Wear Protection Coatings
Targeted material deposition on highly loaded components in mechanical and plant engineering that withstands abrasive loading, friction and impact.
Plasma Powder Transferred Arc welding (PTA welding), also known as Plasma Transferred Arc, is a thermal coating process for targeted surface treatment of components. In the PTA welding process, a plasma arc generates the energy required to melt metallic powder and bond it metallurgically to the base material. The result is highly loadable functional layers with minimal dilution and defined properties.
The process is used primarily where components in mechanical and plant engineering are permanently subjected to wear, heat or corrosion and downtime causes high costs. Instead of regularly replacing components, PTA cladding enables targeted reinforcement or restoration.
This makes PTA welding not only a technical process but an economic solution: longer service lives, lower spare parts costs and plannable maintenance with longer service lives, lower spare parts costs and plannable maintenance.
PTA Cladding for Coating, Repair and Wear Protection
We deploy PTA welding specifically to protect components, restore them and economically extend their service life in industrial use. The process is suitable for highly loaded components where wear protection, corrosion protection or defined functional layers are required. Depending on requirements, different powder materials and alloys are used, matched to component, loading and operating environment.
Repair of Worn Components
Economical alternative to replacement: components are returned to functional condition through targeted material deposition.
Cladding of Functional Layers
Deposition of layers with defined properties, matched to specific technical requirements and loading profiles.
Corrosion and Heat Protection
Protective layers against chemical and thermal influences through targeted selection of corrosion- and heat-resistant powder materials.
Dimensional Restoration
Worn components are returned to their original geometry through targeted material deposition. Suitable for shafts, rollers or sealing faces where precision is decisive.
Contact us with any questions:
We support you in selecting the right welding process and the appropriate solution.
Wear Protection in Practice: PTA Coating of a Screw Shaft
Components in conveying and plant engineering are permanently stressed by abrasion, friction and impact loading. Screws, rollers and shafts consequently lose function and must be regularly replaced. PTA cladding deposits wear-resistant materials precisely where loading is highest – with reproducible layer thickness and metallurgical bond to the base material. Due to the low dilution of approximately five to fifteen percent, the hardness and wear resistance of the deposited material are largely preserved.
Screw Shaft in the Conveying Process
Before
Severe material removal by abrasive bulk materials in continuous operation.
After
PTA coating with wear-resistant powder material, metallurgically bonded to the base material.
Result
Significantly extended service life, less downtime and reduced maintenance intervals.
Advantages of PTA Welding in Industrial Use
PTA welding offers clear advantages in industrial use when components are subjected to wear, corrosion or thermal loading and must function reliably. Through the targeted energy input of the plasma arc and the controllable supply of powder materials, load-bearing and reproducible deposit layers can be produced.
The process bonds the coating metallurgically to the base material, enabling permanent stable use even under high loading. At the same time, PTA cladding supports extending service lives, reducing downtime and making maintenance processes more plannable.
Low Distortion and High Dimensional Accuracy
The controlled energy input of the plasma arc reduces the thermal loading of the component – with high dimensional accuracy and stable geometry even for complex components.
Defined Layer Properties through Low Dilution
With a dilution rate of approximately 5 to 15 percent, the hardness and wear resistance of the deposit material are largely preserved. The wide selection of powder materials and pseudo-alloys enables targeted adaptation to the respective loading.
High Service Lives and Load-Bearing Surfaces
The metallurgical bond between deposit layer and base material ensures high adhesion strength and permanently load-bearing surfaces – even under abrasive, corrosive or thermal loading.
Reproducible Quality for Series Applications
Layer thickness, penetration depth and dilution can be precisely set. This produces homogeneous deposit layers of consistent quality – even for recurring components and series production.
Reduced Maintenance Costs and Less Downtime
Targeted coating instead of frequent component replacement extends maintenance intervals and makes maintenance processes more plannable. Downtime in mechanical and plant engineering is thereby significantly reduced.
Economical Alternative to New Parts and Other Processes
Lower investment costs than laser welding, lower material losses than thermal spraying and the reuse of worn components make PTA welding an economical solution.
When Is PTA Welding the Right Choice?
PTA welding is the right choice whenever components lose function due to wear, corrosion or thermal loading and replacement is not economically viable. Especially for highly loaded functional surfaces or recurring material removal, the process offers a targeted and sustainable solution.
