Thermal Spray Equipment Guide

Thermal Spray Equipment Guide 

Sulzer Metco

Table of Contents 

Introduction 

Equipment Guide • Issue 8 

Sulzer Metco 

Thermal Spray Equipment 3 

Spray Processes 4 

Thermal Spray Equipment – Compatibility Charts of Core Components 

Plasma 5 

HVOF Gas-Fuel 9 

HVOF Liquid-Fuel 12 

Combustion Wire 13 

Combustion Powder 15 

Electric Arc 18 

ChamPro 21 

Thermal Spray Equipment – Overview of Handling & Peripheral Components 

Handling Components 22 

Peripheral Components 24 

Thermal Spray Equipment – Examples of Thermal Coating Systems 

Plasma 25 

HVOF 27 

Combustion Powder and Combustion Wire 29 

Electric Arc 31 

ChamPro 33 

Please note: 

Throughout this brochure, dark blue labels indicate non-CE components 

2

Introduction 

Thermal Spray Equipment 

Only Sulzer Metco can offer equipment solutions for all 

thermal spray processes. And with such a broad selection, 

we have just what you need for your application. 

Proven and reliable, Sulzer Metco has the largest base 

of installed equipment around the world. 

The focus is on the customer’s specific application 

needs. Through on-site investigation and customer consultation, 

our Engineering teams design coating operation 

by combining the most advanced technologies and 

the broadest line of thermal coating products with advanced 

robotics and microprocessor controls, we can 

synthesize the most productive and cost-effective solutions 

for virtually any coatings application. 

Thermal spray systems are self-contained manufacturing 

facilities which can be used both as individual production 

units or integrated into manufacturing lines. The 

subsystems of spray equipment are: 

Core Components 

Core elements are required for all thermal spray solutions. 

These include the coating material to be applied, 

a powder feed delivery system, the atmospheric 

plasma spray gun to heat the coating material 

and propel it to the workpiece, a control 

system that accurately controls the 

gas, electrical and cooling water requirements, 

and a power supply 

to convert incoming AC power 

to the appropriate DC power 

required by the spray gun. 

A heat exchanger is also required 

to cool the spray 

gun. 

Handling Components 

By far the simplest of manual 

spray systems, handling 

equipment precisely 

controls the movement 

of the spray gun and workpiece, 

and their relative position 

to one another. 


Sulzer Metco 

Peripheral Components 

The peripheral components can be divided into four 

parts: Safety components like gas monitoring and warning 

devices; environmental components like a soundproof 

cabin as well as an air filter and exhaust system 

to protect both personnel and the environment; quality 

components as spray plume monitoring and diagnostics 

for the most advanced process control; and productivity 

components like software packages for workpiece management, 

parameter reporting and many others. 

3

Introduction 

Spray Processes 


Sulzer Metco 

Sulzer Metco’s comprehensive portfolio of equipment assures we can deliver systems for every thermal spray application 

and budget requirement. 

Electric Arc 

Wire Spray 

Arc Processes 

ChamPro 

Atmospheric 

Plasma Spray 

Spray Processes 

Gas-Fuel 

HVOF 

Arc Processes 

Electric Arc Wire Spray 

Electric arc wire spray uses two electrically charged feedstock 

wires, of opposite polarity, that are brought together 

at a controlled rate to form an arc. This arc melts the wire 

feedstock and an air stream propels the molten material to 

the substrate. Electric arc wire is commonly used to apply 

bond coat materials, salvage and restoration coatings and 

a wide range of corrosion coatings on large structures. As 

the coolest of all thermal spray processes, it can be used to 

coat many substrates, including metals and plastics. 

Atmospheric Plasma Spray 

Atmospheric plasma spray is the most versatile of all thermal 

spray processes. Using an electric arc to ionize flowing 

processes gases, the hot gas stream can be controlled to 

melt a very wide range of powder feedstock materials. Refers 

to coatings applied in atmospheric conditions to apply 

high-quality coatings of metals, metallic alloys, carbides, 

cermets and oxide ceramics. Atmospheric plasma spray 

coatings are used for many different applications, just a few 

of which include bond coats, corrosion coatings for many 

different conditions, including high-temperature applications, 

wear coatings, restoration coatings, and thermal barrier 

materials. 

