Welding consumables for wear protection, repair and demanding material joints.
Development and production of electrodes to meet specific material and application requirements.
Technical selection aids and calculation tools for safe material decisions.
When data is missing or components fail, we create the foundation for reproduction and optimisation.
Analysis of materials, wear patterns and causes of damage. The goal is to derive appropriate measures for long-lasting solutions.
Our in-house laboratory for material and component analysis. Reliable results without long waiting times.
Hands-on training and presentations on welding consumables, wear protection and material selection – on site at your company.
Targeted build-up and optimisation of components using laser technology. For applications that cannot be realised using conventional methods.
Optimised components for heavily stressed applications. For reduced wear and minimised downtime.
Typical applications and solutions from industrial practice. From wear protection to component optimisation.
Application examples for joint and hardfacing welding. From manual applications to automated processes.
Application examples for soft and hard brazing. From delicate joints to industrial series processes.
Application examples for functional and protective surface coatings. From wear protection to finishing of complex components.
Flame spraying is one of the oldest and at the same time most proven thermal spraying processes. A fuel gas-oxygen flame melts the filler material – as powder, wire or rod – accelerates the particles and applies them to the previously prepared component surface. There they flatten abruptly and form a lamellar layer for protection against wear, corrosion, erosion and oxidation, or for dimensional restoration of worn components.
In contrast to welding processes, the base material is generally not melted. Adhesion occurs predominantly mechanically through interlocking with the roughened surface, supplemented by partial diffusion and adhesion mechanisms. This keeps heat input comparatively low – the process is particularly suitable for temperature- or distortion-sensitive components.
Through the process variants wire flame spraying, powder flame spraying and high-velocity oxy-fuel spraying (HVOF) as well as spray-and-fuse, the spectrum from economical corrosion protection to highly wear-resistant functional layers can be covered.
We deploy flame spraying specifically when components need to be coated over large areas, protected against wear and corrosion, or restored in their geometry – without melting the base material and with low heat input. Through wire, powder and HVOF variants as well as spray-and-fuse, the process can be adapted to material, layer requirement and component geometry.
Robust technology with comparatively high application rates – ideal for metallic protective coatings, corrosion layers and dimensional build-up on steel, aluminium, bronze or zinc alloys.
Great material variety – hard metals, self-fluxing alloys, composite materials. Hardness, toughness and friction behaviour of the layers can be specifically set via powder composition.
Higher particle energies produce denser, strongly adhering layers with lower porosity – layer properties approach those of higher-performance spraying processes, at economically viable equipment costs.
Spray self-fluxing alloy, then fuse with flame or in furnace – the result is a dense, pore-free layer with genuine metallurgical bonding to the base material.
Shafts, bearing seats, sealing surfaces and housings can be specifically restored to their original geometry – economical alternative to component replacement.
We support you in selecting the right welding process and the appropriate solution.
Flame spraying combines economical coating with great material flexibility and low heat input. The base material is generally not melted, so component geometry and microstructure remain largely unchanged.
Through wire flame spraying, powder flame spraying, HVOF and spray-and-fuse, the process can be adapted to application, material and equipment budget – from thin corrosion protection to highly wear-resistant hard metal layers.
Since the base material is not melted, component geometry and microstructure remain largely preserved. Ideal for temperature- or distortion-sensitive components.
Wire, powder or rod as filler material – from unalloyed steels via stainless steels, aluminium and bronze to hard metals and self-fluxing special alloys.
Through process variant and parameters, thin functional layers can be applied as well as strong dimensional build-ups for restoration of worn components.
Compared to PTA or laser cladding, equipment and operating costs are significantly lower – flame spraying is the economical choice for large-area coatings and corrosion protection tasks.
Flame spray layers have a lamellar structure with defined porosity – depending on the application, specifically advantageous, for example for storing lubricants in sliding surfaces.
Spray self-fluxing alloys and subsequently fuse – the result is a dense, pore-free layer with genuine metallurgical bonding. Hard material composite layers with tungsten carbides are possible.
Flame spraying is the right choice whenever components need to be coated over large areas, protected against corrosion or wear, or restored in their geometry – without the base material being thermally stressed. Also where defined porosity is specifically used, for example for lubricant storage, the process demonstrates its strengths.
Typical application fields are conveying technology, mechanical and plant engineering, maintenance, corrosion protection as well as dimensional and shape restoration of shafts, bearing seats, sealing surfaces and housings.
the base material must be thermally protected, for example in thin-walled or distortion-sensitive components.
large-area corrosion protection or wear protection layers are to be applied economically.
shafts, bearing seats, sealing surfaces or housings need to be dimensionally restored.
defined porosity is to be specifically used, for example as lubricant storage in sliding surfaces.
genuine metallurgical bonding with tungsten carbide hard overlays is to be achieved by spray-and-fuse.
Flame spraying, internationally Flame Spraying, is a thermal spraying process with a fuel gas-oxygen flame as energy source. The filler material – wire, powder or rod – is melted in the flame and projected onto the prepared component. Characteristic is that the base material is generally not melted – adhesion occurs predominantly mechanically.
