HVAF Hybrid Coating – Laying it on Thick!

Introduction

The thermal spray process has been a game-changer in various industries, offering a versatile and efficient means of applying protective coatings to a wide range of substrates. One of the strategies that have gained significant attention of late is the ability to apply thicker layers of coatings per pass.

One of the most apparent benefits of applying thicker coatings per pass is the significant reduction in application time. With thicker layers, more coating material is deposited in a single application cycle. This translates to fewer passes required to achieve the desired coating thickness.  Thicker coatings per pass dramatically reduces the overall processing time, which not only enhances efficiency but also lowers labor and energy costs.

Years of Testing

Since we started working with our landing gear OEM partners 7-years ago on the approval of our HVAF Hybrid coating technology, we’ve invested a lot of time spraying and testing multiple coating thickness per pass scenarios.  The testing results demonstrated that our coatings effectively met all the landing gear OEM specification requirements for coatings sprayed at up to 0.0018” per pass.

AERO-HVAF’s AH-06 Torch

Watch our video below that demonstrates our AH-06 Hybrid HVAF torch coating a landing gear pin at a spray rate of 55lbs/hr. (25kg) 5-passes @ 0.0017”/pass.  Total processing time to obtain an 0.0087” thickness took 3.09 minutes.  In comparison a HVOF (hydrogen based) torch spraying at the maximum spray rate of 5lbs/hr. (2.27kg) 36-passes @ 0.00024”/pass would take 38 minutes.  The production gain is quite obvious and in favour of our HVAF coating technology, wouldn’t you agree!

Landing Gear Pin HVAF Hybrid WC-10Co4Cr Coating Video

Numbers Always Tell the True Story!

Thick layers of coating per pass is a strategy that holds immense potential for enhancing efficiency, performance, and cost-effectiveness.  It reduces processing time, minimizes heat exposure, and results in more uniform coatings with improved bond strength. Additionally, it contributes to sustainability efforts by reducing waste and resource consumption.