ChamPro Controlled Atmosphere Spray 

Refers to coatings applied in a chamber, usually at near 

vacuum. ChamPro, using either plasma spray or electric 

arc wire spray, applies superior coatings characterized 

by high densities or very controlled porosities with extremely 

low contamination. Systems can be designed for many applications, 

including the application of refractory metals, thin 

layers and ceramic structures that cannot be achieved using 

any other thermal spray process. 

High Velocity 

Oxy-Fuel Spray 

HVOF 

Combustion Processes 

Liquid-Fuel 

HVOF 

Combustion 

Powder Spray 

Combustion 

Spray 

Combustion 

Wire Spray 

Combustion Processes 

High Velocity Oxy-Fuel (HVOF) Spray 

HVOF uses high-pressure combustion as the heat source 

and to create a high-velocity gas stream that both melts 

and propels a powder feedstock material to the substrate. 

HVOF coatings generally exhibit fine homogeneous microstructures, 

low in oxide and porosity content, that are tenaciously 

bonded to the substrate. 

Gas-Fuel HVOF 

Uses gases such as propane, propylene, hydrogen or 

methane (natural gas) as the fuel source. 

Liquid-Fuel HVOF 

Uses kerosene, preferably Jet-A, as the fuel source. 

Combustion Spray 

As the name implies, combustion spray uses the combustion 

of a fuel gas and oxygen to create a heat source, but 

at lower pressures than HVOF. Combustion spray is an 

economical choice for the application of quality coatings. 

Combustion Powder Spray 

Uses metals, metallic alloys or fine ceramics as the feedstock 

material in powder form. It is often the process of 

choice for the application of certain abradable coatings, 

particularly to avoid volatilization of a fugitive phase during 

the spray process. 

Combustion Wire Spray 

Uses metals or metallic alloys and the feedstock material 

in wire form. It is often used for the application of hard 

coatings for salvage and retoration and is well-known for 

the application of corrosion coatings, even on very large 

structures. 

4


Core Components • Plasma 

Compatibility Chart 

Spray Gun 

(One Cathode) 

1 Please note: Throughout this 

brochure, dark blue labels indicate 

non-CE components 


SM-F1 SM-F1 45° SM-F3 30° 

Sulzer Metco 

SM-F100 

CONNEX SM-F210 SM-F220 SM-F300 

Performance 25 kW 25 kW 8 kW 20 kW 15 kW 16 kW 9 kW 

Minimum Internal 

Diameter 

80 mm 

(3.2 in) 

100 mm 

(4 in) 

60 mm 

(2.4 in) 

75 mm 

(3 in) 

Plasma Gas Ar, H , He 2 

Spray Angle 

Controller 

90° 45° 60° 90° / 45° / 0° 0° / 20° / 30° 90° 90° 

JAM Box 

Material Feeder 

Power Source 

Gas Management 

Center 

5MPE 

9MP 

9MP-CL20 

9MCE 

TriStar IPS-500/200 TriStar IPS-1000 

1 

JAM-1010 

JAM-1020 

JAM-1030 

9MPE 

9MPE-CL20 

GMC Plasma 

UniCoat or 

MultiCoat 

2 

PT-Type 

Single-120-A 

Twin-120-A 

10MR 

Single-220-A 

40 mm 

(1.6 in) 

2 JAM-1010 with 9MCE controller only; 

JAM-1020 with UniCoat/MultiCoat ® and PT-type power source only; 

JAM-1030 with UniCoat/MultiCoat ® and TriStar-type power source only 

1 

5





(One Cathode) 


F4-HB F4-HBS F4MB-XL 3MBM 3MBH 3MBTD 

Performance 55 kW 55 kW 55 kW 40 kW 


Diameter 

– – – – – 

102 mm 

(4 in) 

