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Thermal Spray Coating
Robotics and Automation Aided Processes: Plasma, HVOF, Electric Twin Arc, Flame Wire, Flame Powder, Flame Rod (Ceramic) and Self-Flux Alloy (Fusion)

Thermal Spray Coating (TSC) is the R&D focus and key technology of Frontken's Surface Metamorphosis Technology philosophy. We are the market leader in provision of Thermal Spray Coatings services in the South-East-Asia region, offering the most comprehensive range of coating processes and capabilities customizable for your applications. Frontken's Thermal Spray Coating (TSC) Services allows maximum cost-effectiveness, improving the value and in-service performance of your components and equipment through upgrading and life extension capabilities. We can provide technical consultation for recommendation of materials+process combination, allowing deposition of virtually any type of materials such as such as Metals, Alloys, Ceramics, Cermets, Polymers, Composites or graded materials for your maintenance, repair & upgrade requirements. Process Capabilities: • Plasma    • HVOF    • Electric Twin Arc    • Flame Wire    • Flame Rod (Ceramic) • Flame Powder    • Self-Flux Alloy (Fusion) Why Frontken for your TSC applications? • We operate the largest and most comprehensive TSC facilities in the region • Supported by in-house Research & Development specialists and facilities • Multiple-axes robotic arms and automation systems • Atmosphere-controlled process chambers • In-house post-TSC processes such as welding, machining, fabrication, heat treatment and others • On-Site Anti-Corrosion TSC Capabilities		General Information: What is Thermal Spray Coating? Functions & Benefits Technical Characteristics & Comparisons Industries & Practical Applications HVOF TSC High Velocity Oxy-Fuel TSC is developed to produce extremely high spray velocity capable of forming high quality & high density metals, carbide and cermet type coatings.
Robotic Plasma TSC Material in the form of powder is injected into a very high temperature plasma flame, where it is rapidly heated and accelerated to a high velocity. Advantage of the plasma system is that it can spray very high melting point materials such as refractory metals like tungsten and ceramics like zirconia unlike combustion processes.	Electric Twin Arc TSC In the Electric Twin Arc process, a pair of electrically conductive wires are melted by electrical heat and sprayed onto the substrate. Main applications of the arc spray process are anti-corrosion coatings of zinc and aluminium and machine element work on large components.	Flame Wire TSC This is the most extensively used thermal spray process in which materials in wire form are melted in flame and atomised using compressed air. Substrate temperature can be kept low to minimize distortion and metallurgical changes. Any wire with melting point below 5500°F can be used with this system.
Flame Rod TSC This system is very similiar to wire flame spray sytem with difference in material type and form which is ceramic rod (i.e., chromium, zirconium and aluminum oxides) One benefit of this process is that it can be used in close quarters or where target efficiencies are critical. Rokide coating is especially suited for applications requiring extreme dry abrasion wear resistance	Flame Powder TSC In this process, the basic principle of the heat source is the same as for wire spray except that powders are supplied via a gravity feed through the flame. A much broader range of materials may be used to produce coatings with powder than with wire.	Self-Flux Alloy (Fusion) The coating is first built up via the Powder Flame Spray process. Then the asprayed layer is fused/melted onto the substrate by application of heat treatment via torch and/or vacuum furnace. This produces a metallurgical bond & results in coatings with absence of interconnected pores and very high bond strengths.

Thermal Spray Aluminum (TSA), Zinc (TSZ), Monel & other materials

As the leading service provider of Thermal Spray Coating in the region, Frontken has the manpower, skills & technology to extend application benefits of anti-corrosion coating materials such as Aluminum (TSA), Zinc (TSZ), Monel & others onto large immobile component and structures. Our on-site team can be dispatched to any locations around the world on short notice. Apart from providing quality coatings, we take utmost care in ensuring our jobs are done efficiently and on-time to comply with project/shut-down schedules, potentially saving your business enormous costs & maintenance hours while improving productivity.

What is Thermal Spray Coating ?

Thermal Spray Coating / Metallizing or Metal Spray is a process in which selected materials are heated & propelled, usually within the size range of five to 200 microns, and applied by impact onto a prepared substrate. The particles strikes the surface, become flattened & forms lamellar structure as it cools down. Coating is formed when millions of particles are cumulatively deposited on top of each other, layer by layer. This new layers conforms and adheres to the irregularities of the prepared surface and is bonded to the substrate by either mechanical or metallurgical bonding. Depending on the process & function of coating, the asprayed component may then be finished to size or other specifications. Generally, Thermal Spray Coating processes rely on the same principle of heating a feedstock (powder, wire or rod) to a molten or semi-molten state and accelerating it via compressed gas to a high velocity. Thermal Spray Coating is considered a cold application as substrates typically remain much cooler than coating materials being applied, hence there are minimal distortion and metallurgical damage to components.

Functions & Benefits of Thermal Spray Coating

Thermal Spray Coatings can be applied for the most common function of worn surface reclamation, wear resistance or corrosion prevention. Besides that, thermal spray coatings can also reduce frictional energy losses, act as a diffusion barrier, thermal insulation and electrical insulation among countless other purposes. Thermal Spray Coatings applications are broad-based and can be classified into the followings..

Application Examples:
Piston Rods, Pipe Spools, Valves, Pulleys & Guides, Rolls, Rotor Shafts, Pump Casings, Crankshaft journals, Plunger, Screw Shaft, Pressure Vessel, Turbine Casing, Flame Tubes, Transition Piece and many more . .