newmetalsurfaces

Metal Spray Coating and Premature Equipment Failure

Wed, 24 Sep 2025 00:54:33 GMT

Top causes of premature equipment failure & how surface coatings can prevent them.

If you’re new here, we’re New Metal Surfaces. And part of what we do includes helping Operations Managers keep civil and industrial equipment running reliably.

In high-pressure environments like civil construction and industrial operations, even a short period of downtime can mean major project delays and increased costs. Operations Managers, Fleet Managers, and Equipment Supervisors face constant pressure to keep machinery in top working order. But with many variables out of your control — abrasive conditions, exposure to chemicals, heavy loads, and intense usage — equipment failure can feel inevitable.

The good news? It’s not.

With the right surface coatings, many common causes of premature failure can be mitigated or even eliminated altogether.

Common causes of equipment failure.

Excessive wear and abrasion
High-friction environments wear down surfaces rapidly, especially in moving parts like shafts, rollers, and valves. Over time, components lose their integrity and lead to mechanical failure.
Corrosion from harsh environments
Exposure to moisture, salt, and chemicals can eat away at unprotected metal parts. Corrosion weakens the structure of components and reduces their service life dramatically.
Thermal stress and heat fatigue
In high-temperature applications, repeated heating and cooling can cause parts to crack, warp, or degrade. This is especially common in engines, turbines, and processing equipment.
Poor lubrication retention
Uneven or rough surfaces can fail to hold lubrication, leading to increased friction and faster wear. This compounds wear issues and leads to equipment downtime.
Sub-standard repairs or materials
Quick fixes may restore a component temporarily, but without the right protective surface, the same issues resurface again — often worse than before.

How surface coatings help prevent failure

We apply advanced thermal spray coatings that significantly extend the life of your equipment. Here's how:

Superior wear resistance
Thermal spray coatings form a dense, hard surface that protects critical parts from abrasion and erosion. This reduces wear and keeps your equipment operating for longer periods between maintenance.
Corrosion protection
Specialist coatings can resist chemical and moisture exposure, guarding against rust and corrosion even in extreme or offshore conditions.
Thermal barrier coatings
High-temperature coatings help shield components from heat damage and reduce thermal cycling fatigue, ensuring stable performance over time.
Improved lubrication performance
Coated surfaces can be customised to optimise lubricant retention, reducing internal friction and energy loss.
Precision and reliability
Our coatings are engineered to tight tolerances and applied by experienced technicians. You’ll get consistent, reliable performance — with less downtime and fewer repeat issues.

Turnkey service. Fast turnaround.

Your equipment needs to get back on site quickly. That’s why we offer short lead times, fast turnaround, and end-to-end support. Whether you’re dealing with pumps, shafts, gears, or custom components, we’ll work with you to create a coating solution tailored to your environment.

Thermal Spray Coatings for Extreme Environments

Tue, 26 Aug 2025 02:02:01 GMT

How thermal spray coatings can help you beat the harshest conditions.

In the mining industry, downtime is more than an inconvenience — it’s a direct hit to productivity and profit. For Maintenance Managers, Reliability Engineers, and Site Supervisors, the pressure is on to extend the life of critical components in some of the most abrasive and corrosive environments on the planet. That’s where thermal spray coatings step in (and where NMS comes in).

Why parts fail — and what you can do about it

Mining environments are notoriously tough on equipment. Constant exposure to moisture, dust, slurry, and aggressive chemicals causes components to corrode, wear, and fail long before their time. The result? Costly replacements, production slowdowns, and unscheduled maintenance that can throw off your entire operation.

Thermal spray coatings provide a proven solution — applying advanced protective layers that resist wear, heat, and corrosion while enhancing part performance and longevity.

More on thermal spray coating

You probably already know a bit about it, but here’s some more info, just in case. Thermal spraying involves applying molten or semi-molten material (typically metal or ceramic) onto a component’s surface at high velocity. The result is a bonded coating that improves resistance to:

Abrasion and erosion
Corrosion (even in highly acidic or saline environments)
High temperatures and thermal cycling
Mechanical fatigue and impact

Unlike conventional plating or painting, thermal spray coatings can be precisely tailored to the environment and application — from shafts and impellers to valves, rollers, and pump components.

The benefits for mining maintenance teams.

Extended equipment life
Our thermal spray coatings reduce surface wear, protecting your components from the day-to-day grind. This means longer service intervals, fewer change-outs, and more time between shutdowns.
Reduced downtime
Preventing premature wear and failure keeps your operation moving. Whether you're in the Pilbara or the Goldfields — or outside WA — our coatings help ensure critical assets stay online longer. And when maintenance is needed, it’s planned, not reactive.
Improved reliability and safety
When parts are failing less often, your team isn’t scrambling under pressure. That leads to safer working conditions and a more predictable maintenance schedule.
Cost-effective protection
Replacing a worn part is expensive — but losing production time is worse. Our coatings offer an affordable way to boost the durability of high-wear components, helping you get more out of what you’ve already invested in.

Real results, right here in WA

We’ve supported Western Australia’s mining and resources sector for over 30 years. Our team understands the realities of site maintenance and the importance of fast, reliable turnaround. With ISO certification and advanced thermal spray facilities, we’re ready to help you tackle even the harshest conditions.

Ready to reduce wear and fight back against downtime?

Get in touch today to learn how thermal spray coatings can extend the life of your mining assets.

Choose the Best Thermal Spraying Service for Your Project

Mon, 06 May 2024 01:53:23 GMT

Which Thermal Spraying Services Are Best?

Thermal coat spray is a versatile and advanced process used to enhance, restore, or modify the surface properties of materials. This technique involves the projection of molten or semi-molten materials onto a substrate, forming a durable coating that protects against wear, corrosion, heat, and erosion. By extending the life and performance of treated components, thermal coat spray is widely used in industries such as earth moving and pumps .

Importance of Selecting the Right Thermal Spraying Service

Choosing the appropriate thermal coat spray service is essential for achieving the desired results and ensuring the longevity of your component or project. With so many options available, it’s important to match the right technique to the specific requirements of your industry and operating environment.

A well-chosen thermal coat spray service not only enhances surface performance but also provides cost-effective maintenance and repair solutions. At New Metal Surfaces, we guide you in selecting the best materials and methods for your needs, effectively addressing the technical challenges of various coating applications.

SIGN UP

Enter your email to sign up to our newsletter!

Types of Thermal Spraying Techniques

1. High-Velocity Oxygen Fuel (HVOF)

The high-velocity oxygen fuel (HVOF) technique produces particularly high-quality, dense, and strong coatings. It’s especially beneficial for applications requiring extreme wear and corrosion resistance, such as in marine and industrial environments, where durability and performance are critical.

HVOF uses a combination of oxygen and a fuel gas to generate a high-velocity flame through which the powder material (metal, alloy, or ceramic) is fed. The particles are heated and accelerated to supersonic speeds before impacting the substrate. The rapid cooling of the particles upon contact forms a very dense and well-bonded coating.

2. Arc Spray

Arc spray , also known as twin wire arc spraying, utilises an electric arc to melt feedstock wires that are typically made of zinc, aluminum, or an alloy. This process is known for its excellent coating quality and high deposition efficiency.

Arc spray provides a cleaner operation with relatively higher production rates compared to flame spray, making it suitable for larger-scale projects. It’s particularly effective for applications requiring thick coatings and is commonly used for anti-corrosion purposes in components.

3. Flame Spray

Flame spray coating is one of the most accessible and widely used thermal spraying techniques. It’s particularly valued for its simplicity and cost-effectiveness, making it ideal for a wide range of applications, from restoration works to enhancing mechanical properties of industrial parts.

The method employs an oxy-fuel flame to melt metallic or ceramic feedstock, which is in the form of powder. The molten material is then sprayed onto the substrate using compressed air, creating a robust coating that adheres well to the base material.

Factors to Consider When Choosing Thermal Spraying Services

Assessing the Material Requirements for Your Project

The environment in which the coated component will operate is a critical factor in selecting the appropriate thermal spraying technique and material. Conditions such as exposure to corrosive chemicals, fluctuating temperatures, and mechanical stress will influence the integrity and performance of a coating.

For instance, components used in marine environments require coatings that can withstand saltwater corrosion, while parts used in high-temperature settings might need a coating that can resist thermal degradation.

By thoroughly understanding the operational conditions, New Metal Surfaces can tailor the material choice — whether metal, alloy, ceramic, or composite — to meet the specific demands of the environment. This ensures optimal performance and longevity of the coating.

Analysing the Service Life Expectations

The expected service life of a component is integral in determining the type of thermal spraying process used. Different techniques offer varying degrees of coating durability and thickness, which can affect the longevity of the part under specific operational stresses.

For example, HVOF coatings are chosen for their dense, strong bond, making them suitable for components that endure high wear and tear, which extends the service life. Understanding these expectations allows our team to make informed decisions about the cost-effectiveness of various spraying options and their potential return on investment over the lifecycle of the component.