Plasma Gas Ar, H , He 2 Ar, H , He, N 2 2 


Controller 

0° 90° 

JAM Box 


Power Source 


Center 

9MCE 

5MPE 

JAM-1010 

JAM-1020 

JAM-1030 

10MR 

UniCoat or 

MultiCoat 

2 

9MP 

9MP-CL20 

PT-Type 

9MPE 

9MPE-CL20 

GMC Plasma 

9MC 

JAM-1010 

JAM-1020 

JAM-1030 

Single-120-A 

Twin-120-A 

9MCE 

2 3 


9MCD 

Single-220-A 

UniCoat or 

MultiCoat 

1 3MBTD available in lengths of 457, 610 or 914 mm (18, 24 or 36 in) 

2 JAM-1010 with 9MCE controller only; JAM-1020 with UniCoat/MultiCoat and PT-type power source only; 

JAM-1030 with UniCoat/MultiCoat and TriStar-type power source only 

3 9MCD with 9MC controller only 

Sulzer Metco 

1 

6





(One Cathode) 


9MBH 9MBM 

7MT-2 

7MST-2 11MB-2 iPro-90 

Performance 80 kW 38 kW ; 25 kW 30 kW 95 kW 


Diameter 

– 

80 mm 

(3.2 in) 

55 mm 

(2.2 in) 

Sulzer Metco 

152 mm 

(6 in) 

Plasma Gas Ar, H , He, N 2 2 Ar, H , He 2 Ar, H , He, N 2 2 


Controller 

0° 0° / 65°; 45° 60° / 90° 90° 

JAM Box 


Power Source 


Center 

PT-Type 

JAM-1010 

JAM-1020 

JAM-1030 

5MPE 

10MR 

1 7MT-2, 7MST-2 are extensions for the 9MB gun 

2 7MT-2 with 80 kW when spraying straight ahead 

3 JAM-1010 with 9MCE controller only 

9MC 

9MCD 

9MP 

9MP-CL20 

1, 2 

9MCE 

9MPE 

9MPE-CL20 


UniCoat or 

MultiCoat 

3 4 

3 

5 

GMC Plasma 

Single-120-A 

Twin-120-A 

JAM-1010 

JAM-1020 

Single-220-A 

10MR 

PT-Type 

3 JAM-1020 with UniCoat/MultiCoat and PT-type power source only; 

JAM-1030 with UniCoat/MultiCoat and TriStar-type power source only 

4 9MCD with 9MC controller only 

5 Option kit required for 11MB 

7





(Three Cathodes) 


TriplexPro ® -200 

Performance 65 - 100 kW 


Diameter 

– 

Plasma Gas Ar, H , He, N 2 2 


Controller 

0° / 90° 

JAM Box 


Power Source 


Center 

9MPE 

9MPE-CL20 

UniCoat or 

MultiCoat 

JAM-T630 

Single-120-A 

Twin-120-A 

TriStar IPS- 

500/200 

GMC Plasma 

Single-220-A 

1 JAM-T630 with UniCoat/MultiCoat and TriStar-type power source only 

1 

Sulzer Metco 

8


Core Components • HVOF Gas-Fuel 




8ADJH 

8ADJHE 

9ADJH 

9ADJHE 

1050ADJH 

1050ADJHE 

Performance 113 kW 


Diameter 

Fuel Gases H 2 

Propane, 

Propylene 

– 

2600DJH 

2600DJHE 

Propane H 2 

Spray Angle 0° 

Controller 

JAM Box 



Center 

1 

1 DiamondJet ® gas-fuel HVOF spray guns 

DJF 

– 

5MPE-HP 

9MP-DJ 

– 

DJF 

9MPE-DJ 

2700DJH 

2700DJHE 

Propane, 

Propylene 

DJFEW 

DJCE 2600 

2700DJH-NG 

2700DJHE-NG 

Methane 

(Natural Gas) 

