Nation Coating Systems, Inc., is a supplier of thermal spray coaling for industrial applications and has found their services to be in demand by wind turbine OEM’s and component manufacturers. The thermal spray process applies molten particles to a surface with little to no distortion. It allows for surfaces to be protected from corrosion and can also restore dimensional tolerances to compensate for wear, defects, or machining errors. In many cases, this will allow the component be put into service versus being scrapped.

The initial form of the coating material can be either a rod, wire on a reel, or powdered composition. It is fed into a gun unit where it is heated by either oxy-fuel combination or electric heating to the molten state. The molten particles are accelerated by a gas steam and impinge upon the desired surface. The resulting overlay has a physical, not metallurgical, bond that exhibits exceptional bond strength . The coupling of inertia-driven/highly plasticized particles can produce a coating with very uniform density and within which, porosity can be limited to 1 ½ % or less. Coatings can be metallic, ceramic, or a matrix. Temperature of the component receiving the coating remains under 400º F, which limits distortion and changes to the metallurgical structure.

Coating thickness can range from a few thousandths to a quarter of an inch, depending upon the coating material and method of application. The surface to be prepped by removing all grease, oil, and other potential contaminates and then is grit blasted to provide the necessary surface finish for the interface to ensure proper bonding. The spray application of the coating can be done as the component revolves or on a stationary part through the use of a robotic arm or by manual hand application.

To date, successful applications within a wind turbine have included gearbox housing bores and main shaft journal build up. Other applications range from turbine engine blades to pump involutes. Practically any application that requires a wear or corrosion resistant coating can benefit from this technology.

Additionally, when utilized as a corrosion protective coating, the thermal spray process is more environmentally friendly than hex-chrome, and has become the preferred alterative to the chrome process.

Nation Coating Systems, Inc., offers classes covering the basics and also the latest advancements to help educate interested individuals on the benefits and limitations of this technology.

We are located in Franklin, Ohio—just south of Dayton. Our phone number is: 888-665-5525.