Coating as an Investment

A cost-benefit analysis involves evaluating the upfront costs of different thermal spraying techniques against the costs of not investing in coating (and your machinery). Coatings provide durability, cover maintenance needs, and increase operational efficiency, which saves money in the long run.

For example, continually replacing broken parts instead of proactively coating them is going to cost more than some simple coating investments to begin with. The reduced need for frequent replacements or repairs offsets the higher initial expenditure, making it a worthwhile investment — especially for high-stakes applications.

Industry-Specific Applications of Thermal Spraying Services

Thermal Spraying in the Earth Moving Industry

In the earth moving industry, equipment is subject to extreme mechanical wear and environmental exposure. Thermal spraying is used extensively to enhance the durability and performance of moving parts. Coatings like tungsten carbide applied through processes such as HVOF provide a hard, wear-resistant surface that significantly extends the life of these components, reducing downtime and maintenance costs.

Thermal Spraying for Drills

Drilling equipment, whether used in mining, oil, or gas extraction, operates under some of the most challenging conditions, facing constant abrasion, erosion, and corrosion. Thermal spraying offers a solution by applying protective coatings to drill bits and other components, increasing their resistance to wear and corrosion. Materials used typically include chromium carbide and nickel-based alloys, which are known for their durability and resistance to high temperatures and corrosive substances.

Thermal Spraying for Pumps

Pumps used across various industries, from water treatment to chemical processing, benefit greatly from thermal spray coatings applied to impellers, casings, and seals. Doing so protects against the corrosive and erosive effects of the fluids being pumped. This extends the service life of these parts while enhancing the efficiency and reliability of the pumps. Stainless steel and ceramic coatings are commonly used here due to their excellent corrosion resistance and mechanical properties.

Navigating the Challenges and Best Practices in Thermal Spraying

Common Pitfalls in Thermal Spraying and How to Avoid Them

Thermal spraying comes with its challenges such as porosity, oxidation, and improper bonding, which can compromise the integrity of the coating. To avoid these pitfalls, quality control is crucial. A part of this includes carefully managing the spraying parameters such as temperature, velocity, and material quality. At New Metal Surfaces, our skilled Technicians and advanced monitoring and control equipment also ensure coatings are applied consistently and correctly.

Tips for Collaborating with Thermal Spraying Service Providers

Successful thermal spraying projects require effective collaboration between clients and service providers, like New Metal Surfaces. If you’re looking for a new provider, or need to engage one for the first time, it’s important to go with someone who holds specific, proven experience in your industry. When you do, you’ll receive more nuanced insights into the best materials and methods for your application.

Clear communication about project goals, timelines, and budget is also vital. Additionally, regular updates and meetings will help address any issues promptly, ensuring that the project stays on track and meets all specifications and standards.

Let’s recap.

When you engage New Metal surfaces, these are some of the factors we’ll explore with you to get a thorough understand of the projects requirements.

Material and Environment: The specific conditions in which your component will operate (such as potential exposure to corrosive elements, extreme temperatures, and mechanical wear) are critical to choosing the correct thermal spray.
Service Life Expectations: We consider the expected duration of service for the component, and select a coating that offers durability without the need for frequent maintenance or replacement.
Cost-Benefit Analysis: We’ll help you evaluate the initial cost against the long-term benefits of various thermal spraying methods. High-quality coatings can offer significant savings over time through reduced maintenance and longer service intervals.
Industry-Specific Applications: We’re aware of the distinct requirements and proven solutions within a range of industries and leverage industry-specific expertise accordingly.
Common Challenges: We address potential pitfalls (such as porosity or improper bonding) early and utilises advanced control systems and skilled Technicians to ensure a smooth application.

Make the Right Decision for Your Project.

At New Metal Surfaces, we offer expert thermal coat spray services tailored to your unique project requirements. Whether you need wear-resistant coatings, anti-corrosion solutions, or custom applications, our team delivers high-quality results that ensure the longevity and efficiency of your components.

Contact us today to discuss how our thermal coat spray solutions can benefit your next project.

Importance of Quality Control in Metal Spraying in Perth

Mon, 29 Apr 2024 09:00:00 GMT

Quality Control in Metal Spraying.

Metal spraying, a critical process utilised across various industries in Perth, demands a rigorous approach to quality control to ensure superior outcomes. In this article, we’ll explore why quality control is not just a compliance measure but a fundamental component that enhances the effectiveness and durability of metal sprayed products.

Understanding Metal Spraying

Metal Spraying in Perth

Perth has emerged as a hub for advanced industrial techniques, with metal spraying at the forefront. This process involves applying a metallic coating to surfaces for protection against corrosion, wear, and tear, or to restore dimensions of engineering components.

As a mining State, quality control in metal spraying is paramount in Perth and WA. It ensures that each phase of the spraying process adheres to strict standards, guaranteeing the structural integrity and functionality of the coated items.

Process & Applications

Metal spraying, also known as thermal spraying, involves melting a source material, typically in wire or powder form, and then spraying it onto a surface where it cools and solidifies to form a protective coating. From aerospace to automotive and marine environments — and especially engineering and mining in WA — metal spraying plays a crucial role. It provides solutions for surface enhancement and part repair, extending the life and performance of critical components.

SIGN UP

Enter your email to sign up to our newsletter!

Benefits of Quality Control in Metal Spraying

1. Boosts Structural Integrity & Longevity

A part of quality control involves ensuring that the coatings applied are robust and adhere to the base materials. This is crucial because it prevents the coating from peeling, cracking, or wearing unevenly, which could undermine the structural integrity of the component.

For industries such as construction, the integrity of each piece could impact safety and operational efficiency. As such, rigorous quality control ensures that every sprayed component can withstand physical stresses and environmental conditions over extended periods. This longevity reduces the need for frequent replacements or repairs, providing economic benefits and enhanced safety.

2. Improves on Performance & Functionality

The performance of metal sprayed components depends on the uniformity and quality of the application. Quality control measures, such as precise application techniques and thorough inspection processes, ensure that coatings meet the required thickness and surface smoothness.

For instance, in the mining industry, metal spraying reduces friction and wear in components such as pistons and cylinders. Properly controlled metal spraying enhances the functionality of these components so they perform optimally within the engine.

3. Compliant with Industry Standards & Regulations

Compliance with industry standards and regulations is not just a bureaucratic checklist — it’s a critical component of operational integrity, and something we take very seriously at New Metal Surfaces. These standards ensure that our metal spraying activities promote safety, reliability, quality, and efficiency. For example, we adhere to ISO standards like ISO 9001 — a quality management standard that ensures our services are quality controlled and that we have a system in place for managing and reviewing our processes. This helps us deliver the best quality that we can.

By adhering to these standards, we ensure legal compliance for ourselves as well as our customers, bolstering their reputation as reliable and safe operators. Quality control ensures that every component sprayed at New Metal Surfaces meets these demands.

4. Reduction of Defects & Rework

When precision is paramount, even minor flaws in coating can lead to significant failures. Quality control measures minimise defects and the subsequent need for rework, both of which are costly and time-consuming. When each phase of the metal spraying process — from material selection and preparation to the actual spraying — is closely monitored and controlled, the likelihood of defects such as splits, cracks, porosity, or uneven coating thickness is significantly reduced.

We have quality control checkpoints throughout the spraying process to allow for early detection of potential issues. This proactive quality management means we can facilitate immediate corrective actions before they escalate into larger, systemic problems that would require rework.

5. Cost Savings in the Long Run

Our quality control systems lead to substantial cost savings over time for our customers. By ensuring that each sprayed component adheres to the highest quality standards, companies reduce the frequency of maintenance and replacement of parts.

This is particularly crucial in sectors where equipment and machinery are subjected to harsh operational conditions, such as mining or heavy manufacturing. Durable, high-quality coatings extend the lifespan of these components, thereby decreasing the overall cost of ownership through fewer disruptions in operations and reduced labor for repairs.

Key Components of Quality Control in Metal Spraying

Material Selection & Preparation

The initial step in ensuring quality in metal spraying processes involves the meticulous selection and preparation of materials. The choice of material depends on:

The desired properties of the final coating.
The specific requirements of the substrate.
The intended application.

For instance, materials such as zinc, aluminum, and copper provide different protective qualities, from corrosion resistance to electrical conductivity. Preparing these materials involves cleaning and sometimes pre-treating the substrate to enhance adhesion.

This might include abrasive blasting to prepare the surface for spraying by creating a rough surface that the coating will better adhere to. Additionally, the physical form of the material (powder or wire) must be chosen based on the specific spraying equipment and desired coating characteristics. This thorough preparation ensures that the subsequent metal spraying process is optimised for adhesion, coverage, and overall quality.

Precision in Spraying Techniques

A precise application technique is critical to achieving a high-quality finish. This encompasses several aspects:

The angle of application.
The distance between the spray gun and the substrate.
The speed of application.