Sulzer Metco 

9






8ADJM 9ADJM 1050ADJM 2600DJM 2700DJM 3600DJM 



Diameter 

Fuel Gases H 2 

Propane, 

Propylene 

– 

Propane H 2 


Controller 

JAM Box 



Center 

1 

1 DiamondJet ® gas-fuel HVOF spray guns 

DJC 

9MP-DJ 

DJCEH 

9MPE-DJ 

9MPE-DJCL20 

JAM-GF 

JAM-GLF 

GMC HVOF 

Methane, 

Ethylene, 

Propane, 

Propylene 

UniCoat-GF 

UniCoat-GLF MultiCoat 

Single-120-H 

Twin-120-H 

Single-220-H 

H 2 

Sulzer Metco 

10






DJT-2 DJT-2 45° DJT-2M 



Diameter 

2 3 4 

Fuel Gases depending on front gun hardware 

Spray Angle 90° 45° 90° 

Controller depending on front gun hardware 

JAM Box 


depending on front gun hardware 


Center 

9MP-DJ 

1 

9MPE-DJ 

9MPE-DJ-CL20 

Single-120-H 

Twin-120-H 

depending on front gun hardware 

1 1 

Single-220-H 

1 DJT-2, DJT-2 45°, DJT-2M are extensions for DiamondJet ® guns 

2 DJT-2 90°: 230 mm (9 in) with air-cooled hardware; 400 mm (16 in) with water-cooled hardware 

3 DJT-2 45°: 180 mm (7 in) with air-cooled hardware; 280 mm (11 in) with water-cooled hardware 

4 DJT-2M: 180/230 mm (7/9 in) with air-cooled hardware; 280/400 mm (11/16 in) with water-cooled hardware 

Sulzer Metco 

11


Core Components • HVOF Liquid-Fuel 




WokaJet ® -410 WokaJet ® -410-S WokaJet ® -440 WokaStar ® -610 WokaStar ® -610-S WokaStar ® -640 


Ignition Type Hydrogen Spark Plug Hydrogen Spark Plug 


Diameter 

– 

Fuel Kerosene 


Controller 

0° 

JAM Box 



Center 

5MPE-HP 

UniCoat-LF 

UniCoat-GLF MultiCoat 

JAM-LF 

JAM-GLF 

9MPE-DJ 

9MPE-DJ-CL20 Single-220-H 

LMC 

GLMC 

Sulzer Metco 

EvoCoat-LF 

Single-120-H 

Twin-120-H Twin-140-H 

1 WokaJet-440 and WokaStar-640 and EvoCoat-LF feature full EvoLink Intelligent Gun Technology 

2 No JAM Box and no Gas Managment Center is required when using the EvoCoat-LF controller 

3 Twin-140-H with EvoCoat-LF controller only 

1 

– 

– 

1 

1,2 

3 

12


Core Components • Combustion Wire 




16E 16E-H 16E-P 16E-HT 5K 



Diameter 

Fuel Gases Acetylene Acetylene Propane 


Controller 

3AF 

3GF 

JAM Box – 



Center 

1 Optional gun hardware available for different fuel gases 

1 1 1 1 

– 

2W 

– 

Propylene, 

Propane 

5KE 

6C 

Acetylene, 

Hydrogen, 

MPS, MAPP, 

Methane, 

Propane 

Sulzer Metco 

5K-6C 

5K-6CE 

6CEW 

13


Core Components • Combustion Wire 




EGD-K 5XT-6 3XT-1 3XT-2 3XT-3 



Diameter 

Fuel Gases 

– 

Acetylene, 

Hydrogen, 

MPS, MAPP, 

Methane, 

Propane 

Acetylene 


Controller 

0° 0° / 45° 

MultiCoat 

JAM Box – 



Center 

1 1 1 1 

100 mm 

(4 in) 