Typical application areas include rotationally symmetrical components such as shafts, screws, rollers and valve and sealing faces in mechanical and plant engineering. Through the controlled energy input via the plasma arc, the component is subjected to significantly less thermal loading than with conventional processes such as MIG or MAG. This reduces distortion and preserves component geometry.
PTA cladding is particularly suitable for applications where:
components such as screw conveyors, rollers regularly wear through abrasion, friction or impact loading
defined layer properties such as hardness or corrosion resistance are required
dimensional accuracy and low component distortion are decisive
an economical alternative to a new part or to thermal spraying is sought
Corrosion Protection in Practice: PTA Coating of Valve Components
Valve and sealing faces in process and plant engineering are permanently exposed to chemically aggressive media and thermal loading. Corrosion in sealing areas leads to leakage, loss of function and unplanned downtime. PTA cladding deposits corrosion-resistant powder materials precisely on the loaded functional surface. The layer is metallurgically bonded to the base material and built up in a defined layer thickness.
Valve Components
Before
Corrosion attack and material fatigue in the sealing area due to aggressive media.
After
PTA coating with corrosion-resistant powder material, metallurgically bonded to the base material.
Result
Greater service life, sealed functional surfaces and reduced downtime.
PTA Welding Compared to Other Coating Processes
Classification and Characteristics of PTA Welding
PTA welding sits between MIG/MAG welding, thermal spraying and laser welding and combines properties from both process groups: the high adhesion strength of a welding process with the precise layer control of a coating process. The combination of metallurgical bond, low dilution and controlled energy input via the plasma arc distinguishes the process from conventional welding and coating processes.
Layer thickness, penetration depth and dilution can be precisely set, enabling reproducible layer quality.
Added to this are the high reproducibility and good automation capability, which make PTA cladding particularly suitable for series applications and recurring components.
Differences to MIG/MAG, Thermal Spraying and Laser Welding
MIG/MAG Welding
Higher dilution of the base material, greater thermal influence on the component and more distortion. PTA welding, by contrast, enables more precise control of energy input and layer thickness.
Thermal Spraying
Mechanical surface adhesion without metallurgical bond. PTA welding, by contrast, produces a metallic composite bond with significantly higher adhesion strength and loadability for highly stressed components.
Laser Welding
High precision at significantly higher investment and operating costs. PTA welding offers comparable layer quality at lower acquisition costs and more economical spare and wear parts.
Precise Technology. Clear Process. How We Work.
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.
1. Component Analysis
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.
2. Selection of Welding Consumable
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.
3. Component Preparation
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.
4. Cladding
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.
5. Quality Inspection
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.
Andreas Frische
Technical Management
Finding the Right Welding Process
Not sure which welding process is right for your application?
We support you in selecting and combining the right processes.
+49 5202 97790-54
Available from 07:45 - 16:30
a.frische@capilla-gmbh.de
Available from 07:45 - 16:30
Without the right welding consumable, there is no stable solution.
Alongside the process, the welding consumable plays a central role. It largely determines the properties of the weld joint or coating, from hardness and wear resistance to corrosion and heat resistance.
capilla offers welding consumables for a broad application spectrum, matched to material, process and operating conditions.
Automated Welding Processes at the capilla LCC
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.
Frequently Asked Questions about PTA Welding
PTA welding, also known as Plasma Powder Transferred Arc welding, is a thermal coating process for targeted surface treatment of components. The abbreviation PTA stands for Plasma Transferred Arc and describes the arc-transferred welding process.
The process is used primarily for wear protection, corrosion protection and the repair of highly loaded components in mechanical and plant engineering. Typical applications are rotationally symmetrical components such as shafts, screws, rollers and valve and sealing faces.
capilla offers PTA cladding for industrial applications and supports the selection of appropriate welding consumables.
A PTA coating is a metallurgically deposited protective layer applied to a component by plasma powder transferred arc welding. It bonds metallurgically with the base material and forms a permanently load-bearing functional layer with defined properties.
In contrast to thermally sprayed layers that only adhere mechanically to the surface, a PTA coating produces a metallic composite bond with high adhesion strength. Layer thickness and powder material can be specifically matched to the respective loading, for example for special hardness, corrosion resistance or heat resistance.
capilla produces PTA coatings for components such as shafts, screws, rollers or valve and sealing faces.