These factors need to be meticulously controlled to ensure uniform thickness and optimal material properties of the coating. Advanced spraying techniques, such as high-velocity oxygen fuel (HVOF) spraying, require operators to maintain strict control over the spraying parameters. This precision ensures that the coatings are applied evenly without excessive buildup or thin patches, which could compromise the coating’s protective qualities. Our technicians are proficient in these techniques and understand the nuances of controlling the spray process for different materials and shapes.

For Better Quality, Spray with New Metal Surfaces.

At New Metal Surfaces, quality control is not just a procedural step. It’s a commitment to excellence that permeates every level of our metal spraying processes. Contact us today to ensure your metal spraying needs are met with the highest standards of quality, reliability, and professionalism.

ISO 9001:2015 Certification

Thu, 06 Jul 2023 04:49:36 GMT

New Metal Surfaces is proud to announce that we have achieved ISO 9001:2015 certification for the provision of thermal spraying and coating technologies, including but not limited to Arc Spray, HVOF (High-Velocity Oxygen Fuel, Machining and Grinding.

This is a fantastic achievement that allows our customers to have confidence and trust that the services we provide will be of the highest quality.

Over the past two years, New Metal Surfaces has undergone some big changes in order to improve our systems and processes to ensure that we can continue to deliver high-quality service to all our customers.

If you are looking for a trustworthy and competent thermal spray coating provider, get in touch today. You can be assured that you will receive the highest quality service possible.

SIGN UP

Enter your email to sign up to our newsletter!

You can read our quality policy here , or view our certificate below.

Perth’s HVOF coating specialists

For businesses seeking cost-effective ways to boost their equipment’s performance longevity, HVOF coating is a stellar choice. The high-density coating will ensure industrial components withstand their harsh environments, no matter the application, with long-term protection.

If you’re in need of HVOF coating services, get in touch with New Metal Surfaces. Our experienced team will deliver top-notch, customised solutions for all your coating needs. With the highest quality HVOF coatings in the industry, we’re sure you’ll be satisfied with the protection and performance of your equipment.

Contact our friendly team today to learn more.

Why Should You Choose HVOF Coating For Your Equipment?

Tue, 06 Jun 2023 04:44:39 GMT

Industrial equipment is subjected to harsh environments, extreme temperatures and corrosive substances on a daily basis.

Naturally, this takes a toll on its performance and lifespan.

To overcome these challenges, industrial equipment requires robust and reliable coatings that can withstand these harsh environments and provide long-term protection.

Thermal spraying, or thermal coating, is a popular technique used to provide this kind of protection. There are several types of thermal coatings, including combustion powder spraying, arc spraying and HVOF coating.

HVOF (high-velocity oxygen fuel) is a thermal spray process that uses a high-velocity mixture of fuel gas and oxygen to heat and accelerate the coating material to supersonic speeds. The high-velocity particles are then sprayed onto the surface of the equipment, creating a dense and hard coating.

HVOF coating is one of the most effective thermal coatings. If you’re considering a coating for your industrial equipment, consider the unique properties HVOF has to offer:

SIGN UP

Enter your email to sign up to our newsletter!

HVOF produces a high-density coating

A high-density coating provides excellent protection against abrasion, erosion and cavitation, making it ideal for heavy-duty industrial equipment.

Low porosity

As a result, the HVOF coating produced has a very low porosity level, typically less than 1%. Porosity is significant to the coating’s protective capabilities. Low porosity means the coating is much less prone to wear and tear, and is also much more resistant to corrosion.

Hardness

The high-density coating produced by HVOF is also much harder than other types of thermal coatings. The high degree of particle deformation and compaction results in a dense, hard coating. The hardness of HVOF coatings is typically in the range of 800 to 1200 HV, which is significantly higher than other types of thermal coatings. While the high-density coating can protect the equipment from wear and tear, the hardness of the coating can provide additional protection against scratches and dents. This is ideal for equipment used in harsh environments.

HVOF coatings have a high bond strength

HVOF produces coatings with high bond strength. This is because the particles are accelerated to supersonic speeds using a high-pressure gas stream, which provides the particles with a high kinetic energy. When the particles strike the substrate, they deform and flatten, creating a strong mechanical bond between the coating and the substrate.

Durability and lifespan

High bond strength improves the overall durability and lifespan of the coated equipment. This strong bond ensures that the coating remains firmly attached to the substrate and is less likely to peel away or flake off. This makes HVOF coating ideal for equipment that is subjected to high stress or where the equipment is exposed to high levels of vibration or shock, such as machinery used in the mining or oil and gas industries.

High temperatures

The high bond strength of HVOF coatings also enables the coating to withstand high temperatures without degrading or breaking down. This is particularly important for equipment that operates at high temperatures, such as gas turbines, boilers and exhaust systems. The high bond strength ensures the coating remains firmly attached to the substrate, even when exposed to extreme temperatures, protecting the equipment from corrosion and wear.

Wide range of substrates

HVOF coatings create excellent adhesion to a wide range of substrates, including metals, ceramics and composites. This versatility makes HVOF coating suitable for a variety of industrial applications, where equipment is made from different materials.

In HVOF coatings, the strong mechanical bond between the coating and the substrate ensures that the coating remains firmly attached, providing long-term protection against wear, corrosion and degradation. This makes HVOF coating an excellent choice for industrial equipment that requires long-term protection and durability.

HVOF is a versatile coating

HVOF coatings can be applied to a wide range of substrates, including metals and alloys, which makes them suitable for a variety of industrial applications.

Customisable

HVOF coatings can be customised to the specific requirements of different applications. They can be tailored to provide enhanced wear resistance, corrosion resistance or thermal insulation. This flexibility allows HVOF coatings to be used in a wide range of industries, including aerospace, automotive and manufacturing.

Repairs

HVOF coatings can also be used to repair or refurbish worn or damaged parts. The coating can be applied to the damaged area, restoring the part to its original condition. This is a cost-effective and convenient alternative to replacing the part.

Complex shapes and surfaces

In addition, HVOF coatings can be applied to large and complex shapes and surfaces. This is because the spraying process is highly controllable, allowing for precise and even application of the coating. This is great for parts with complex geometries, such as turbine blades or engine components.

The versatility of HVOF coating makes it a highly desirable option for industrial applications. Its ability to be applied to a wide range of substrates, customised for specific needs and repair worn parts, makes it a valuable addition to any industrial machinery.

HVOF coatings can enhance surface properties

HVOF coatings can enhance the properties of equipment, making them more resistant to wear, corrosion and erosion as desired. The material used in HVOF coatings is typically composed of metals or alloys, which can be tailored to provide specific properties depending on the needs of the application.

HVOF coatings can enhance the following properties of equipment:

Wear resistance: With a smooth and even finish, HVOF coatings can improve the wear resistance of equipment which can help to extend the lifespan of the equipment and reduce maintenance costs.

Corrosion resistance: Specific HVOF coating material can be chosen to fortify the substrate material, providing an effective barrier against corrosion. This can be particularly important for equipment used in harsh environments, such as marine or chemical processing industries.
Abrasion resistance: HVOF coatings can provide enhanced abrasion resistance to equipment. The dense and hard coating can withstand high-velocity impacts from abrasive materials, making it ideal for equipment used in abrasive environments, such as mining or oil and gas industries.
Thermal properties: HVOF coating material can provide thermal insulation, which is particularly useful for equipment used in high-temperature environments. HVOF coatings can also be used to dissipate heat away from critical components, protecting them from thermal stress and potential failure.

The enhanced surface properties provided by HVOF coatings make them a highly desirable option for industrial applications. The ability to tailor the coating material to specific needs, such as wear resistance, corrosion resistance, abrasion resistance or thermal insulation, can help to improve the performance and lifespan of the coated equipment, reducing maintenance costs and downtime.

HVOF coating is a cost-effective solution

HVOF coating can restore worn or damaged equipment to its original condition and improve its performance. This is often more cost-efficient than replacing the equipment, which can be expensive and time-consuming.

The dense and durable nature of HVOF coatings means they can provide the coated equipment with long-lasting protection. This can reduce the frequency of maintenance and repair, reducing costs and downtime, and improving productivity.

HVOF coating is cost-effective due to its ability to provide a long-lasting, durable coating that can improve the performance and extend the lifespan of equipment.

Perth’s HVOF coating specialists

Contact our friendly team today to learn more.

Large Gearbox Shaft Repair

Thu, 01 Jun 2023 03:15:49 GMT

We had the pleasure of working with one of our valued customers to repair a large gear shaft. The challenge for this component was not in the process we used to repair the journal, but in the size of the shaft. The shaft was just under 10T, over 4m long and had a repair journal of 680mm.

We pride ourselves on our ability to solve complex problems for our customers, and this was no different.

Check out the before and after pictures to see the transformation.

SIGN UP

Enter your email to sign up to our newsletter!

CUSTOMER TESTIMONIAL

“We were very happy with the service New Metal Surfaces provided and have had no issues with anything to do with quality. My customer was shown the shaft and was happy with the result.”

