Oxygen Fuel] Coatings to Australia with the original 'J' Gun which was the first High Pressure / High Velocity Oxygen Fuel [HP/HVOF] coating system. The combustion in this system produces a very high pressure flame which increases the velocity of the powder to over 3 times the speed of sound. This produces coatings which are very dense, strong with high tensile and compressive strength, which enable much thicker coatings to be applied than previously possible with other processes.
HP/HVOF coatings are used in applications requiring the highest density and strength not found in other thermal spray processes. New applications, previously not suitable for thermal spray coatings are now becoming viable which means all industry can now benefit from these advances in the metal spray process.

Tungsten Carbide & Ceramics
Tungsten Carbide makes an excellent wear surface when Thermal Sprayed especially by the HP/HVOF coating system. It is comparable with corundum or sapphire in hardness and can only be polished and finished with diamond wheels and compounds.
WC is resistant to acids, has a high melting point of 2,870 °C , is extremely hard 8.5-9.0 Mohs scale [diamond is 10.0] and has low electrical resistivity. WC Coatings can be as thin as a few microns or millimeters thick.  Ceramic Coatings provides chemical/acid, erosion, and/or corrosion resistance, heat oxidation & abrasion protection, as well as heat & electrical non-conductivity.
Ceramic coatings also prevent wear from fretting, galling, rubbing or sliding as well as particle erosion and can be utilized in virtually any environment where longer life is required.  Both Tungsten Carbide and Ceramic coatings are being used in countless areas of industry and there possible applications can only be limited by our imagination.

Machining and Grinding
Flame Coatings have an extensive range and capacity for machining, milling, boring, cylindrical grinding, crankshaft grinding, internal grinding, surface and diamond grinding.  We have many decades of experience in precision finishing and always work to the closest tolerances possible with uttermost quality to standard required.

General Welding and Maintenance
As well as experts in Thermal Spraying, Flame Coatings has had many years experience in all welding processes including Mig, Tig and stick. Our knowledge and experience in hard face welding enables us to recommend the best solutions to any repair or hard facing solution for any application. We can also successfully repair metals such as cast iron, aluminium and bronze.