Acetylene, 

Hydrogen, 

MPS, MAPP, 

Methane, 

Propane 

Controller depends on gun hardware 

1 5XT-1 and 3XT-1, -2, -3 are extensions for both 16E type and 5K type guns 

2 Optional angular air cap required to spray at an angle of 45° 

2W 

– 

2 

Sulzer Metco 

14


Core Components • Combustion Powder 




5P-II 5PT-II-1 5PT-II-2 



Diameter 

– 168 mm 

Fuel Gases Acetylene, Hydrogen 


Controller 

0° 80° / 0° / 45° 

3AF 

JAM Box – 

Material Feeder built-in 


Center 

– 

1 2 2 

1 5PT-II is CE conformant with the safety handle SHA 

2 5PT-II-1, -2 are extensions for the 5P-II gun 

3 Depending on specific application, spray angle and material applied 

4 Standard spray angle is 80°; optional hardware required to spray at an angle of 0° or 45° 

3GF 

3 

4 

Sulzer Metco 

15






6P-II-H 6P-II-HE 6P-II 6P-II-A 



Diameter 

– 

Fuel Gases Acetylene, Hydrogen 


Controller 

0° 

JAM Box 



Center 

5MPE 

9MP 

3AF 

– 

5MPE 

9MPE 

– 

3GF 

5MPE 

9MPE 

9MP 

6C 

Single-120-A 

Twin-120-A 

6CE MultiCoat 

JAM-F 

Single-220-A 

GMC Flame 

Sulzer Metco 

9MPE-CL20 

16






6PT-II-1 6PT-II-2 



Diameter 

Fuel Gases 

168 mm 

2 

Spray Angle 80° / 0° / 45° 3 

Controller depends on hand-held or 

JAM Box 

machine-mount configuration 

depends on hand-held or 

machine-mount configuration 

Material Feeder depends on controller 

or configuration 


Center 

depends on controller 

1 

1 6PT-II-1, -2 are extensions for the 6P-II gun 

2 Depending on specific application, spray angle and material applied 

3 Standard spray angle is 80°; optional hardware required to spray at an angle of 0° or 45° 

1 

Sulzer Metco 

17


Core Components • Electric Arc 




Sulzer Metco 

PPG PPGH PPGH-E PPGT-100 PPGT-190 PPGT-200 PPGT-290 

Melting Capacity 3 

32 kg/h 


Diameter 

– 70 mm 

Wire Diameters 1.6 – 2.3 mm 

Spray Angle 0° 0° 90° 0° 90° 

Controller / 

Power Source 

2 

SmartArc VISU ARC 350 

Material Feeder integrated in controller and gun 

1 PPGT-100, -190, 200, -290 are extensions for the PPG type SmartArc guns 

2 VISU ARC 350 can be used in combination with Push 4 and PPG gun only 

3 Using zinc wires 

1 

1 1 1 

18






LD/U3 LD/U2 LD/Schub 5 LD/SE 2 

Melting Capacity 5 

25 - 60 kg/h 20 - 30 kg/h 30 - 35 kg/h max. 200 kg/h 


Diameter 

– 

Wire Diameters 2 / 2.5 mm 1.6 - 2.5 mm 1.6 - 2.5 mm 1.6 - 3.48 mm 


Controller / 

Power Source 

1 


ECO ARC 250 

ECO ARC 350 

ECO ARC 600 

FLEXI ARC 200 

FLEXI ARC 300 

CAP 300 

TUBE 300 

VISU ARC 350 

Push 4 Push 1 Push 6 

1 ECO ARC 250 only uses 2 mm wires; 

2 ECO ARC 350 only uses 2.3 and 2.5 mm wires 

3 ECO ARC 600 only uses 2.5 mm wires 

4 Only in use with FLEXI ARC 300 

5 Using zinc wires 

2 

3 

4 

STRONG ARC 

integrated 

within 

gun hardware 

Sulzer Metco 

19





Melting Capacity 


Diameter 

Standard 

Wire Diameter 


Extension 

300 mm 

1 1 

Extension 

500 mm 

depends on gun hardware 

and power supply 

100 mm 

(4 in) 



Controller / 

Power Source 


Material Feeder depends on gun hardware 

1 These extensions are used with the LD/U2, LD/U3 and LD/Schub 5 guns 

Adapter needed between spray gun and extension 

Customzied lengths available on request 

Sulzer Metco 

20


Core Components • ChamPro 




F4-VB 03CP PPG PPGT 

Performance 45 kW 120 kW – 

Melting Capacity – 32 kg/h 


Diameter 

– 

70 mm 

(2.8 in) 

Wire Diameters – 1.6 - 2.3 mm 


Controller 

0° 0° 90° 

JAM Box 


Power Source 


Center 

Single-120-V 

Twin-120-V 

MultiCoat SmartArc 

JAM-2030 

JAM-3030 

60CD 

– 

integrated within 

gun hardware 

TriStar IPS- 

2000/3000 SmartArc 350RU 

GMC Plasma 

– 

Sulzer Metco 

21



Overview 


Sulzer Metco 

Workpiece Geometry Handling Sulzer Metco 

Component 

Gun Manipulator Workpiece 

Manipulator 

Flat geometry requires 

moving the 

spray gun in two 

directions 

Cylindrical workpiece 

requires the 

gun to move in two 

directions, but usually 

the workpiece 

will be rotated and 

the gun will be 

moved linear 

Rotationally symetrical 

workpieces requires 

the gun to 

move in two directions. 