— Product Manager

BEFORE

AFTER

HVOF Thermal Spray Coating FAQ

Tue, 09 May 2023 05:23:14 GMT

Is HVOF thermal spray coating right for you?

At New Metal Surfaces, we specialise in the application of thermal spray coating solutions. Our family-owned business has been using HVOF thermal spray coating to repair components across a range of industries since 2011. It’s a process we firmly believe in and a service we’re proud to deliver.

Learn a little more about the HVOF thermal spray coating process with a few of our most frequently asked questions answered below.

SIGN UP

Enter your email to sign up to our newsletter!

What is HVOF thermal spray coating?

HVOF thermal spray coating is a process that involves accelerating small particles of heated metal onto a surface using a high-velocity stream of gas. This creates a durable, protective coating of industrial components to enhance their performance and lifespan.

What are the benefits of HVOF thermal spray coating?

HVOF thermal spray coatings can be used to improve wear and corrosion resistance, thermal insulation, adhesion and surface finish. They can also be applied to a variety of materials and surfaces, making them a versatile solution for a range of industries.

What industries use HVOF thermal spray coating?

HVOF thermal spray coating is used in a variety of industries, including industrial pumps, drilling, material handling, earth moving, oil and gas, aerospace, and power generation. Any industry that requires durable, high-performance components can benefit from HVOF coatings.

What materials can be used for HVOF thermal spray coating?

A wide range of materials can be used for HVOF thermal spray coating. We can spray a variety of cermets such as tungsten carbides in metallic binders and metal alloys. The material used will depend on the component being coated, its application and its required properties.

How is the HVOF thermal spray coating applied?

HVOF thermal spray coating is typically applied by injecting an oxygen-kerosene mixture into a combustion chamber within the spray gun which is then ignited. Powdered material is injected, and the high-velocity stream of gas partially melts and propels it onto the desired surface. This process is controlled to achieve a specific thickness and uniformity.

How does HVOF thermal spray coating compare to other types of coating?

HVOF thermal spray coating is known for its superior wear resistance and corrosion resistance compared to other types of coating, such as laser cladding and hard chroming. It can also be applied to a wider range of materials and surfaces than other coating methods. Want a more detailed look at how thermal spraying and laser cladding compare, Check out this blog.

Can HVOF thermal spray coating be used to repair damaged components?

Yes, HVOF thermal spray coating is commonly used to repair components that have been damaged by wear or corrosion. The damaged area is prepared and then coated with the appropriate material to restore the component to its original condition.

How long does HVOF thermal spray coating last?

The lifespan of an HVOF thermal spray coating will depend on a variety of factors, including the material used, the application, and the conditions in which the component is used. Generally, HVOF coatings are known for their durability and long lifespan compared to other types of coating.

WE’RE READY

Why Arc Spray is a Great Thermal Spray Solution for Most Coatings

Mon, 08 May 2023 05:38:48 GMT

What is arc spraying?

Arc spray, also known as twin wire arc spray, or metal spray, is the all-rounder of industrial coating applications. A popular choice for its strength in coating many different types of materials, at New Metal Surfaces we commonly use arc spray to repair worn or damaged machine parts, correct mis-machined components and improve corrosion control and electrical conductivity.

SIGN UP

Enter your email to sign up to our newsletter!

Arc Spray Application

Arc spray is a thermal spray process that uses an electric arc to melt wires to create a dense and durable coating. Arc spray coatings are applied using robotic equipment at New Metal Surfaces following the steps below:

Step 1: Surface Preparation
The substrate (or surface) must be cleaned and prepared before applying the coating. This may involve grit blasting and using chemical solutions to remove any contaminants and create a rough surface for the coating to adhere to.

Step 2: Wire Feeding and Arc Generation
Two wires, typically made of metal or alloy, are fed into the arc spray gun. An electric arc is generated between them, causing them to melt.

Step 3: Atomisation and Propulsion
The molten material is atomised into small particles using compressed air and propelled towards the substrate at high speed. The particles hit the substrate and flatten out, creating a coating.

Step 4: Coating Build-up
The process is repeated to build up the thickness of the coating. The coating can be applied in multiple layers to achieve the desired properties and thickness.

Why is Arc Spray a Great Thermal Spray Option?

Versatile

Arc spray is a versatile coating solution that can be applied to a wide range of substrates.

Arc spray can also use a wide range of materials for various applications. The choice of material will depend on the properties required for the coating, such as hardness, chemical resistance, and thermal conductivity.

Adhesion and Bond Strength

Arc spray produces coatings with excellent particle adhesion and bond strength. Whilst it doesn’t reach the same level of bond strength as a process like HVOF (click the link to learn more about HVOF coatings) it is still a process that has high tensile strength, low porosity, and great corrosion resistance.

High Deposition Rates and Thicknesses

Arc spray is a coating process that allows for high deposition rates of material. It can be used to apply large amounts of material to coatings quickly and achieve greater thicknesses than some other thermal spray processes.

Fast and Efficient

Arc spray is a fast and efficient coating process, especially when automated. It can be used to apply coatings quickly and evenly to large surfaces, reducing the amount of downtime and increasing productivity.

Arc spray offers a cost-effective, high-quality coating solution for machine parts and industrial components. The high deposition rates, the thickness that can be achieved and the ability to enhance qualities, like corrosion resistance and electrical conductivity, are what make arc spray such a popular coating choice.

WE’RE READY

A Brief Glossary: HVOF Thermal Spray Coating

Tue, 18 Apr 2023 02:00:00 GMT

Throughout our website, we use terminology you may not be familiar with to describe some of the services we provide. Where this is unavoidable, we hope that you’ll still be able to get to know us and what we do.

Below we’ve put together a brief list of definitions that may help to guide you through one of our primary services: HVOF thermal spray coating.

SIGN UP

Enter your email to sign up to our newsletter!

HVOF Thermal Spray Coating:

A process that involves accelerating small particles of heated metal onto a surface using a high-velocity stream of gas. This creates a durable, protective coating that can be used to enhance the performance and lifespan of industrial components.

High-Velocity Oxygen-Fuel (HVOF):

A specific thermal spray coating process that uses a high-velocity stream of gas (typically oxygen or a mixture of oxygen and fuel) to spray a heated material onto a surface.

Low Porosity:

Porosity is the degree and amount of ‘holes’ within a coating through which environmental material can enter and damage the substrate. HVOF offers a low level of porosity in its coatings due to the high impact velocities that are achieved by the in-flight particles. This makes them less susceptible to corrosion and other types of damage.

Coating Adhesion or Bond Strength:

How well the sprayed material and the surface mechanically interlock and ‘stick’ together. This is typically measured by the force required to separate the coating from the surface. Good adhesion or bonding is essential for a durable, long-lasting coating.

Corrosion Resistance:

The ability of a material to resist degradation caused by (chemical reactions with) its environment, such as exposure to moisture or corrosive chemicals. Corrosion resistance is important for preventing the wear and failure of industrial components.

Wear Resistance:

The ability of a material to resist damage or erosion caused by mechanical forces, such as friction or impact. Wear resistance is important for protecting critical components from damage and extending their lifespan.

WE’RE READY

Advantages of HVOF Thermal Spray Coatings for your Industry

Wed, 22 Mar 2023 03:26:04 GMT

Advantages of HVOF Thermal Spray Coatings for Industrial Components

Are you looking to get better mileage from your industrial components?

HVOF thermal spray coatings are a high-quality solution. HVOF (high-velocity oxygen-fuel) thermal spray coating uses a high-velocity stream of gas to spray molten particles onto a surface, creating a dense, durable layer.

These coatings are suitable for a wide range of materials and industries, improving performance, durability, and component life. Below are the key benefits of HVOF thermal spray coatings:

SIGN UP

Enter your email to sign up to our newsletter!

1. Exceptional Wear and Corrosion Resistance

HVOF thermal spray coatings are known for their exceptional wear and corrosion resistance. The dense, low-porosity coating provides protection from environmental wear and tear, such as corrosion, erosion, and abrasion. This extends the life of your components by reducing the frequency of maintenance and/or replacement.

Due to the wear and corrosion resistance of HVOF thermal spray coatings, they are particularly beneficial in applications where components are routinely exposed to harsh environments or corrosive materials. In the oil and gas industry, components such as valves and pumps are exposed to corrosive fluids and gases. HVOF thermal spray coatings can help to protect these components from corrosion and wear and reduce the risk of failure or downtime.

2. Strong Adhesion for Long-Lasting Protection

HVOF thermal spray coatings strongly adhere to the surface of a component. This is due to the high velocity of the gas stream, which helps to create a mechanical bond between the coating and the surface. Stronger adhesion means the coating is less likely to peel, flake or chip away, ensuring long-lasting protection. This is especially important for components exposed to high levels of stress or impact.

3. Customisable Coating Thickness

HVOF thermal spray coatings can be applied in a range of thicknesses, depending on the requirements of your components. This allows for greater flexibility in the design and construction of your components, as well as the ability to optimise the coating for specific performance requirements. For instance, components that require a high degree of wear resistance may benefit from a thicker coating, while components that require greater thermal conductivity may require a thinner coating.

