Brenco > Surface Engineering

Thermal spray technologies

HVOF spray illustrationHigh pressure, high velocity oxy-fuel (HP-HVOF)

Using a liqued fuel and oxygen to create a heat source, a high velocity flame is produced with near supersonic speeds that projects the chosen material in the form of a powder onto the substrate. This method is generally used to apply hard wear resistant materials such as tungsten carbides, chrome carbides, Inconel and Stellite™. Also used as an alternative to hard-chrome plating.

Plasma spray

An inert gas such as nitrogen or argon is ionised via an electrical charge to produce a ‘plasma’ flame. This process is most commonly used for the application of high melting temperature ceramic materials, such as chrome oxide, aluminium oxide, titanium dioxide and zirconia oxide.

Twin-wire arc spray
Two electrically charged wires are brought into contact with one another to create an arc and melt the material. This is then atomised and propelled onto the substrate using compressed air or inert gas. This is a fast and efficient method of applying metallic wires, such as aluminium, copper, bronze and stainless steels, to wear resistant materials, such as FeCrBSi.

Flame spray
Flame spray uses an oxy-fuel source to melt both wire and powder feedstocks. Typical materials include nickel and aluminium for corrosion resistance, graphite composites for the repair of abradable seals, and molybdenum for wear resistance.

Spray & Fuse
HVOF or flame sprayed feedstock is fused to the substrate by torch or vacuum furnace. This produces a metallurgical bond and results in coatings without interconnected pores and with very high bond strengths. Overlay materials used are nickel or cobalt-based alloys.

Rilsan® coating

An oxy-fuel source is used to melt Rilsan powder particles when re-covering ink transfer and oscillator rollers used in the printing industry. Good abrasion and chemical resistance is achieved with relatively high thicknesses. Replaces traditional nylon-coated rollers.

Cladding technologies

Laser cladding
Laser cladding is a process to perform overlay welding using a laser instead of an arc. Deposits a material (normally metallic), known as clad, serves as a support material for repairs, wear prevention and corrosion resistance. Cladding provides additional benefits of very low dilution and minimal or no distortion.

Plasma transferred arc (PTA)
PTA welding is a high energy welding process that uses an inert gas. This process deposits precise coatings of controlled alloys onto mechanical components subject to intense wear. Materials such as tungsten carbide, Stellite™ and corrosion-resistant alloys can be applied.

Equipment list

Thermal Spray

HP-HVOF (liquid fuel)  
Plasma Spray  
Twin Wire Arc Spray  
Flame Spray (powder / wire/cord)  
Spray & Fuse  


Laser Cladding with 8-axis automation  
Plasma Transferred Arc (PTA) Cladding
with 6-axis automation