This keeps heat input comparatively low, and component geometry and microstructure are protected. Layer thicknesses from a few tenths of a millimetre to several millimetres are possible. In the high-velocity variant (HVOF), particle energies and layer quality are significantly increased – at moderate equipment costs.
With spray-and-fuse, the character of the layer bonding can be specifically changed: a self-fluxing alloy is first sprayed and then fused – the result is a dense, pore-free layer with genuine metallurgical bonding to the base material.
Arc spraying is the most direct alternative within thermal spraying processes – also wire-based, but with an electric arc between two wires as energy source instead of a fuel gas-oxygen flame. Advantages are higher application rates and better adhesive tensile strength. Limitation: only electrically conductive wire materials can be processed. Flame spraying retains the advantage with broader material variety – with powder, rods and non-conductive materials – as well as simpler plant technology and mobile application.
Plasma spraying is the high-quality counterpart among thermal spraying processes – with significantly higher process temperatures, even high-melting materials such as ceramics and oxides can be processed. The layers are denser and of higher quality. Flame spraying is by comparison simpler, more robust and less expensive – the economical choice when the specific layer quality of plasma spraying is not strictly required for the application.
PTA welding is not a spraying process, but a fusion metallurgical cladding process: the base material is locally melted, the deposit layer is fully metallurgically bonded – with corresponding dilution and higher heat input. Flame spraying, in contrast, produces a purely mechanically adhering layer without dilution of the base material. With spray-and-fuse, this gap can be bridged by metallurgically bonding the flame spray layer through subsequent fusing.
Every cladding project follows a structured workflow – from the initial component analysis to the inspected deposit layer. This produces reproducible results tailored to loading conditions, material and operating environment.
In the first step, the geometry, material and operating conditions of the component are recorded. This includes the type of loading – such as wear, corrosion or thermal stress – as well as the required layer properties. On this basis, the appropriate welding process is selected and the process is designed.
Depending on requirements, different welding consumables and alloys are used, for example for wear protection, corrosion protection or heat resistance. The material selection is matched to the base material and the subsequent loading to achieve a permanently stable bond.
Before cladding, the component is prepared accordingly. This includes cleaning the surface, removing contamination and, if necessary, mechanical preparation of the coating area. A clean surface is the foundation for a metallurgical bond and reproducible layer quality.
Cladding is carried out with precisely set process parameters. Energy input, material feed and welding speed are controlled specifically to set layer thickness and penetration behaviour in a controlled manner. This produces homogeneous deposit layers with defined properties.
After cladding, the layer is mechanically post-processed as required, for example by turning or grinding, to achieve the required dimensional accuracy. Finally, the quality inspection of the weld seam and deposit layer is carried out before the component is returned to the customer.
Not sure which welding process is right for your application?
We support you in selecting and combining the right processes.
In flame spraying, powder, wire or rod filler material, particle energy and process variant (wire, powder, HVOF) determine layer properties – from thin corrosion protection layers via dimensional build-ups to hard metal coatings with tungsten carbides.
capilla supplies powders, wires and self-fluxing alloys for wire flame spraying, powder flame spraying and HVOF, complemented by hard material composite systems for spray-and-fuse – matched to loading, base material and application.
At the Laser Competence Centre (LCC), capilla brings together modern technologies for automated coating and manufacturing. Components are precisely built up, heat-treated and tailored to the application using laser-based processes. Layer thickness, material deposition and process parameters can be precisely controlled – even for complex geometries and series applications.
This produces coating and manufacturing solutions that go beyond conventional welding processes and cannot be realised with traditional approaches in this form.
Flame spraying is a thermal spraying process in which a filler material – as wire, powder or rod – is melted by a fuel gas-oxygen flame and applied to a previously prepared component surface. The melted spray particles flatten on impact, solidify abruptly and form a layer-by-layer built-up coating.
In contrast to welding processes, the base material is generally not melted. Adhesion occurs predominantly mechanically through interlocking with the roughened surface, supplemented by partial diffusion and adhesion mechanisms. This keeps heat input low – the process is particularly suitable for temperature- or distortion-sensitive components.
capilla deploys flame spraying for corrosion protection, wear protection, dimensional restoration and hard overlays via spray-and-fuse.
In flame spraying, the filler material is continuously introduced into a fuel gas-oxygen flame – as powder, wire or rod. The flame generates both the melting heat and the acceleration of the resulting spray particles. Additional process gases increase particle velocity and support material transport to the component surface.
The particles hit the prepared – usually blast-roughened – surface, flatten abruptly and solidify in a lamellar structure. Adhesion is created primarily by mechanical interlocking with the roughness depth, supplemented by diffusion and adhesion mechanisms. Careful surface preparation is decisive for adhesion strength and layer quality.
capilla advises on the appropriate process variant and correct surface preparation for every application.
