Views: 0 Author: Site Editor Publish Time: 2025-11-11 Origin: Site
Thermal Spray Equipment plays a pivotal role in extending the life and performance of components used across heavy industry, aerospace, automotive, and medical fields. Jinan Tanmng New Material Technology Co., Ltd. combines advanced production lines and imported high-end systems to deliver reliable coating solutions that improve wear resistance, corrosion protection, and high-temperature performance for critical parts.
Thermal spray equipment is the set of machines and peripherals designed to heat coating feedstock (wires, rods, powders) to a molten or semi-molten state and accelerate it toward a substrate where it forms a solid coating. The purpose of this process is to impart surface properties that the base material alone cannot provide — for example, a steel roll becomes wear-resistant; a pump rod becomes corrosion-resistant; a turbine part gains high-temperature protection. The equipment itself ranges from simple flame guns to highly engineered plasma torches and supersonic spray installations. Each equipment family controls thermal input, particle velocity, and deposition dynamics in order to produce coatings with targeted microstructures and performance.
Flame spraying relies on combustion of fuel and oxygen to melt feedstock. It is a widely used, cost-effective method for applying metallic and cermet coatings. Flame systems are well-suited for large-area repairs and components where extreme bond strength and microstructure control are less demanding than with plasma or high-velocity processes. Benefits include relatively low capital cost and good productivity for bulk rebuilding and anti-corrosion overlays.
Plasma spraying uses an electric arc to ionize gas, creating a high-energy plasma jet that melts powder feedstock and propels it onto the part. Plasma systems deliver higher particle temperatures and better control over the coating chemistry and microstructure, producing denser and more adherent coatings. They are commonly used where coating integrity and performance under thermal stress matter — such as in aerospace or advanced manufacturing.
Supersonic or high-velocity thermal spray equipment accelerates particles to very high speeds using a supersonic gas jet or kinetic-energy-enhanced process. The result is coatings with exceptional adhesion, low porosity, and finely controlled splat formation. These systems are ideal for wear-resistant overlays, thin functional layers, and applications that require minimal heat input to the substrate.
Functional rolls, dryer cylinders, and press rolls receive surface strengthening treatments to resist abrasion, adhesive wear and often corrosive exposure. Jinan Tanmng’s multiple arc and supersonic lines are designed to handle the large-scale roll geometries typical in papermaking, enabling restoration and hardfacing while maintaining tight tolerances.
Plungers, pumping rods, drill pipes and pipeline sections are subject to abrasive wear, corrosion and chemical attack. Thermal spray coatings applied by plasma or HVOF (high-velocity oxy-fuel) processes extend service life and reduce downtime for maintenance-intensive equipment.
Boiler tubes and related components face high temperature and erosive particles. Specialized anti-corrosion and four-tube wear-resistant strengthening projects protect these components and improve plant reliability.
Where thermal stability, precise surface chemistry and biocompatibility matter, plasma and supersonic systems provide the control needed to deposit specialized ceramics and alloys for thermal barriers, structural protection and biomedical surfaces.
By depositing hard alloys and ceramics, thermal spray coatings significantly reduce abrasive and adhesive wear. The correct choice of equipment allows dense, well-bonded coatings that resist particle impingement and material loss.
Thermal spray provides metallic overlays and specialized corrosion-resistant alloys that isolate the substrate from corrosive media. When applied with proper surface preparation and process control, these coatings dramatically extend service life.
Rather than replacing large or expensive components, thermal spray allows economical rebuilding to original dimensions followed by precision machining. This remanufacturing approach reduces lead times and conserves resources.
High-temperature environments benefit from ceramic and metal-ceramic composite coatings that thermal spray equipment can deposit. Plasma systems are particularly effective for these applications due to their high particle temperatures and material versatility.
Selecting the right feedstock and matching it to the appropriate equipment is essential for achieving the desired coating performance. Common materials include:
Metals and alloys: nickel, chromium, stainless steels, cobalt-based alloys for wear and corrosion resistance.
Cermets: tungsten carbide-cobalt combinations for extreme abrasion resistance.
Ceramics: alumina, zirconia and related materials for thermal barriers and electrical insulation.
Composite coatings: mixes of metallic binders and hard particles to balance toughness and surface hardness.
Process matching is also critical. For example, porous but thick flame-sprayed layers may be acceptable for some corrosion protection tasks, while critical wear parts will benefit from HVOF or supersonic deposition to minimize porosity and maximize adhesion.
