Plasma Spray

Plasma Spraying is an extremely versatile thermal coating process.  A plasma is produced and controlled through a specially designed torch by excitation of an inert gas passing through an electric arc, creating a very hot ionized gas.  Plasma Spraying provides a unique opportunity to mix and blend materials that are otherwise incompatible.  Complex alloys, elemental materials, composites and ceramics can often be produced with this technique for use in target material fabrication.

The coating material, in powder form, is injected into the gas stream where it becomes molten and accelerated onto the substrate.  Here, layer by layer, a buildup through intraparticle bonding and sintering reaction takes place.

This technology is especially advantageous for rotatable sputtering targets.  Plasma sprayed materials can be applied in thickness ranging from this R&D applications to production coating requirements.  Our equipment can process materials up to 216" in length.  Typical applications are:

• Decorative Coatings
• Electronic Components
• Semiconductor Devices
• Architectural and Automotive Glass
• Mirrors
• Conductive Coatings
• Display Technology
• Photovoltaics
• Optical Coatings
• Anti-Reflective Coatings

Flame Spray

The flame spray process was initially introduced around 1910 in Switzerland by Max Ulrich Schoop.  The process included the spraying of ceramics, metals and "metal oxides".

The development of the process was enhanced in the 1950's as the United States applied greater emphasis to space exploration.  Many new metal alloys were developed in the hard facing field.  Today, flame spraying is a well recognized process implementing wire metals as the coating material.  It could be defined as the process of melting materials in a heating zone and accelerating them in a molten state onto a target to form a coating.  In the spraying process, the hot particles are quenched, or rapidly cooled, upon hitting the substrate.

The actual atomizing and propelling of the coating particles is accomplished by a surrounding stream of compressed gas.

Process Materials Inc., has extensive R&D capabilities and maintains one of the industries most complete spraying and production facilities available.  Through precise control of spraying parameters, Process Materials obtains an unparalleled level of coating quality and uniformity.

Quality Control

All aspects of material production are rigidly controlled assuring thorough compliance with customer specifications.  From incoming raw material to final product, Process Materials adheres to the highest quality standards.

Advanced Grinding Capabilities

Process Materials utilizes numerically controlled equipment to assure the highest degree of accuracy and precision on finished dimensions.  Our facility maintains the most modern and complete grinding capability to satisfy the most demanding applications.

Precision Machining Support

Process Materials provides complete precision machined capabilities.  Process Materials can machine the most sophisticated parts for coating and finishing.

At Process Materials, we possess a complete facility for plasma spraying and flame spraying (metalizing) to service your coatings to gain durability and utilization advantages.

Contact Process Materials to discuss your material requirements today.

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