Precision Thermal Spray Coating for Restoring and Enhancing Critical Equipment
Our highly skilled thermal spray technicians are experts in the process, consistently delivering quality coatings that meet ASTM standards, including ASTM C633-01 and ASTM G98. With meticulous attention to detail in surface preparation, masking, grit blasting, and process parameter control, we ensure every coating is applied with precision, ensuring maximum performance and longevity for your equipment.
Our Thermal Spray Capabilities
At PDS Balancing, we offer a variety of thermal spray processes to meet the unique needs of your industry and applications. Our services include:
Combustion Flame Spray
Combustion flame spraying is an ideal solution for substrates that are sensitive to stress and heat distortion. This method utilizes a gaseous fuel source and oxygen to melt the coating material, typically in the form of powder, wire, or rod, at temperatures reaching 4,600-4,800°F. The molten material is then propelled onto the substrate at high velocity, forming a durable and protective coating. This process is effective in providing resistance to corrosion, wear, and heat, making it a versatile option for a range of applications.
Two-Wire Electric Arc Thermal Spraying
The twin-wire arc process is highly efficient for component restoration, particularly for bearing fits. This process uses two electrically charged wires that generate intense heat at their contact point, melting the wire material, which is then atomized and sprayed onto the workpiece. The twin-wire arc method is well-suited for applying 420 stainless steel coatings, known for their exceptional resistance to galling and fretting. This method is highly reliable and allows for quick turnaround times, reducing downtime for critical equipment.
Key Benefits of Thermal Spray Coating
Restores Components to OEM Specifications
Our thermal spray coatings are designed to bring your worn components back to their original specifications, often enhancing performance and extending the lifespan of the equipment.
Cost-Effective and Time-Efficient
Thermal spraying is a faster, more cost-effective alternative to full part replacement. By restoring critical surfaces, we help you avoid the long lead times and high costs associated with manufacturing new components.
Environmental Responsibility
The thermal spray process generates minimal waste and does not involve hazardous materials, making it an environmentally friendly choice for restoring equipment.
Our Thermal Spray Services
Custom Coatings: We offer custom thermal spray coatings tailored to your specific application, including stainless steel, tungsten carbide, and specialized alloys.
Traction Coatings: Our traction coatings are designed to improve the surface grip of rolls and rotating components, making them ideal for industries such as printing, papermaking, and packaging.
Protective Coatings: Our thermal spray coatings provide exceptional resistance to wear, corrosion, erosion, and heat, helping to extend the life of your components even in the most demanding environments.
Custom Coating Options
Stainless Steel Coatings
Our stainless steel coatings are an excellent choice for applications that require strong resistance to corrosion and wear. These coatings are commonly used on shafts, crankshaft bearings, and other moving parts in industries ranging from manufacturing to energy. With high strength, low shrinkage, and excellent crack resistance, stainless steel coatings are durable and cost-effective.
- Key Features:
- High-strength coating
- Excellent wear and corrosion resistance
- Can be applied up to .100″ in thickness
- Hardness rating of Rc 40-43 with bond strength between 4,000 to 10,000 PSI
Tungsten Carbide Coatings
Tungsten carbide coatings are known for their extreme hardness and resistance to wear and corrosion. They are an ideal choice for components exposed to abrasive conditions, such as rolls and dies in manufacturing and processing industries. Tungsten carbide coatings provide exceptional durability and can be finished to a smooth surface, extending the operational life of your components.
- Key Features:
- Less than 1% porosity
- Hardness exceeding Rc 70
- Bond strength averaging 8,500 PSI
- Suitable for finishing down to a 6 Ra surface finish
Traction Coatings
Used extensively in the printing and papermaking industries, traction coatings improve the grip of rolls and rotating components, increasing the efficiency of your machinery. These coatings can be customized to meet the specific needs of your application, with options available in stainless steel, carbide, and nickel alloys.
Thermal Spray Coating Projects
Metallizing Wind Turbines:
We applied thermal spray coatings to restore and protect wind turbine components exposed to harsh environmental conditions, extending their operational life and reducing maintenance downtime.
Bearing Fit Restoration:
Using our twin-wire arc thermal spray process, we restored bearing fits to OEM specifications, ensuring long-term reliability and reducing the risk of premature failure.
Traction Coating for Paper Rolls:
Our team applied traction coatings to paper rolls in a large manufacturing facility, improving grip and performance while reducing downtime due to maintenance issues.
Why Choose PDS Balancing for Thermal Spray Services?
Experienced Technicians: Our team has extensive experience in thermal spray coatings, ensuring every job meets ASTM standards and customer specifications.
Advanced Equipment: We utilize cutting-edge twin-wire arc and combustion flame spray equipment to apply coatings with precision and reliability.
Proven Results: Thousands of components have been successfully restored with our thermal spray coatings, and we continue to deliver high-performance solutions that stand the test of time.