4. Enhanced Component Performance

HVOF thermal spray coatings can be used to improve the functionality and performance of components. For example, the increased wear resistance provided by the coating can reduce friction and improve the efficiency of moving parts; this can reduce energy consumption and increase productivity. Additionally, the improved corrosion resistance provided by the coating can help to maintain the integrity of your components, minimising the risk of failure or downtime.

4. Versatility Across Industries

HVOF thermal spray coatings can be applied to a wide range of metal materials, which makes them ideal in a variety of industries, such as industrial pumps, drilling, material handling, earth moving, oil and gas, and power generation. Furthermore, the versatility of these coatings means that they can be used on a wide range of components, from spindles to impellors to pump housings to drill shafts to hydraulic suspension rods, for protection or to improve their performance.

Well-suited to a range of industries, HVOF thermal spray coatings are a strong, customisable coating which extends the life, performance and durability of industrial components. They improve and restore components made from all kinds of materials to minimise downtime and maximise efficiency.

WE’RE READY

For your coating needs, consider New Metal Surfaces for an effective, high-quality and long-lasting solution. Our premium HVOF coatings can produce deposits with less than 1% porosity, offering more protection, better wear resistance and higher bond strength than other coating solutions.

Get in touch with us today and let’s get the most out of your equipment.

What is a HVOF (High Velocity Oxygen Fuel) coating?

Mon, 23 Jan 2023 03:46:49 GMT

What is hvof thermal coating?

HVOF or High-Velocity Oxygen Fuel is a thermal spray coating process. Thermal spray coatings are created by accelerating small particles of heated metal or ceramic towards the work surface so that it mechanically deforms and bonds resulting in a dense coating.

What is the purpose of HVOF (High-Velocity Oxygen Fuel) coating?

Thermal spray coatings are used to improve or restore the surface of a component. Using thermal spray, we can apply coatings to a wide range of materials utilizing a wide range of coating types. We can restore the dimensional accuracy of metallic parts and cost-effectively improve wear resistance, corrosion resistance, thermal conductivity, and magnetic permeability.

HVOF coatings are one of a range of thermal spray coating solutions that we provide to our customers.

Invented in the 1980s by Jim Browning, HVOF coatings work by injecting an oxygen-kerosene mixture into a combustion chamber within the gun, this is then ignited, and the gases are accelerated through the nozzle. The powder is injected into the combustion zone, partially melted, and propelled onto the workpiece.

See figure 1. For a simplified cross-section of an HVOF gun below.

SIGN UP

Enter your email to sign up to our newsletter!

We spray several different materials using HVOF but the most common materials that we spray are variations of tungsten carbides and chrome carbides. These combinations provide dense, wear-resistant and corrosion-resistant coatings.

What are the advantages of HVOF coatings?

There are several different advantages that HVOF coatings have over other thermal spray coatings, laser claddings and hard chrome.

Low Porosity, Low Oxide Coatings

Due to the impact velocities that are achieved by the in-flight particles, HVOF coatings have comparatively low porosity levels. Lower oxide levels are also achieved in the coating due to the lower in-flight exposure time to oxygen – the particles spend very little time in the flame.

Wear Resistant Coatings

Because of the low porosities and low oxide levels that are achieved, HVOF coatings are also typically more wear resistant than the same materials sprayed by other methods. This lower porosity, lower oxide coating helps to increase wear resistance for many different component types.
HVOF is also capable of spraying coatings with significantly higher levels of wear resistant particles, such as tungsten carbide, when compared to other coating systems. The higher the percentage of wear resistant particles like tungsten carbide, the more wear resistant a coating becomes. HVOF can achieve 88% tungsten carbide in a coating. In comparison, laser can only achieve 60% tungsten carbide.

Corrosion Resistant Coatings

Because of the low porosity of the coating (less than 1%) and the low oxide content, HVOF coatings are more corrosion resistant than other coating methods.

Safer Coatings

Other coatings, specifically Hard Chrome coatings require the very toxic, carcinogenic hexavalent chromium to manufacture them. HVOF coatings on the other hand do not produce toxic chemicals and are much safer not only for our thermal spray technicians but also the environment.

What are the limitations of HVOF coatings?

One limitation of HVOF coatings is the need to have a direct line of sight whilst spraying. It is not possible to spray internal surfaces on small cylindrical components to any significant depth. This is due to the coating being most efficiently deposited with the gun perpendicular to the surface to be coated. As the coating angle decreases, so does deposit efficiency. Parts typically need to be sprayed no more than 30° from perpendicular with nothing in the way of the particle stream.

When would HVOF coatings be the right choice?

HVOF coatings are a great option for many different types of components. In our workshop we see a lot of shafts, sleeves, spindles, rotors, mandrels, yokes, and rods come in for HVOF coatings due to the advantages it provides that are listed above.

Essentially HVOF coating will be suitable for a component if you have a line of sight for spraying and you are desiring to increase some of the following characteristics.

Provide superior rebuild and salvage operations.
Increase abrasion resistance.
Increase sliding wear resistance.
Increase resistance to fretting, galling or adhesive wear.
Increase resistance to cavitation effects.
Increase resistance to chemical attack.
Increase control of oxidation and sulfidation.
Increase atmospheric and high-temperature corrosion control.

In general, HVOF coatings are a much more wear-resistant coating than other options, which allows for longer component life cycles and that provides you with less downtime for critical machinery.

How can New Metal Surfaces help?

If HVOF coatings are something that you are interested in, speak with us today and we can work together on how we can best benefit your business using HVOF coatings.

WE'RE READY

If becoming a thermal spray technician is something that interests you, or you would like to know more, get in touch with us – we would love to hear from you.

HD1500 Rear Axle Housing Repair

Tue, 10 Jan 2023 08:47:08 GMT

Axle Housing Repair

Recently, one of our valued customers sent a couple of HD1500 Rear Axle Housings to our workshop for axle housing repair, focusing on fixing their damaged bearing areas.

Check out the before and after pictures to see the transformation.

SIGN UP

Enter your email to sign up to our newsletter!

BEFORE

AFTER

A Day in the Life of a Thermal Spray Technician

Tue, 10 Jan 2023 02:28:19 GMT

Many of the customers and people that we speak with have either a basic understanding of thermal spraying or have never heard about it. This dichotomy is most notable when speaking with potential new employees, so to help showcase the amazing work our thermal spray technicians do we want to take you through the typical day of our thermal spray operators.

WHAT IS THERMAL SPRAYING

Before we show you what a typical day for our thermal spray technicians is like, it’s important to understand some of the basics of thermal spraying.

Thermal spraying is a term that we use to describe our repair processes at New Metal surfaces. Thermal spray coatings are created by accelerating small particles of heated metal or ceramic towards the work surface so that it mechanically deforms and bonds resulting in a dense coating.

Thermal spray coatings are used to improve or restore the surface of a component. Using thermal spray, we can apply coatings to a wide range of materials utilizing a wide range of material types. We can restore the dimensional accuracy of metallic parts and cost-effectively improve wear resistance, corrosion resistance, or thermal conductivity.

SIGN UP

Enter your email to sign up to our newsletter!

WHAT IS A THERMAL SPRAY TECHNICIAN?

A thermal spray operator is one of the people responsible for applying the thermal spray coatings that we so often talk about. They are one of the key pillars within our workshop, without them, we would simply be another highly skilled machine shop.

Thermal spray technicians are part of our spray shop. They work within a small team and operate our different thermal spray coating booths.

READING & INTERPRETING THE JOB CARD

To begin the day, our technicians read and interpret the job cards that they have for that day. The job card is the central document for our workshop – it contains all the information necessary to complete the job repairs to the customer's needs and satisfaction.

The job card will detail all the steps that are required for our workshop to complete the component repairs, from prep machining to spraying, to finish machining – everything is covered.

For the spray technicians, the job card details what thermal spray process is required, what part of the component is to be sprayed, what materials are required and, the amount of material needed to achieve the desired coating.

This step is vital to the thermal spray process, as it is the basis for understanding the needs of the customer, without this we will make mistakes and be required to begin the repair process from the beginning.

PREPPING THE COMPONENT

Once the spray technician understands the needs of the component repair, they will begin by prepping the component for grit blasting. Most of the components we spray are required to be grit blasted prior to the application of the thermal spray coating. This is to ensure that we are achieving the highest quality coating we can.

To prepare the component for grit blasting, our technicians will ‘mask’ the areas of the component not being sprayed to protect those areas from any damage. Once masked our technicians will grit blast the designated area, ready for it to be sprayed.

SETTING UP THE COMPONENT

Once the component has been grit-blasted, it is then ready for the technicians to prepare the component for spraying, this is done by painting the area that will not be sprayed with a specific paint that protects it from the thermal coating. They will then set the job up in the spray booth in either a lathe or on the rotator, depending on the type of component.

