Kermetico HVAF and HVOF Thermal  Spray Coating Equipment and Technology

Kermetico designs and manufactures HVAF and HVOF thermal spray coating equipment.  We spray with the the equipment, in our shop in California, USA. Our solutions in our job shop, become improvement, our entire product line has evolved from our spray shop work. Practical pragmatic hermal spray coating effort serves as our real-world R&D lab.

Kermetico, Inc. builds HVAF and HVOF systems run a a range of different velocity guns for the efficient spraying of tungsten carbide and metal coatings.

Our coatings sprayed with our Kermetico systems have high density and hardness, combined with excellent ductility.  .  This means outstanding wear and cavitation resistance of our impermeable, corrosion-resistant layers.

This high quality comes with lower coating costs.  Kermetico HVAF systems use energy effectively, resulting in high spray rates and deposits per pass four to eight times higher than conventional HVOF.  

We manufacture thermal spray equipment combining the advantages of both technologies: high quality + low cost of HVAF and compliance with HVOF standards.

Convertible HVOF and HVAF equipment:

  • C7 – an HVAF/HVOF system for spraying large parts
  • C6 – a general purpose HVAF-HVOF gun
  • CID – an HVAF&HVOF gun to spray internal diameters 80 mm (3.15″) and larger

Multi-purpose HVAF AK systems, with a variety of spray guns:

  • AK7 – a high-power gun for the thermal spray of large parts
  • AK6 – a gun to spray tungsten and chromium carbide onto a balanced mix of parts
  • AK5 – a compact gun to spray smaller parts, thin walls and complex surfaces
  • AK5-ID – a compact gun to spray internal surfaces 200 mm (8″) and larger
  • AK-ID – an 80 mm (3.15”) and larger internal diameter spray gun
  • AK-IDR – a rotating ID gun to spray 4” (100 mm) and larger bores
  • AK-HH – a handheld gun for on-site coating

Specialized equipment:

  • SL – a specialized gun for spraying low melting point metals
  • SP – a dedicated gun for the most efficient precious metals’ deposition
  • STi – a specialized gun for the deposition of titanium and Ti-alloy coatings

Additional equipment:

  • Blasting Grit Feeder:  the grit blast preparation of parts to reduce coating cost
  • Gas Permeability Tester for an instant check of a coating’s through porosity
  • Powder De-Duster to remove fine particles from a metallic powder

The key characteristics of each process are spray particle temperature and velocity, as achieved during coating application.

Particles of different materials and various sizes are heated and accelerated very differently even using the same method or even different spray guns within the same process.

It is useful to understand the technological windows in thermal spray, as well as the trends in equipment and technology development.

Kermetico HVAF, HVOF, Plasma, Detonation, Cold Spray Particle Temperature vs. Velocity

Kermetico HVAF Coating Features

Kermetico HVAF carbide overlays are superior to HVOF rivals regarding wear resistance, corrosion protection and production cost. The high speed of the in-flight particles (higher than 1,000 m/s | 3,300 ft./sec.) in our process enables the production of very dense coatings with high bond strength.

These coatings are gas-tight and form an impermeable barrier between an environment and a base material.

An Impermeable Kermetico HVAF WCCoCr Coating

Moreover, the low spraying temperature (1,960-2,010°C | 3,560-3650°F depending on fuel gas) and gentle particle heating lead to minimal feedstock phase transformation and almost nonexistent elemental depletion/decomposition of the in-flight particle.

A Phase Analysis of WCCoCr Powder (Black) and an HVAF-Sprayed Coating (Red)

Furthermore, the replacement of pure oxygen used in HVOF processes with air in our HVAF process significantly reduces the oxide content in HVAF coatings, which is desirable for coating quality.

The Main Features of Our Corrosion and Wear Resistant Tungsten Carbide Coatings

WC-10Co-4Cr Coating Features A Typical HVOF Kermetico HVAF System Modes
                                                                        Economy                       Balanced                                     Ultra
Deposition efficiency, %                                   40-55                            60-70 48-58                                 36-42
Hardness, HV300                                          1,050-1,250               1,050-1,250 1,250-1,350                  1,350-1,600+
Young’s Modulus E, GPa                                    300                               400 450                                        450
Apparent metallographic porosity                    <0.8                             <0.8 <0.5                                        <0.3
Bond strength, MPa (PSI)                                                                      80+ (12,000+)
Range of as-sprayed roughness, µm (µ in.)     3.5-4.5 (150-180)                                            1-3.2 (40-130)

Kermetico HVAF & HVOF equipment produces WC-based coatings with the highest fracture toughness, substantially exceeding known samples.

Since the primary mechanism of wear of tungsten carbide coatings is attributed to the material brittleness, Kermetico’s HVAF overlay exhibits better wear resistance than pure HVOF versions.

Kermetico, Inc. – Design and Manufacture of Thermal Spray Equipment Since 2006

We produce complete high velocity air and oxy fuel systems. Since our incorporation in 2006, we have installed more than 60 systems in the USA, Europe, Japan, and China. 

Some of the systems are at work in Universities and National Labs, but most of them are used in production thermal spray shops.

We equip our systems with different spray guns; they are reliable and technologically efficient.

And they are not expensive.

For example, our HVAF system with the AK6 gun pays back your investment spraying a second metric ton of tungsten carbide.

We proudly design and produce our high velocity thermal spray equipment in the USA and install it all over the world.

You are welcome to visit our R&D center in Benicia to meet our designers and see our equipment in action.

Thermal Spray Coating Services in California

We provide HVAF and HVOF thermal spray coating services in California, USA.

We efficiently deposit wear resistant and corrosion resistant coatings for varied applications, including:

  1. hard chrome replacement
  2. corrosion-resistant vessel coatings
  3. erosion resistant coatings for pipes, elbows and fittings
  4. coatings for rolls in steel and paper industries
  5. repair of industrial parts
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