Rotation will 

be done by a turntable, 

using a tilting 

turntable enables 

the workpiece to 

change its angle 

relative to the gun 

also 

Workpieces with 

specific rotational 

surfaces to be 

coated like engine 

blocks require the 

gun to be rotated 

continuously 

Workpieces with 

complex, three dimensionally 

curved 

surfaces require the 

gun to be moved 

freely in space 

XY CN handling 

with two axes 

CN linear handling 

with one axis 

None, workpiece 

fixed 

Fixed Turntable 

Continuously rotating 

gun 

Lathe Series LPro lathes 

Rotating and tilting 

table 

Rotating and tilting 

table with positionable 

axes 

None, workpiece 

fixed 

6 axes robot Depending on the 

geometry usually 

an additional tilting 

turntable 

Sulzer Metco can seamlessly integrate any type of handling component 

into a thermal spray coating system, safely and with excellent performance. 

Series UT tables 

Series Robax 

turntables 

Series 9H 

turntables 

Rotaplasma 

22



Overview 

Turntables 


UT-1 UT-5000 9HL-Type Robax-250 Robax-400 

Loading Weight 200 kg 5000 kg 225 kg 250 kg 400 kg 

Max. Rotation 300 U/min 200 U/min 360 U/min 300 U/min 300 U/min 

Faceplate Tilting – 0 .. 90° 0 .. 90° 

Lathes 

Max. Loading 

Weight 

Max. Workpiece 

Length 

RotaPlasma ® 

LPro* 

6000 kg 

7000 mm 

RotaPlasma ® 

Rotation 30 .. 200 U/min 


SM-F210 

SM-F300 

Internal Diameter 40 .. 500 mm 

Spray Controller MultiCoat 

Sulzer Metco 

In addition to these standard turntables, Sulzer Metco offers a wide range of specific workpiece manipulators with 

multiple workpiece positions and various other, highly specialized functionality on request. 

1 The LPro type lathes are available in three versions; one as pure lathe, one with an integrated linear gun 

handling and one with an integrated linear robot handling (robot not included) 

Robots 

Sulzer Metco is capable of integrating any type of robot 

for gun manipulator into a coating systems on specific 

customer request. 

1 

Other Gun Manipulators 

Sulzer Metco offers a wide range of customer specific 

gun handling devices on request. 

23



Safety 

Components 

Description GSM-II monitors potentially dangerous 

concentrations of flammable 

or explosive gases and shuts 

them off before critical levels are 

reached. 

Environmental 

Control 

Components 

Description Heat exchanger and water chillers 

in varoius sizes and cooling 

capability specifically designed for 

thermal spraying. 

Quality 

Components 

Productivity 

Components 


GSM-II Signal Lamps 

Signal lamps inform and alert the 

operator acoustically and visually 

on the state of the system. 

Heat Exchanger Filter Spray Booth 

Accuraspray 

Description Accuraspray provides 

precise, real-time measurement 

of the intensity, 

position and geometry of 

the thermal spray plume, 

and measures spray 

particle temperature and 

velocity. 

SUM IT 

Description MultiCoat software add-on 

to monitor consumables 

as the spray powder, process 

media and current. 

1 For MultiCoat ® only 

Filters and complete exhaust systems 

to protect the operator and 

the environment from the potentially 

dangerous spray dust. 

EvoLink 

EvoLink is a data acquisition 

and storage device 

for spray guns; data is acquired 

directly at the gun 

as well as onboard record 

of gun operating hours 

and gun identifying data. 

1 1 

IO Status 

Page 

MultiCoat software add-on 

to speed up the fault finding 

process by displaying 

the input/output ports of 

the PLC. 

Maintenance 

Tool 


to display the maintenance 

status of the system 

components and the 

upcoming maintenance 

schedules; supports ISO 

certifications. 

