Industries / Metallurgy and mechanical engineering
Metallurgy and mechanical engineering
Engineered surfaces for demanding loads.
Coatings for dimensional restoration, wear resistance and protection of industrial working surfaces. Selection considers temperature, contact loads, friction and environmental exposure.
Components and protection zones
Mill rolls
Improved wear resistance in hot, cold and profile rolling.
- Zones:
- Roll barrels, journals, edges and other loaded contact surfaces.
- Coatings / bond coat:
- WC-CoCr, Cr3C2-NiCr
- Substrate:
- Forged steel.
Guide rollers
Protection against abrasion and corrosion while maintaining strip quality.
- Zones:
- Outside diameter, end faces, flanges and journals.
- Coatings / bond coat:
- Cr3C2-NiCr, WC-CoCr
- Substrate:
- Alloy steel.
Hydraulic cylinder rods
Reduced friction, wear and risk of scoring in mating pairs.
- Zones:
- Rod surfaces, seal zones and threaded areas.
- Coatings / bond coat:
- CrN, DLC (a-C:H), WC/C
- Substrate:
- Hardened steel.
Dies and moulds
Protection against wear, adhesion and thermal exposure.
- Zones:
- Working surfaces, edges, radii and vent channels.
- Coatings / bond coat:
- WC-CoCr, Cr3C2-NiCr, Mo
- Substrate:
- Tool steel.
Bearing seats and housings
Restoration of fits and protection against fretting, corrosion and galling.
- Zones:
- Bores, support faces and bearing seats.
- Coatings / bond coat:
- Mo, NiCrBSi, WC-CoCr
- Substrate:
- Cast iron and steel.
Shafts, sleeves and high-wear tooling
Longer service life while maintaining geometry and tolerances.
- Zones:
- Working diameters, cutting edges and contact edges.
- Coatings / bond coat:
- Engineered system selected for the service environment
- Substrate:
- Structural and tool steels.
Materials and applications
| System | Materials | Application |
|---|---|---|
| WC–CoCr carbide (HVOF) | WC-10Co-4Cr, WC-12Co | Rolls, rollers, sleeves and wear plates; high wear resistance. |
| Cr3C2–NiCr carbide (HVOF / APS) | Cr3C2-25NiCr, Cr3C2-37NiCr | Pumps, valves, dies and forming tools; abrasion and corrosion protection. |
| Molybdenum-based (HVOF) | Mo, Mo-Ni, Mo-Cr | Shafts, seats, dies and mating interfaces; galling reduction. |
| Low-friction (APS / PVD) | CrN, DLC (a-C:H), WC/C | Rods, seals and guides; reduced friction and adhesion. |
| Protective metallic (APS / HVOF) | NiCrBSi, NiAl; stainless steel | Housings, passages and hot components; corrosion and oxidation protection. |
| Thermal barrier (APS) | Y2O3-ZrO2, Al2O3-TiO2 | Mould inserts, nozzles and thermally loaded parts. |
Coating structure
- Functional layer
- Bond coat, if required
- Component material
Schematic, not to scale. Layer count and bonding mechanism depend on the selected material and process.
Coating processes
- HVOF
- APS
- Cold spray (CS)
- Laser cladding
- Electroplating
- Electroless nickel
Typical applications, not a component specification. Composition, thickness, surface preparation and acceptance criteria must be selected for the operating conditions and validated by testing.