Once set up, the technician is then ready to program the robot to spray. Depending on the component, a program may already be available for use, or with the help of senior spray technicians a new program will be coded for the job.

APPLYING THE THERMAL SPRAY COATING

Now that the job is set up and the programming complete, the component is ready to be sprayed. Almost all our thermal spray coatings are completed robotically to create the safest working environment possible. This means that whilst the robot is spraying the component, the technicians will monitor the coating from outside the booth to ensure that the robot is applying the coating correctly.

After each program run, the spray technician will record different measurements to make sure that the spray process is progressing smoothly. This will usually be things like the component temperature, the coating thickness, and other important factors.

Once the coating is completed, the technician will do a final inspection and record the thickness of the coating on the job card, and input material data into our job management system.

The component is then ready to be moved through the workshop to the next step in its repair journey.

HOW TO BECOME A THERMAL SPRAY TECHNICIAN

Now that you know what a thermal spray technician does, how would someone become a thermal spray technician. Due to the relatively niche market, there are not many experienced thermal spray technicians, however for this reason they are extremely sought after by companies like us.

To start a career as a thermal spray technician there are no specific qualifications that are required. What we look for in our thermal spray technicians, are hard working individuals who can work well in a team, and who can apply critical thinking to solve any problem that may arise.

WE'RE READY

If becoming a thermal spray technician is something that interests you, or you would like to know more, get in touch with us – we would love to hear from you.

What is Thermal Spraying? And why should you consider it?

Mon, 10 Oct 2022 04:17:26 GMT

Currently at New Metal Surfaces, we offer our customers three thermal spray coating options:

SIGN UP

Enter your email to sign up to our newsletter!

HVOF

TWIN WIRE ARC SPRAY

COMBUSTION POWDER SPRAY

Let’s take a deeper dive into what thermal spraying is, and why we believe you should consider it when looking at repairing your components.

THE BASICS

At New Metal Surfaces, when we say thermal spray coatings, we mean a coating that is produced by accelerating small particles of heated metal or ceramic towards the work surface (your component) so that it mechanically deforms and bonds resulting in a new coating. Essentially, a thermal spray coating is what we apply to your damaged or new components to restore or improve the surface of your component.

Through these coatings we can restore dimensional accuracy of metallic parts, and cost effectively improve some of your component’s characteristics, such as wear resistance, corrosion resistance, thermal conductivity and more. These improvements are made due to the selection of materials that we use in our thermal spray coatings, which can be altered dependent on the needs of your components.

There are a number of different terms that we use when describing thermal spray coatings, so let’s take a look at them.

BONDING & BOND STRENGTH

When we talk about a thermal spray coating bonding to the work surface, or we mention the bond strength of a coating, we are talking about how well the sprayed material and the work surface mechanically interlock and ‘stick’ together. The bond strength is the measure of the perpendicular force required (per unit area of coating) to pull the coating off the work surface.

There are many factors that affect the bond strength of a coating, these include:

The blast depth and surface profile
The velocity of the sprayed material
The physical and chemical properties of the sprayed material
The temperature of the sprayed material and the work surface
The thermal spray process that is used
Thickness of the coating
The material deposition rate
And much more…

At New Metal Surfaces we grit blast your components coating areas, because the rough surface profile that is produced from the grit blasting allows the sprayed material to better mechanically lock onto the work surface.

An advantage that our HVOF coatings have over the other processes we use for our thermal spray coatings is that the HVOF process produces coatings with higher bond strengths due to the high impact velocity that is achieved.

COATING THICKNESS

The thickness that can be achieved from a coating is dependent on the bond strength that can be achieved. For example, as more coating is deposited on a work surface, the residual stress in the coating is increases, once it reaches a point where that stress in more than that of the bond strength, the coating will fail. This is why we only spray certain thicknesses for certain materials – If we were to spray a material onto a work surface above that recommended thickness, we cannot guarantee that the coating will not fail.

Once again, another advantage of HVOF coatings is that we are able to produce low stress coatings that are extremely dense, and therefore more durable, in some cased, than other thermal spray processes that are offered by New Metal Surfaces.

POROSITY

When we mention that our HVOF coatings achieve little porosity, we are referring to the lack of pores or voids within that coating. Depending on the application of your component, porosity will be a detrimental or an important factor. Our HVOF coatings can achieve deposits with less than 1% porosity.

COATING PROPERTIES

At New Metal Surfaces we work with our customers to determine the best coating for their specific component needs, this allows us to produce a coating that has the properties that matter to you. For example, different choices in sprayed materials can produce coatings that have very different properties to each other.

Some of the properties that can be achieved by thermal spray coatings are:

Increased wear resistance
Increased corrosion resistance
Increased heat resistance
Increased electrical conductivity, or resistivity
Increased abrasion resistance

Depending on the application of your component, we can tailor a coating that will allow it to perform more efficiently, and for longer periods of time – saving you money on continual replacements.

WHY YOU SHOULD CONSIDER THERMAL SPRAY COATINGS

We hope that the article that you have just read gives you a basic understanding of the different factors and elements to consider when choosing a thermal spray coating. Whilst some of these terms or processes might seem complicated (because they are), you can rest assured that our team knows what we are doing, and that your components would be safe in our hands.

By choosing a thermal spray coating, we will be able to work with you to enhance your component for your specific application. So, if you have a component that is in frequent need of repair or replacement, or if you want to improve the efficiency of your machinery, get in contact with us today to see how your business could be improved using thermal spray coatings.

WE'RE READY

Get in touch with us today to see how we can assist you with your thermal spray coating needs.

RCR Mining Technologies - Mill Trunnion Repair

Thu, 15 Sep 2022 01:27:28 GMT

RCR Mining Technologies has been a valued customer of New Metal Surfaces for many years. Over the past couple of years, they have continually trusted our team to deliver high quality work to restore their worn and damaged components.

THE PROBLEM

RCR Mining Technologies engaged our team to devise a repair solution for a damaged mill trunnion from one of their clients’ sites. We worked with RCR in June to provide a solution that would allow them to get their clients mill up and running again, whilst they waited on a new mill trunnion, that due to long lead times would not be ready until 2023

THE SOLUTION

1. Our team began by visiting RCR Mining and inspecting the damaged area in person to provide a recommendation for the best repair procedure given the substrate material and what application the component would be used.

2. Once the client approved our repair, we began by prepping the trunnion for spraying. During this process, we welcomed representatives from RCR to inspect the component and be present for the MPI crack testing. This allowed us to understand exactly the needs of our client and provide assurances of the quality of work that they will receive.

BEFORE

DURING PREP MACHINING

DURING SPRAYING

3. Once the trunnion was prepped, our spray technicians grit blasted the prepped surface, and applied a HVOF coating to the damaged area. The material we chose for this HVOF coating as it provided a good combination of adhesion, wear resistance and corrosion resistance.

4. After spraying the damaged area, the mill trunnion was placed back on our Vertical Borer to be finish machined to its final dimensions.

5. The finished result was a restored mill trunnion that was finished on time and installed on site by RCR in early July that will ensure the end client is able to get their mill back up and running.

AFTER

CUSTOMER TESTIMONIAL

“The service provided by New Metal Surfaces was next level. From quoting to the follow ups visits at the workshop and the interactions with their machinists during MPI checks. The metal spray solution provided our client with the ability to get their mill back up and running while they wait for a new mill trunnion in 2023 due to long lead times.

RCR appreciated the professional and friendly service provide by New Metal Surfaces and look forward to working together on future projects.” — Vince, OSR Manager.

The Benefits of Thermal Spraying

Fri, 24 Jun 2022 03:53:27 GMT

THE BASICS OF THERMAL SPRAYING

Thermal spray coatings are used to improve or restore the surface of a component. Using thermal spray, we can apply coatings to a wide range of materials utilizing a wide range of material types. We can restore dimensional accuracy of metallic parts and cost effectively improve wear resistance, corrosion resistance, or thermal conductivity.

Currently at New Metal Surfaces, we offer our customers three thermal spray coating options:

OUR THERMAL SPRAY COATING SOLUTIONS:

HVOF

TWIN WIRE ARC SPRAY

COMBUSTION POWDER SPRAY

At New Metal Surfaces we primarily apply our coatings to either, restore a damaged or worn components, or to enhance a new component. Let’s look at the advantages of applying thermal spray coatings in both situations.

RESTORING DAMAGED COMPONENTS

Arguably one of the most common uses of thermal spray coatings are to restore a damaged component back to working order. Many of our customers require us to restore the dimensional accuracy of various components in order to get their machinery back in action. Some of the benefits of using thermal spray coatings to repair worn components are;

A reduced cost to restore the component compared to replacing it with a brand-new component. In many situations, it is far more cost effective for our customers to choose to repair their components using thermal spray coatings than to buy replacements.

Thermal spray coatings can extend the lifecycle of a component. Depending on the environment that the component is exposed to, we can tailor our coatings so that the component will not only be restored but will last longer due to the properties of the coating.