Sulzer Metco 

Spray booth protects the environment 

and the operator from the 

potentially hazardous emissions of 

the thermal spray process. 

Size and other functionality on 

specific requests. 

1 1 

Workpiece 

Database 


to monitor and control 

the data from the spray 

process and the handling 

system related to each 

workpiece. 

24


Examples of Thermal Coating Systems • Plasma 


Air Control Unit 





Typical Semi-Automated Plasma-Spray System with Manual Gun Operation 

Mid-Range Plasma Spray System with Automated Handling 


Spray Booth 

Gun Manipulator 

Controller 

Controller 


Handling Interface Box 

Power Supply 

Heat Exchanger 

Filter 

Power Supply 

Sulzer Metco 


Chiller 

Chiller 

25


Examples of Thermal Coating Systems • Plasma 

Power Supply 

Process Control Center 


MultiCoat 

Operator‘s Desk 

Filter 


Part Manipulator Lathe 


Robot Controller 

Electrical Distribution Unit 

High-End MultiCoat ® Plasma Spray System with Fully Automated Handling 

Sulzer Metco 

CN Controller 

Gun Manipulator Robot 

Gas Management Center 

JAM Box 


26


Examples of Thermal Coating Systems • HVOF 

Air Distribution Unit 


Typical Manual HVOF Spray System 


Mid-Range HVOF Spray System with Automated Handling 



Controller 

Handling Interface 

Box 

Chiller 

Controller 



Sulzer Metco 

Chiller 

Controller 

Filter 

27


Examples of Thermal Coating Systems • HVOF 


Part Manipulator Lathe 


HVOF Spray Gun 

Plasma Spray Gun 


MultiCoat 

Operator‘s 

Desk 

CN Controller 




Chiller 

JAM Box 

Filter 

Sulzer Metco 

Power Supply 


High-End MultiCoat ® HVOF and Plasma Spray System with Fully Automated Handling 

Electrical Distribution Unit 

28


Examples of Thermal Coating Systems • 

Combustion Powder and Combustion Wire 

Typical Manual Combustion Powder System 

Air Cleaner 



Semi-Automatic Combustion Wire Spray System 




Controller 

Controller 

Gas Supply 

Gas Supply 

Sulzer Metco 


29


Examples of Thermal Coating Systems • 

Combustion Powder and Combustion Wire 


Part Manipulator Turntable 

High-End Combustion Wire Spray System with Fully Automated Handling 


Filter 

Gun Manipulator Turntable 



Controller 


Sulzer Metco 

30


Examples of Thermal Coating Systems • Electric Arc 

Typical Manual Electric Arc System 



Controller 

and Power Supply 


Semi-Automatic Combustion Electric Arc Spray System 


Filter 

Handling Interface Box 

Sulzer Metco 


Controller and Power Supply 

31


Examples of Thermal Coating Systems • Electric Arc 





Part Manipulator Turntable 

High-End Electric Arc Spray System with Fully Automated Handling 

Controller 

and Power Supply 

Sulzer Metco 

Filter 

32


Examples of Thermal Coating Systems • ChamPro 

In the ChamPro Plasma or Wire arc spray Systems, 

the spray process runs under a controlled atmosphere. 

This environment (mostly Argon) is chemically inert and 

under a low pressure condition of approx. 50 mbar. This 

prevents unwanted oxidation of the spray material. A 

ChamPro System typically consists of modified Plasma 

or Wire arc system components, ChamPro com- 

ChamPro • VPS System 

Vacuum Controller 

Process 

Control Center 




ChamPro Components 



Filter 

Power Supply 

Vacuum Pumps 

Sulzer Metco 

ponents used to create and maintain a controlled 

atmosphere, as well as special Handling and 

Peripheral components. All Champro Plasma systems 

can optionally be delivered with reverse transferred-arc 

part cleaning. 

Chiller 

Robot Controller Spray Controller 

Vacuum Filter 


JAM Boxes 

Spray Chamber 

Handling with 

Workpiece Manipulator 

and Gun Manipulator 

VPS is a batch-processing system. Once a batch of 

parts has been loaded, the chamber is pumped down 

and back-filled with argon. The parts are then coated, 

followed by a cool-down cycle and back-fill with air to 

ambient pressure. The parts are then unloaded and the 

cycle is repeated with the next batch of parts. 

