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Self-Fluxing and Self-Fusing Alloys for Dense Coatings

For a fully dense coating that is highly wear and corrosion resistant, choose a self-fluxing alloy applied using a thermal spray process followed by a post-coat fuse. Self-fusing alloys offer many of the benefits of self-fluxing alloys when post-coat fusing is not feasible.

Self-Fluxing and Self-Fusing Alloys for Dense Coatings
Self-fluxing Materials

Self-fluxing materials are first applied using a thermal spray process, such as

  • Combustion Powder Thermospray™
  • Atmospheric Plasma Spray
  • High Velocity Oxygen Fuel (HVOF) spray

While the coatings can be used "as-sprayed," post-coat fusing is recommended to coalesce the coating, thereby making it fully dense and with optimal surface properties.

Characteristics and Benefits of Fused Coatings
  • Fully dense-coating microstructure
  • High coating hardness
  • Excellent wear and corrosion resistance
  • Coatings are metallurgically bonded to the substrate
  • Coatings can be ground to tight dimensions with a good finish
Self-fusing Materials

For situations when post-coat fusing may distort the component or the substrate cannot tolerate the heat of the fusing process, self-fusing materials are a good alternative. These materials partially coalesce during the spray process without requiring a post-coat fusing.

Characteristics and Benefits of Self-fusing Materials
  • Easy to use, one-step coating process
  • Very low porosity
  • Very good coating hardness
  • Very good wear and corrosion resistance
  • Bonds well to the substrate
  • Coatings can be ground to tight dimensions with a good finish
Flexibility to Suit Your Production Needs

In many cases, the coatings are easily applied using a simple combustion powder Thermospray™ system. Fusing, when required, is often accomplished manually using a simple oxy-acetylene torch.

For higher production volumes or mass production, a fully automated system can be used to apply the coatings. Fusing can be batch-processed in furnaces or accomplished using Radio Frequency (RF) induction coils. When done properly, part distortion is negligible to non-existent.

We offer a range of self-fluxing and self-fusing alloys to suit various application requirements. For the highest wear resistance, we supply products with carbide hard phases.