In the PTA welding process, a plasma arc is struck between a non-consumable tungsten electrode and the workpiece and focused by a constricting plasma gas. Via a separate powder feed, metallic powder is introduced into the arc, melted there and transferred into the weld pool on the component surface.
The energy input is precisely controlled via the power source, allowing penetration depth, layer thickness and dilution to be specifically set. A shielding gas screens the welding process from the environment and prevents oxidation. Typical dilution rates are approximately five to fifteen percent, so the properties of the deposit material are largely preserved.
capilla uses the PTA welding process for reproducible deposit layers in series and one-off production.
The central advantages of PTA welding are the low dilution with the base material, high dimensional accuracy through reduced distortion and reproducible layer quality for series applications. The metallurgical bond ensures significantly higher adhesion strength than thermally sprayed layers.
Added is the economic component: investment and operating costs are lower than laser welding; compared to component replacement, downtime and spare parts costs are reduced. The wide selection of powder materials enables targeted adaptation of the layer to different loadings such as abrasion, chemical attack or thermal loading.
capilla uses PTA cladding to coat components economically and extend their service life.
PTA welding differs from other cladding processes primarily through the combination of low dilution, precise energy input via the plasma arc and metallurgical bond to the base material. Compared to MIG/MAG welding, the thermal loading of the component is significantly lower; compared to thermal spraying, a metallic composite bond is created instead of mechanical surface adhesion.
In comparison to laser welding, the process delivers similar layer quality at significantly lower investment and operating costs. Layer thickness, penetration depth and dilution can be precisely set, enabling reproducible deposit layers even in series production.
capilla advises on the selection of the appropriate welding process for component, material and loading profile.
The application areas of PTA welding include wear protection, corrosion protection, heat protection and the repair of worn components in mechanical and plant engineering. The process is used wherever highly loaded functional surfaces with defined properties are required and component replacement is not economically viable.
Typical industries are process engineering, power engineering, conveying technology, oil and gas industry and industrial manufacturing. The targeted material selection and the controlled layer formation make PTA cladding suitable for both one-off production and series applications.
capilla carries out PTA coatings for components from these industries and supplies the appropriate welding consumables.
PTA welding protects components against wear and corrosion by metallurgically depositing a wear- or corrosion-resistant powder material on the loaded surface. The protective layer thus formed bonds metallurgically with the base material and resists abrasive material removal, chemical attack or thermal loading.
Depending on requirements, different powder materials are used, for example hard-phase-containing materials for abrasive loading or nickel- and cobalt-based alloys for corrosive and thermal loading. Due to the low dilution, the protective properties of the layer are largely preserved and act reliably even under continuous loading.
capilla selects the appropriate welding consumable on the basis of material, loading profile and operating environment.
PTA welding is suitable for repair when a component has lost its original geometry or functional surface through material removal and replacement is not economically viable. Especially for geometrically complex, material-intensive or long-lead-time components, the process is an economical alternative to a new part.
Through the controlled energy input, the component geometry is preserved during repair; through the metallurgical deposition, the restored layer achieves high adhesion strength and loadability. Components can thus be returned to their original functional state, often even with improved layer properties.
capilla deploys PTA welding for the repair of shafts, rollers, sealing faces and comparable functional components.
By means of PTA cladding, various metallic powder materials can be processed, including nickel-, cobalt- and iron-base alloys as well as hard-phase-containing materials for special wear resistance. Pseudo-alloys, i.e. mixtures of several powder components, can also be specifically deposited to achieve specific layer properties.
As base materials, steels, stainless steels and nickel-base alloys are suitable, which can be weld-metallurgically bonded with the deposit material. The specific material selection depends on the subsequent loading of the component, for example requirements for hardness, corrosion or heat resistance.
capilla offers a broad range of welding consumables for PTA cladding, matched to material, process and operating conditions.
A prerequisite for PTA welding is a weldable component with a cleanly prepared surface. Contamination, oxide layers and residues must be removed before cladding as they can impair the metallurgical bond with the base material.
Decisive are also the correct selection of powder material matched to base material and subsequent loading, as well as the correct setting of process parameters such as energy input, powder quantity and welding speed. Component geometry also plays a role: rotationally symmetrical components can be processed particularly well and coated in automated fashion.
capilla advises on component preparation, material selection and appropriate process design.