33



ChamPro • SVPS System 





The SVPS System is equipped with a preheating chamber 

and a loading mechanism containing the part 

manipulator. 


Chiller 

Spray Controller 

Vacuum Pumps 

Power Supplies 


JAM Boxes 

Sulzer Metco 

Chiller 

Vacuum Filter 

This allows the chamber to be maintained under a 

constant, controlled spray atmosphere for continuous 

processing. 

34



ChamPro • HC-LVPS System 

Vacuum Filter 

Part Manipulator 

Sting 



Handling Controller 

Vacuum Pumps 


Spray Controller 

The HC-LVPS System is equipped with one or two loading 

mechanisms and preheating chambers. This allows 

for the continuous coating of parts; the spray chamber 



JAM Box 

Power Supply 


Part Manipulator 

Sting 

Sulzer Metco 


Process 

Control Center 

is maintained under a constant, controlled spray atmosphere. 

A robot loads and unloads the parts. 

35


Sulzer Metco is a global leader in surface engineering solutions and services offering: 

• A broad range of thermal spray, thin film and other advanced surface technology equipment, 

integrated systems and materials 

• Specialized coating and surface enhancement services 

• Manufactured components for the turbine, automotive and other industries 

• Customer support services 

Sulzer Metco provides a comprehensive manufacturing, distribution and 

service network, catering to aerospace, power generation, automotive and 

other strategic growth industries. 

Equipment Guide 

Sulzer Metco 

To take control of your surface engineering challenges, contact your Sulzer Metco sales office, visit our website at 

www.sulzermetco.com or email us at info@sulzermetco.com. 

Sulzer Metco (US) Inc. 

Headquarters - Americas 

Westbury NY, U.S.A. 

Phone: +1 516 334 1300 

+1 888 262 8544 

West Coast Distribution 

Brea CA, U.S.A. 

Phone: +1 800 826 3826 

Sales Latin America 

Doral FL, U.S.A. 

Phone: +1 305 477 2525 

Sulzer Metco (Canada) Inc. 

Ft. Saskatchewan AB, 

Canada 

Phone: +1 780 992 5100 

Sulzer Metco Europe GmbH 

European Headquarters 

Hattersheim, Germany 

Phone: +49 6190 8090 

Sp.z.o.o. Oddzial w Polsce 

Poznan, Poland 

Phone: +48 61 847 44 20 

Succursale en France 

Bron Cedex, France 

Phone: +33 4 72 81 60 80 

Sucursal en España 

Madrid, Spain 

Phone: +34 91 570 33 49 

Branch Benelux 

AB Standdaardbuiten, Netherlands 

Phone: +31 165 880 405 

Filiale Italiana 

Cusago (MI), Italy 

Phone: +39 02 903 9241 

Filial Norden 

Stockholm, Sweden 

Phone: +46 8 680 7580 

Sulzer Metco AG (Switzerland) 

Wohlen, Switzerland 

Phone: +41 56 618 81 81 

Sulzer Metco WOKA GmbH 

Barchfeld, Germany 

Phone: +49 36961 861 0 

Sulzer Metco (UK) Ltd. 

Cwmbran, Gwent, U.K. 

Phone: +44 1633 488090 

Sulzer Metco (Japan) Ltd. 

Tokyo, Japan 

Phone: +81 3 5920 3302 

Sulzer Metco (Singapore) Pte. Ltd. 

Headquarters Asia/Pacific 

P. R. Singapore 

Phone: +65 6545 0870 

Sulzer Metco Surface Technology 

(Shanghai) Co. Ltd. 

Shanghai, P. R. China 

Phone: +86 21 5226 2000 

Sulzer Metco (Australia) Pty. Ltd. 

Padstow, NSW, Australia 

Phone: +61 2 9796 2011 

www.sulzermetco.com • info@sulzermetco.com 

Information is subject to change without prior notice 

Issue 8 • © 2010 Sulzer Metco

Thermal Spray Equipment Guide

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