Another advantage of thermal spray coatings is the wide range of materials that can be applied. Materials include metals, alloys, ceramics and more. Depending on the process used, the material can be in powder or wire form. At New Metal Surfaces we work with you to determine what material or combination of materials will form the best coating for your specific needs.

ENHANCING NEW COMPONENTS

An increasingly popular use of thermal spray coatings is to apply coatings to new components before they are exposed to their operating environments. This enables us to work with our customers to develop coatings specific to the intended service. Some of the benefits of applying thermal spray coatings to new components are;

Increased service life of the component. When we apply a coating that is customized for the conditions that the component will be exposed to, we are able to extend the life cycle beyond what would normally be possible with an uncoated component.

Decreasing down-time. Lower wear and corrosion rates result in less maintenance, which is cost effective for our customers in the long term.

Customized solutions. By apply thermal spray coatings to new components, we can work with our customers to customize the characteristics of the coating to suit the intended application of the component. For example, we can provide coatings to increase resistance to corrosion, reduce electrical conductivity, and much more. Speak to us today to see how we can tailor a coating for your specific needs.

WE'RE READY

Get in touch with us today to see how we can assist you with your thermal spray coating needs.

Secondary Cone Crusher Main Shaft Repair

Tue, 24 May 2022 01:37:27 GMT

Our customers regularly engage us to deliver high quality repairs and coatings for many different components. They continually trust our team to deliver high quality work to restore their worn and damaged components.

THE PROBLEM

New Metal Surfaces was engaged to repair the main shaft for one of their customers Secondary Cone Crushers. As the main shaft is exposed to hot-cold temperature transitions as part of the fitting process, attention to detail and accuracy were vital to this repair.

THE SOLUTION

1. Based on the specifications provided to us by our customer, our team of specialists began by providing a recommendation for the best material given the substrate material and what application the component would be used.

2. Once we received confirmation, we began by prepping the damaged area for spraying. As the shaft was 4.5 tonne and approximately 2000mm long, this component was machined using our 5m lathe. This process preps the surface so that it is ready to be grit blasted and then sprayed.

3. Once prepped, our spray technicians grit blasted the surface, and applied a HVOF coating to the damaged area. We chose a HVOF coating as it has a superior bond strength compared to an Arc spray coating, resulting in a denser, harder coating that has little porosity and could be machined to our customer's desired surface finish.

4. After spraying the journal, the component was put back on the Lathe to go through finish machining to achieve its final dimensions.

BEFORE

PREP MACHINING

HVOF SPRAYING

FINISH MACHINING

AFTER

CUSTOMER TESTIMONIAL

“We contacted New Metal Surfaces to repair our client's secondary cone crusher main shaft, and we were really happy with the service provided to us. The shaft has now been fitted and it has gone in well, as we expected it would.”

— Project Engineer

Laser Cladding vs Thermal Spraying: What’s the difference?

Wed, 23 Feb 2022 00:57:22 GMT

Laser Cladding vs Thermal Spray: Which Coating Method is Best for Your Components?

Over the past few years, a growing number of laser cladding companies in Australia have been promoting laser cladding as superior to all thermal spray coatings. As an industry leader in thermal spray coatings, we wanted to demonstrate how thermal spray can be the better coating application for your needs.

Before we delve into the differences between thermal spraying and laser cladding, let's start with a brief explanation of these techniques.

Thermal Spraying:

Thermal spraying is a process used to apply a coating to the surface of a material, like metal, to protect it from wear, corrosion, or heat. Imagine spraying paint from a can, but instead of paint, you're using tiny melted particles of metal or ceramic. These particles are heated up (often by a flame or an electric arc) and then sprayed onto the surface, where they cool and form a protective layer.

Laser Cladding:

Laser cladding is a technique that uses a high-powered laser to melt a coating material and a thin layer of the surface it’s being applied to. The melted coating material, often a type of metal or alloy, fuses with the surface as the laser moves along. This creates a strong, well-bonded layer that can improve the surface's properties, like making it more resistant to wear or corrosion. Think of it like using a laser to weld a protective layer onto an object.

THERMAL SPRAY VS LASER CLADDING

We’ve put this comparison together to help you make an informed decision about the right option for your components. In every instance, thermal spray comes out as the superior wear resistant product. Plus, it is typically cheaper than laser, without all the hassles of heat treatments and complicated weld procedures.

Even so, if you feel that laser cladding is the best option, especially given the expertise of laser cladding companies in Australia, ensure you request a qualified weld procedure. This should specify both the substrate (and its preparation) and the coating. Ask about expected distortion levels, potential residual stresses, and any required post-weld heat treatments to prevent failure in service. For components subject to cyclical loading, like rotating shafts, consider confirming the laser cladding procedure with fatigue testing.

Or alternatively, choose thermal spray .

Gear Drive Services — Gearbox Planetary Carrier Repair

Fri, 10 Dec 2021 02:01:04 GMT

Gear Drive Services has been a valued customer of New Metal Surfaces for many years. They continually trust our team to deliver high quality work to restore their worn and damaged components.

THE PROBLEM

For this job, Gear Drive Services engaged us to repair the worn seal journal on their planetary carrier back to better than new.

THE SOLUTION

1. Our team of specialists began by inspecting the damaged area and providing a recommendation for the best material. This was done by considering the substrate material, as well as what application and environment the component would be used in.

2. Once decided, we began by prepping the component for spraying. This involves machining the seal area undersize using our Vertical Borer — a process that preps the surface so that it's ready to be grit-blasted and sprayed.

3. Once prepped, our spray technicians grit-blasted the surface, and applied a HVOF coating to the damaged seal area. This coating was chosen for its superior bond strength (compared to Arc Spray coatings), resulting in a denser, harder coating that has little porosity.

4. After spraying the seal area, the component was put back on the Vertical Borer to be finish machined to its final dimensions.

5. The finished result is a restored seal area that will perform better and last longer than the original.

CUSTOMER TESTIMONIAL

“We’ve worked with New Metal Surfaces for many years and were once again really happy with the service provided to us.”

— Stuart Kenyon, Project Manager

BEFORE

PREP MACHINING

HVOF SPRAYING

FINISH MACHINING

AFTER

The three main types of Thermal Spraying

Wed, 17 Nov 2021 00:00:04 GMT

The three main types of Thermal Spraying

Thermal spraying is a highly complex process that’s used to restore dimensional accuracy to metal components, or to change the surface properties of the sprayed items. The goal is to cost-effectively improve wear resistance, corrosion resistance, or thermal conductivity. Rather than replacing an item, you can restore it instead. And we really do mean “restore” — items come out as good as new, saving you significant replacement costs.

But, when we say, “thermal spraying”, what do we actually mean? The essential feature of any thermal sprayed coating is that when the sprayed material comes into contact with the work surface, it deforms to mechanically lock into the induced profile of the repair surface.

At New Metal Surfaces, we offer three types of thermal spray solutions — High Velocity Oxygen Fuel (HVOF), Twin Wire Arc Spray, and Combustion Powder Spray. Although they have overlapping outcomes, each uses a very different method. There’s no one size-fits-all when it comes to thermal spraying. The type of thermal spraying chosen depends on the component, desired outcomes, application, industry, and operational environment.

Let’s break these down in a little more detail.

1. HIGH VELOCITY OXYGEN FUEL (HVOF)

Historically, thermal spray technology centred around techniques of heating particles into a softened state before impact to guarantee adequate deformation. HVOF introduced a revolutionary method. The HVOF system accelerates the combustion gases to velocities greater than the speed of sound. By introducing the powder into this stream, the powder is both accelerated and heated before impacting the prepared surface and plastically deforming, which results in a coating that is able to achieve bond strengths greater than 10,000 psi.

HVOF offers a low-porosity, dense coating that provides better wear resistance and more protection than other coating solutions. Interesting fact: our premium HVOF coatings can produce deposits with less than 1% porosity.

So, when would you use HVOF?

You’d typically apply HVOF to:

Provide superior rebuild and salvage operations.
Increase abrasion resistance.
Increase sliding wear resistance.
Increase resistance to fretting, galling or adhesive wear.
Increase resistance to cavitation effects.
Increase resistance to chemical attack.
Increase control of oxidation and sulfidation.
Increase atmospheric and high temperature corrosion control.

2. TWIN WIRE ARC SPRAY

Twin Wire Arc Spray could be described as an all-purpose coating, as it can be applied in a range of applications. Twin Wire Arc Spray utilises two metallic wires being fed into the torch at matched speeds. When these wires meet, they create an electric arc that melts the wire ends (hence the name of the method). Compressed air is then used to atomise and accelerate these particles onto the work surface.

Twin Wire Arc Spray is extremely diverse, and although it’s not right for all components, this is the most “popular” thermal spray solution.

How do I know if Twin Wire Arc Spray is the choice for me?

At New Metal Surfaces, we use Twin Wire Arc Spray to:

Reclaim worn, damaged, or mis-machined parts.
Increase atmospheric and high temperature corrosion control.
Rebuild and salvage components.
Provide electrical conductivity.
Provide anti-skid and traction coatings.

