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Thermal Spray/High-Velocity Oxygen Fuel (HVOF)

An Excellent Alternative to Chrome Plating

Since 2010, our Thermal Spray division has specialized in the repair of Hydraulic Cylinders, Shafts, Rods, and Rollers. Our methodical Hydraulic’ Shaft repair approach is simple: Make the old, dented, worn, abused Hydraulic’ Shaft (that’s coming out of the field) look new again! Equally important, our objective is to provide our hydraulic customer three advantages:

  • Provide an alternative solution to repair an existing Rod or Shaft (vs. having to invest in a brand-new Rod or Shaft).
  • Provide a significant cost-savings vs. purchasing a new Rod or Shaft,
  • We’re committed to prompt turnaround while offering an improved, longer lasting surface finish when the rod returns to the “playing field.”
Thermal Spray—High Velocity Oxygen Fuel

What is Thermal Spray/HVOF?

High Velocity Oxygen Fuel (HVOF) coating is a thermal spray process in which fuel and oxygen are combined, fed into a combustion chamber, and ignited. The gas produced in the combustion chamber has an extremely high temperature and velocity as it is ejected through a nozzle at supersonic speeds. Simultaneously, an alloy powder is injected at a high-speed into the gas stream which propels the coating towards the substrate (i.e. the Shaft or Rod) to create a strong mechanical bond. The result is a coating with extremely high-density (very low porosity) and incredible bond strength to the substrate material. In addition, the HVOF coating provides high-wear properties, high hardness (mid 80’sRc) and excellent corrosion resistance.

More importantly, depending upon the environment and surroundings of the Hydraulic Cylinder, Rod, or Shaft, we can most likely propose an alloy or powder to combat the elements to withstand the atmosphere, the abusive chemicals by enhancing wear, improve hardness, and reduce corrosion. The Thermal Spray/HVOF’ process is an excellent alternative to Chrome plating.

Thermal Spray—High Velocity Oxygen Fuel

Our Thermal Spray/HVOF’ Capabilities:

Repairing Cylinder Rods, Shafts, Rollers, etc.—

  • We have diamond-wheel cylindrical grinding capabilities for pre and post/finish grinding Shaft’ applications.
  • We offer diamond-wheel cylindrical grinding for our customers—we can process Rods 20” diameter and 20 foot in length. See photo below.
    Thermal Spray—High Velocity Oxygen Fuel
  • Currently, we pre-cylindrical grind, HVOF Thermal Spray, and finish cylindrical grind Shafts/Rods up to 17” diameter and 10 ft. in length. Reminder: The incoming Rods/Shafts need to have Centers at each end, and the Rods need to be concentric.
  • Our cylindrical grinding capabilities are very precise—we routinely hold a +/- .001” tolerance of the OD.
  • In addition, our finish grinding process will generate a micro-finish of 10-12Ra. However, we can attain a higher (6Ra), if required.
  • Again, our goal is three-fold: (1) promptly repair our customer’s hydraulic Rod (within 2 weeks), (2) make the Rod/Shaft look “new” again, and (3) have the Rod perform in the field better and longer than the original Rod.
  • The Thermal Spray/HVOF’ process can be ramped-up on a production basis via automation, robotics, rotary tables, and innovation.
  • We can mask specific locations that don’t require HVOF and “localize” the areas that do require added hardness, increase wear resistance, enhanced corrosion protection, etc. We can adapt to your needs!
  • Again, we offer a variety of alloy powders that we can spray to best meet your application.

What HVOF’ Materials Can We Thermal Spray?

  • Tungsten Carbide: Tungsten Carbide coatings are extremely dense, well bonded and can be applied to a high thickness (.030” per side). HVOF Tungsten Carbide materials are recommended for applications that are subject to wear.
  • Tungsten Carbide-Cobalt-Chrome: Tungsten Carbide-Cobalt-Chrome coatings are more wear resistant in most applications than Tungsten Carbide coatings and are more corrosion resistant because of the Chromium content. The Tungsten Carbide-Cobalt-Chrome is recommended for applications with abrasive or sliding wear and are exposed to some corrosion. HVOF Tungsten Carbide-Cobalt-Chrome coatings are an excellent alternative to hard chromium plating.
  • Tungsten Carbide-Nickel Superalloy: Spraying a material with Tungsten Carbide-Nickel Superalloy produces a well bonded coating with a high level of wear resistance to abrasive grains, hard surfaces, and fretting. These coatings are ideal for hydraulic rods, ball valves, drilling, and saltwater applications.
  • Chromium Carbide: Chromium Carbide coatings have high microhardness and are well bonded. These coatings are ideal for providing resistance to solid particle erosion, abrasion, and tribo-corrosion at elevated temperatures.
  • Stainless Steel: Spraying a material with HVOF Stainless Steel (all grades) produces a dense and well bonded lower cost coating. These coatings are used for protection against corrosion, cavitation, and low temperature particle erosion in salvage and repair applications.
  • We offer a wide variety of other HVOF’ powders including Inconel, Monel, Hastelloy, Titanium, etc. Please let us know your challenge and the application!

What are the Benefits of High Velocity Oxygen Fuel (HVOF)

  • HVOF coatings are perfect for protecting Shafts, Cylinders and flat parts that are susceptible to damage from wear and corrosion.
  • Spraying parts with an HVOF coating is superior to that of chromium plating.
  • High density & high mechanical bond strength.
  • Improved hardness, toughness & wear.
  • The HVOF coating thickness can be .060”-.080” thick or more per side—thus, we can salvage/repair badly damaged cylinder rods, shafts, rollers, etc.
  • Increased corrosion resistance.
  • If necessary, we can straighten the rods, shafts & cylinders prior to repairing.
  • Then, after the HVOF’ Thermal Spray process, we diamond wheel cylindrical grind the OD to a close tolerance (typically +/- .001”) and with an excellent micro-finish (typically 12-16Ra, but we can reach a 4-6Ra if needed).
  • In addition, we can HVOF’ Thermal Spray a flat surface component, gears, blades, splines, etc. so to enhance the hardness and wear.
  • We can mask-off areas of a component and “localize” the HVOF process to a specific area that sees corrosion, high wear, or needs additional hardness.

We’re ready to restore your next Rod, Cylinder, Shaft, Roller, or any “Rotating Part that Sees Wear & Abuse. Our Thermal Spray/HVOF’ process accomplishes the following:

  • Protects from Wear and Erosion
  • Excellent in High Temperature Environments
  • Withstands Harsh Chemicals Atmospheres
  • Tremendous Corrosion Resistant Properties
  • Excellent Anti-Galling Material Options
  • Restoring Dimensional Integrity (can add .040” to .100” per side)
  • Super Dense, High Mechanical Bond Properties
  • Perfect for Anti-Skid Traction (Thermal Spray Only)
  • Apply Thermal Spray Technology on a New Rod, Shaft, etc. and Reduce the Preventative Maintenance for the Life Of the Component.
Thermal Spray—High Velocity Oxygen Fuel