Supersonic Thermal Spraying Service Provides Abrasion-Resistant Coatings

XupersoniClad from Castolin Eutectic, a developer in the protective coatings industry, is a thermal spraying service that utilizes supersonic spraying technology. The service provides advantages in the protection of components, vessels and structures from abrasion, erosion and wear, according to the company.

XupersoniClad enables the application of various coatings, such as nickel alloys, carbide coatings and low melting point metal spraying, across numerous industries. These include chemical, waste-to-energy and biomass plants, and sectors requiring increased resistance to surface abrasion, corrosion protection and friction coefficient improvement.

Developed from the high-velocity air-fuel (HVAF) process, XupersoniClad applies abrasion-resistant wear coatings on forms such as metal, carbide and metal alloy powders. The company says it also provides a solution for new-generation high entropy alloy (HEA) coatings, combining five or more elements to outperform traditional materials in both room and high-temperature scenarios.

XupersoniClad is well suited for industries requiring enhanced abrasion, wear and erosion resistance, particularly recycling, concrete, brick and tile production industries, as well as vessel and boiler interiors. An application highlighted by the company is the mitigation of the damaging effects of cavitation on liquid pumps, propellers, impellers and control valves.

XupersoniClad is a warm spray process, said to be more efficient than the previous high-velocity oxy-fuel (HVOF) process, operating at lower temperatures and higher particle velocity, making it suitable for almost all common thermal spray materials, except ceramics.

The advantages of XupersoniClad include the range of coating thicknesses with minimal heat input into the substrate, low deformation and a smooth, ductile finish. Additionally, the use of XupersoniClad produces a dense, consistent microstructure designed for corrosion resistance. This process also offers the capacity to apply thin, precisely layered coatings while maintaining high bond strength and resistance to stress-induced delamination. XupersoniClad’s benefits also extend to the protection against cavitation, offering a well-bonded, dense and ductile protective coating that can withstand shock waves which can damage traditional hard coatings.

With the ability to apply coatings to the internal diameter of pipes as small as 80 mm, XupersoniClad increases its usability even further. An additional feature that accelerates the process is the capability for “hot grit” blasting, which is said to be faster, more focused and energy-efficient than traditional surface preparation methods.

To help expand the use of XupersoniClad, Castolin Eutectic has upgraded its facility in Belgium with a mobile container for on-site services, promoting accuracy and repeatability with the help of a cobot to manage large projects.