A robust thermal spray outcome depends on the full chain of steps: substrate cleaning, abrasive blasting or grit blasting for surface profile, preheating where needed, controlled deposition, and post-deposition finishing. Modern plants incorporate:
Precise torch and flow control to maintain consistent particle temperature and velocity.
In-line monitoring for coating thickness and roughness.
Heat-control strategies to manage substrate distortion.
Final machining and inspection using high-precision equipment.
Jinan Tanmng invests in more than 50 sets of high-precision machining equipment to ensure coatings meet dimensional and surface specifications. This combination of spray capability and precision finishing guarantees that coated parts are ready for immediate service or final assembly.
Tanmng operates multiple dedicated production lines — including arc spraying, supersonic spraying, plasma spraying and an ultra-high-speed laser cladding line — which enables flexible response to diverse application needs. Key production strengths include:
Scale: multiple production lines allow parallel processing of different job types and high throughput for larger projects.
Equipment diversity: imported high-end thermal spraying systems provide advanced control over coating chemistry and microstructure.
Precision post-processing: extensive machining assets allow tight tolerances after coating.
Application expertise: experience across papermaking rolls, petrochemical parts and power-generation components ensures process know-how for specific industry challenges.
These capabilities make it possible to supply both standard protective overlays and tailor-made coating solutions for specialty parts.
When integrating thermal spray coatings into product lifecycle planning, purchasers should consider:
Turnaround and lead time: established production lines and managed workflows reduce downtime for refurbishment jobs.
Repairability: in-service repair strategies should be designed so that coatings allow future maintenance cycles with minimal substrate damage.
Total cost of ownership: while initial coating costs exist, reduced replacement frequency and improved uptime typically lower overall life-cycle costs.
Environmental and safety controls: proper exhaust, dust handling and operator safety systems are essential in a qualified thermal spray facility.
Jinan Tanmng’s equipped production facilities and experienced operations team are structured to handle these requirements, ensuring reliable scheduling, compliance and safe operation on every job.
Coating lifetime depends on operating environment, substrate preparation, and coating selection. Typical maintenance practices include periodic inspections for wear profiles, non-destructive testing where needed, and scheduled touch-up applications. Choosing the right equipment and material combination at the outset — for instance supersonic HVOF for high-wear components — typically extends intervals between repairs and minimizes unplanned downtime.
By enabling remanufacture rather than replacement, thermal spray technology contributes to resource conservation and reduced waste. Longer-lasting components mean fewer raw materials consumed and a smaller environmental footprint over the asset lifecycle. In addition, modern supersonic and plasma systems achieve higher deposition efficiencies and less rework, improving material utilization rates.
As industrial demands for durability, corrosion resistance and thermal protection grow, thermal spraying systems remain an essential technology for extending component life and improving equipment performance. Jinan Tanmng New Material Technology Co., Ltd. brings comprehensive production capabilities — including multiple arc, supersonic and plasma spray lines plus ultra-high-speed laser cladding and precision machining — to deliver coatings that meet stringent industrial needs. For inquiries, product specifications, or project consultations, Contact us to discuss how our thermal spray solutions can support your equipment longevity and operational efficiency.
Q1: What kinds of components are best suited for treatment with thermal spray equipment?
A1: Components that face surface-driven failures — such as rolls, pump plungers, drill rods, boiler tubes and valves — are excellent candidates. Thermal spray coatings restore dimensions and add specialized properties like wear and corrosion resistance while minimizing the need for full part replacement.
Q2: Which thermal spray method offers the best wear resistance for oilfield components?
A2: High-velocity processes, including supersonic HVOF and similar kinetic spray approaches, typically deliver dense, low-porosity coatings with excellent adhesion and are widely preferred for oilfield components subject to severe abrasion and erosion.
Q3: How does Jinan Tanmng ensure coating quality for large-diameter rolls and complex geometries?
A3: Tanmng’s combination of dedicated spraying lines, imported high-end systems, and over fifty precision machining units allows consistent surface preparation, controlled deposition, and post-coating machining to tight tolerances, ensuring uniform coatings for large and complex parts.
Q4: What material choices are common for thermal spray coatings in power plant applications?
A4: For power generation, corrosion and high-temperature resistance are priorities. Common selections include chrome-based alloys, nickel alloys, and ceramic-metal composites, chosen to match specific operating temperatures, oxidation conditions, and erosive environments.