Comparison of Thermal Spray Technology vs. Laser Cladding

HVOF – High Velocity Oxy Fuel Premium mechanical bond (exceeds 10,000 psi) least amount of porosity and hardest values in the Tungsten Carbide option. Usually used for WC's and Cobalt (Stellite) options. Arc Wire and Flame spray Arc-Wire and Flame spray enable for cost effective repair or substantial coating coverage due to thick deposit. Frequently used for Stainless Steel's, Aluminum, Zinc or NiCrB self fluxing alloys. Plasma Slightly lower adhesion and more porosity, but is the only process capable of spraying the oxide (ceramic) family due to the heat zone of equipment. Fused coating is a post process heating after Thermal Spray processing on self-fluxing powders that can change mechanical bond to alloyed adhesion. Parts must be engineered to tolerate fusing temperatures of up to 2000 degree F.

When do you choose thermal spray? 

• Thin layer (<.020in) • High volume – multi fixtured parts • Cost sensitive • Field work (coat onsite) • Crack sensitive material • Sliding Abrasion Wear •Wide variety of material choices

When do you choose laser?

Thick build up (>.100in.) • When metallurgical bond is crucial with low heat input • Accurate, selective cladding w/o masking • Near net shape cladding (not rapid prototyping) • Repair with post process machining