3. COMBUSTION POWDER SPRAY OR FLAME SPRAY

Combustion Powder Spray (sometimes called ‘Flame Spray’) involves powdered material being fed into a flame to melt. The thermal expansion of the combustion is then used to accelerate the particles onto the chosen work surface. This method of thermal spraying is cost-effective, reliable, and allows for the application of metallic and ceramic materials.

Should I use Combustion Powder Spray?

At New Metal Surfaces, our team employs Combustion Powder Spray in a few, very specific applications for a more tailored approach. For example, our chrome oxide ceramic coating provides excellent corrosion resistance due to its low chemical reactivity. This coating is most suitable in industrial pumping applications where the fluids or slurries being moved can be highly corrosive and abrasive. It’s best suited to:

Industrial pumping applications.
Increase abrasion resistance.
Increase sliding wear resistance.
Increase corrosion resistance.
Increase atmospheric and high temperature corrosion control.

How will you know which method is right for your component?

The good news is you don’t have to know! Our team of experts comprehensively inspect each component as it comes to us and consider a range of factors like the component’s wear and tear, age, size, industry, operating environment, and more. Then, we’ll let you know which thermal spray application is best for your circumstances.

Gearbox Refurbishment — Customer Testimonial

Wed, 02 Jun 2021 08:03:55 GMT

THE PROBLEM

David Brown Santasalo engaged us for an industrial gearbox refurbishment. We utilised HVOF Spray, Twin Wire Arc Spray, and Custom Machining to complete the project to the highest standard.

THE SOLUTION

New Metal Surfaces is now the chosen provider for all metal surfacing requirements.

CUSTOMER TESTIMONIAL

“We’ve relied on New Metal Surfaces for metal surface recoveries for over eight years. We use them for HVOF and Metal Arc Spray, and they’re also excellent when it comes to breakdowns. As gearbox service and repair engineers specialising in mining equipment, we have significant resurfacing requirements, including gears and shafts, housings, and general machining. New Metal Surfaces don’t just increase the life of machinery, they also repair it, so that it has a second life.

There are a lot of metal resurfacing providers to choose from — we asked around within the industry, including BHP and RIO, and New Metal Surfaces came to us highly recommended. Their reputation was that they can’t be beaten for quality, cost, and lead-time, and that has been our experience.

Essentially, everything comes down to cost, and while they’re very good with their quotations, it’s a real bonus that they are also really helpful to deal with. The way they project manage and communicate helps us to do the same at our end. We work hand-in-hand with them and they’re always transparent. They contact us with updates before we contact them, so we always know things are on schedule and can plan accordingly.”

— David O’Sullivan, Account Manager

Thiess — Customer Testimonial

Tue, 01 Jun 2021 08:06:11 GMT

SERVICES

New Metal Surfaces provided Thiess with remanufacturing machine services and repairs of mining grade machinery. We used HVOF and Twin Wire Arc Spray to complete this work.

Outcome

We’re the preferred provider for metal spray and machining of Thiess’ Caterpillar components.

CUSTOMER REVIEW

“Thiess engage New Metal Surfaces for machining and metal spray on a variety of Caterpillar machinery that require component rebuilds. They are professional, but at the same time, straightforward and easy-going. It is a very good relationship that helps us do our job better because they actively work with us — this is a benefit to them being WA owned and operated.

Additionally, they get everything done on time. When things are needed straight away, they will go out of their way to get it done — nothing is a problem. Their work is always very high quality (you can be sure they will do the job properly, so you don’t have to worry about reworks), and they’re competitively priced. We engage them for a large quantity of work and consistently do three quote surveys; New Metal Surfaces come up best.

New Metal Surfaces have a great capacity and the capabilities to do everything we need. This means that we don’t need to engage any other resurfacing suppliers which makes things easier.”

— David White, Workshop Supervisor

Gear Drive Services — Customer Testimonial

Mon, 31 May 2021 08:07:53 GMT

Gearbox Refurbishment: HVOF spray, ARC spray and custom machining

SERVICES

Gear Drive Services came to New Metal Surfaces seeking industrial gearbox refurbishment and associated parts repair. We utilised HVOF Spray , Twin Wire Arc Spray , and Custom Machining to complete the project to the highest standard.

OUTCOME

We’re now the chosen provider for metal single part component resurfacing.

Comment

“For the last 11 years, we have engaged New Metal Surfaces for our fixed plant mining equipment requiring HVOF, recovery of shafts and covers. They effectively work across a wide range of machinery; single part components that could vary in size from 1kg to 6-tonnes. They are able to handle a significant capacity.

New Metal Surfaces are great to deal with; they’re good guys and we have a great relationship with them. They will always help you out when you need it, get problems solved, and manage to turnaround fast deliveries.

They tick the boxes of good capabilities, smooth processes, a fair price, and quality work. Other than that, their new workshop sets them apart; they have the best HVOF setup in Western Australia. New Metal Surfaces have the largest capacity for a thermal spraying company that I have come across.”

— Bradley Howe, Operations Manager

Want to Know More About Our Solutions? Contact Us for Details!

Hofmann Engineering — HVOF and Custom Machining Customer Testimonial

Sun, 30 May 2021 08:09:55 GMT

HVOF and Custom Machining

SERVICES

Hofmann Engineering required reclaimed bearing and seal diameters on the Output Shaft of a Dragline Machine. We utilised HVOF and Custom Machining to do this.

OUTCOME

We’re now Hofmann Engineering’s preferred resurfacing provider.

CUSTOMER REVIEW

“New Metal Surfaces have been our preferred vendor for the last four or five years because they’re cost-effective and always provide a quick turnaround. We recently used New Metal Surfaces for reclaiming the bearing and seal diameters for the output shaft of a dragline machine located in Queensland.

Once again, they provided us with very good service. We dropped the part off, they called us within the time parameters promised to let us know that the work had been done and we were able to send the 8-tonne part on to Queensland with minimum downtime.”

— Mike Hill, Gearbox Fitting Manager

Want to Learn About Our HVOF Technique? Click Here for More Info

newmetalsurfaces

Metal Spray Coating and Premature Equipment Failure

Top causes of premature equipment failure & how surface coatings can prevent them.

Common causes of equipment failure.

How surface coatings help prevent failure

Turnkey service. Fast turnaround.

Thermal Spray Coatings for Extreme Environments

How thermal spray coatings can help you beat the harshest conditions.

Why parts fail — and what you can do about it

More on thermal spray coating

The benefits for mining maintenance teams.

Real results, right here in WA

Ready to reduce wear and fight back against downtime?

Choose the Best Thermal Spraying Service for Your Project

Which Thermal Spraying Services Are Best?

Importance of Selecting the Right Thermal Spraying Service

SIGN UP

Types of Thermal Spraying Techniques

1. High-Velocity Oxygen Fuel (HVOF)

2. Arc Spray

3. Flame Spray

Factors to Consider When Choosing Thermal Spraying Services

Assessing the Material Requirements for Your Project

Analysing the Service Life Expectations

Coating as an Investment

Industry-Specific Applications of Thermal Spraying Services

Thermal Spraying in the Earth Moving Industry

Thermal Spraying for Drills

Thermal Spraying for Pumps

Navigating the Challenges and Best Practices in Thermal Spraying

Common Pitfalls in Thermal Spraying and How to Avoid Them

Tips for Collaborating with Thermal Spraying Service Providers

Let’s recap.

Make the Right Decision for Your Project.

Importance of Quality Control in Metal Spraying in Perth

Quality Control in Metal Spraying.

Understanding Metal Spraying

Metal Spraying in Perth

Process & Applications

SIGN UP

Benefits of Quality Control in Metal Spraying

1. Boosts Structural Integrity & Longevity

2. Improves on Performance & Functionality

3. Compliant with Industry Standards & Regulations

4. Reduction of Defects & Rework

5. Cost Savings in the Long Run

Key Components of Quality Control in Metal Spraying

Material Selection & Preparation

Precision in Spraying Techniques

For Better Quality, Spray with New Metal Surfaces.

ISO 9001:2015 Certification

SIGN UP

Perth’s HVOF coating specialists

Why Should You Choose HVOF Coating For Your Equipment?

SIGN UP

HVOF produces a high-density coating

Low porosity

Hardness

HVOF coatings have a high bond strength

Durability and lifespan

High temperatures

Wide range of substrates

HVOF is a versatile coating

Customisable

Repairs

Complex shapes and surfaces

HVOF coatings can enhance surface properties

HVOF coating is a cost-effective solution

Perth’s HVOF coating specialists

Large Gearbox Shaft Repair

SIGN UP

CUSTOMER TESTIMONIAL

﻿ BEFORE

AFTER

HVOF Thermal Spray Coating FAQ

Is HVOF thermal spray coating right for you?

SIGN UP

What is HVOF thermal spray coating?

What are the benefits of HVOF thermal spray coating?

What industries use HVOF thermal spray coating?

BEFORE