The difference lies in the form of the filler material. In wire flame spraying, a continuously fed wire is introduced into the flame and melted. The liquid material is atomised and applied to the component. Advantages are simple handling, robust technology and comparatively high application rates – typical application fields are corrosion protection and dimensional build-up on steel, aluminium, bronze or zinc alloys.
In powder flame spraying, the filler material is fed into the flame in powder form. This variant offers a significantly greater material variety – complexly alloyed materials, hard metals, self-fluxing alloys and composite materials can be processed. Hardness, toughness, corrosion resistance and friction behaviour of the layers can be specifically set via powder composition.
capilla selects wire or powder variant depending on material system, layer requirement and cost-effectiveness.
High-Velocity Oxy-Fuel spraying (HVOF) is an enhanced-performance variant of powder flame spraying. Through optimised flame output and higher particle velocities, layers with significantly higher density, lower porosity and better adhesion strength are produced. The layer properties approach those of higher-performance thermal spraying processes.
HVOF is particularly deployed where high-quality wear protection or functional layers are required – such as hard metal coatings with tungsten carbide-cobalt on rollers, shafts or functional surfaces. Investment and operating costs remain economically viable and significantly below those of laser cladding processes.
capilla supplies powder materials and composite materials for HVOF coatings with hard metal, special alloys or self-fluxing systems.
The central advantages are low heat input, broad material variety, economical equipment and operating costs and scalability from thin corrosion protection layers to several millimetres of dimensional build-up. The base material is generally not melted – component geometry and microstructure remain largely preserved.
The usually only mechanical adhesion can be a disadvantage, supplemented by characteristic porosity of the layer. Depending on the requirement, this is advantageous (lubricant storage) or disadvantageous (corrosion in the porosity). With HVOF, layer density can be increased; with spray-and-fuse, genuine metallurgical bonding can even be achieved.
capilla selects the appropriate process variant (wire, powder, HVOF, spray-and-fuse) specifically according to requirement and component.
The material spectrum is exceptionally broad. In wire flame spraying, unalloyed and alloyed steels, stainless steels, aluminium, bronze, copper and zinc alloys are standard – ideal for corrosion protection layers and dimensional build-up. In powder flame spraying, additionally complexly alloyed materials, hard metals and self-fluxing special alloys are used.
Particularly interesting are composite systems with hard material fractions such as tungsten carbide. In combination with self-fluxing nickel-based matrices and subsequent fusing, highly wear-resistant composite layers with genuine metallurgical bonding are produced – a particularly high-performance solution for highly stressed functional surfaces.
capilla stocks wires, powders and self-fluxing alloys for all industrially relevant material systems.
Flame spraying is industrially used across a broad application spectrum. In corrosion protection, metallic protective coatings are applied, frequently by wire flame spraying with zinc, aluminium or bronze. In wear protection, powder variants and HVOF with hard metals, carbide composite materials or self-fluxing alloys are used.
In the area of dimensional restoration, shafts, bearing seats, sealing surfaces and housings are specifically built up, then mechanically machined to nominal dimension. Typical industries are mechanical and plant engineering, conveying technology, pump and valve industry, energy technology and the maintenance of industrial components.
capilla deploys flame spraying for corrosion protection, wear protection and dimensional restoration individually designed.
Flame spraying is particularly suitable for the servicing of worn or damaged components when the base material must not be thermally stressed and an economical alternative to component replacement is sought. Typical repairs are dimensional restoration of bearing seats, sealing surfaces, shafts and housings as well as build-up of lost functional surfaces.
Due to the low heat input, component geometry, microstructure and material properties remain largely unchanged. After the spray application, the layer is mechanically machined to the nominal dimension – the component is then functional, in many cases with improved wear or corrosion resistance compared to the original condition.
capilla supports economical repair of high-quality components through appropriately designed flame spraying applications.
The choice of process depends on layer requirement, material and cost-effectiveness. Wire flame spraying is the first choice for corrosion protection and dimensional build-up with metallic filler materials – robust, fast and comparatively inexpensive. Powder flame spraying is used when material variety and hard metal fractions are required, for example in wear protection with hard phases.
HVOF (High-Velocity Oxy-Fuel) is the choice for highest layer quality, low porosity and best adhesion strength – for example for hard metal coatings on rollers or highly loaded functional surfaces. Spray-and-fuse achieves genuine metallurgical bonding and is the first choice for highest-stress wear protection layers.
capilla selects the flame spraying process matched to component, loading and cost-effectiveness.
Flame spraying uses a fuel gas-oxygen flame as energy source. Other thermal spraying processes – such as arc spraying, plasma spraying or cold gas spraying – work with electrical energy or high-pressure gases and achieve, depending on the variant, higher particle energies, different layer properties or material suitabilities.
Flame spraying is by comparison particularly economical, robust and flexibly deployable – also mobile and without major equipment investment. Plasma spraying delivers higher layer quality at significantly higher equipment costs. Cold gas spraying dispenses with particle melting and is reserved for special cases. HVOF is the high-performance variant of flame spraying and bridges the gap to higher-performance spraying processes.
capilla advises on process selection across the entire spectrum of thermal spraying and cladding processes.