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Universal flame spraying system applies high performance polymer-based VICOTE® Coatings powder to metal substrates

Flame spraying is a process for applying a coating, which until recently, has been limited to the application of a metal coating and/or ceramic metals (cermets), via the spraying through a flame and resultant melting, of powdered metals onto the substrate to form the coating. Performance limitations of these metal and/or ceramic coatings have been tolerated due to the lack of an application technology suitable for applying high performance polymer coatings via flame spraying. Recent technological developments have made it possible for VICOTE® Coatings, made from VICTREX® PEEK™ polymer, to be applied by this method creating a tough, durable, chemically resistant and high temperature coating.

Jointly researched and developed by Victrex plc, a world leader in high performance polymers, and Alamo Supply Co. Ltd., experts in the manufacture of flame spraying systems, the cost-effective process uses Alamo's PG550™ flame spray equipment to apply the VICOTE Coating to various metal substrates. The PG550 unit is equipped with a unique gun nozzle design that sprays the VICOTE Coating onto a metal substrate, providing a tough high temperature durable coating.

This innovative flame spraying solution can be used to create a high performance surface finish on parts that would be difficult or costly to produce by other means. It is positioned to deliver performance enhancements for original equipment manufacturers, designers, fabricators and coaters, and for the repair and upgrading of in-service equipment. Flame spraying of VICOTE Coatings can help to provide wear, heat, erosion, abrasion, and corrosion resistance exceeding that of existing solutions.

ADVANTAGES OF FLAME SPRAYING

• No oven needed - improved energy efficiency
• In field/on site application possible
• Easy entry to flame spraying without the need for large capital investment
• Equipment is easy to use & set up
• Use on parts where Faraday Cage could be a problem - can coat complex geometries
• Coating can be machined & lapped to tolerance if required
• Potential for use on thermally sensitive substrates such as aluminum

VICOTE Coatings Overview
VICOTE Coatings, made from VICTREX PEEK polymer, provide excellent scratch and wear resistance, strength and durability for demanding applications that require exposure to extreme conditions such as high temperature, chemicals and abrasion. Using VICOTE Coatings can extend application life, improve product performance and functionality, reduce systems cost and facilitate design freedom to achieve product differentiation.

KEY BENEFITS OF VICOTE COATINGS

• Exceptional abrasion and erosion resistance
• Excellent mechanical properties including hardness and compression strength
• Inherently lubricous, excellent wear surface with low particulate generation and non-galling
• Excellent gamma radiation resistance (>10⁹ Rads)
• High temperature performance with a continuous use temperature of up to 260°C (500°F). Withstands lead-free solder processing temperatures.
• European RoHS (Restriction of Hazardous Substances) compliant
• Dairy 3A and FDA compliant; the majority of VICOTE Coatings grades can be used in environments involving food contact
• Eco-friendly - No primer required, zero VOCs (volatile organic compounds), halogen-free, low outgassing and extractables
• Excellent chemical resistance, superior to exotic metals
• Low moisture absorption and excellent hydrolysis resistance
• Good electrical insulator at high temperatures
• Tough & durable

POTENTIAL VICOTE COATINGS APPLICATIONS USING FLAME SPRAYING TECHNOLOGY
This new process is well suited for implementation in a large number of industries including; oil and gas, chemical plant, agricultural, transportation, aerospace, food processing, printing, glass, construction, and machining.

• Impellers
• Pump shafts
• Pump housings
• Industrial rollers
• Chemical storage tanks
• Cylinders
• Valves
• Glass production equipment
• Babbit bearing
• Compression parts
• Hermetically sealed pumps

Case Study
Methodology
Alamo Supply Co., Ltd, (Houston, Texas) manufactures flame spray equipment, including the PG550™ Universal Flame Spray System. The unit is equipped with a unique gun nozzle design that is capable of spraying VICOTE powder Coating onto various metal substrates. Victrex recommends that its VICOTE 702 and VICOTE 705 powder grades are the best choice for use with the PG550 unit.

During flame spraying, a stream of powder passes through the gun and is heated to such a temperature that the powder melts and is deposited at high velocity as 'splats' on the surface of the substrate. The resulting coating provides high wear, abrasion, erosion, scratch and corrosion resistance especially at high temperatures.

Benefits
This new solution and the performance characteristics of VICOTE Coating offer design and processing advantages. The coatings can be applied to thermally sensitive substrates. With flame spraying, no oven is required to cure the coating, typically required for electrostatically applied powders.

Additionally, in-field and on-site application is possible. The equipment is relatively easy to set up and use and the process of flame spraying can be done without a large capital investment.

Independent laboratory tests have shown that provided the recommended pre-treatment and processing steps are carried out flame spraying of VICOTE Coatings will provide superior adhesion between the coating and the substrate and provides very good corrosion resistance versus exposed metals especially against; salts, acids, alkalis, water and steam, aromatic and halogenated hydrocarbons. Salt Spray testing conducted by an independent laboratory on steel panels flame spray coated with VICOTE Coating showed the lowest level of rusting having a rust area no greater than 0.05% of the total area.

For details on VICOTE Coatings as an excellent choice for Flame Spraying, please download:
VICOTE Coatings Flame Spray Flyer

To obtain more information from a Victrex Sales Engineer:

Americas Sales or Technical Information:
800-VICTREX
484.342.6001
americas@victrex.com

Global Sales and Technical Information:
+ (44) 1253 897700
victrexplc@victrex.com
eurosales@victrex.com
japansales@victrex.com
scsales@victrex.com

For more information about VICOTE Coatings, to access VICOTE Coatings literature or request a sample, visit www.vicote.com.

Would you like to learn more now, or acquire data specifications for VICOTE Coatings?
Contact a VICOTE Coatings technical expert at Ask the Expert for more information.

VICTREX® IS A REGISTERED TRADEMARK OF VICTREX MANUFACTURING LIMITED. PEEK™, PEEK-HT™, T-SERIES™, MAX-SERIES™, ST™, and APTIV™ ARE TRADEMARKS OF VICTREX PLC. VICOTE® IS A REGISTERED TRADEMARK OF VICTREX PLC.

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