Plasma Spray Process

Atmospheric Plasma Coating Process

Plasma spray works by feeding the powders of a coating material a plasma jet. Materials then melt and are then sprayed over a surface to create a coating. With the material cooling upon contact, almost any metal or ceramic coating can be used for application. Because the temperature of the coating can be properly controlled to stay below 250°F, there’s no fear of overheating that causes warping or deformation to the part being coated. Plasma spray works well for equipment that is of food grade, needs to be nonstick, and has low friction. Using a plasma spray process may also be helpful for equipment that may experience abrasion, high temperatures, corrosion, and electrical conductivity. Plasma spray is an effective method for machine repair.

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Plasma Spray Coating Process

How it Works

Some materials, such as ceramics, require a tremendous amount of energy to soften and transform into the desired coating. Materials like this are heated in the plasma stream at temperatures around 16,500° C and subsequently sprayed at Mach 2 speeds onto the surface to be coated.

The inherent versatility and control of the process permits the deposition of a wide variety of spray materials including metals, alloys, ceramics (oxides, carbides), and cermets. Such coatings offer excellent properties for abrasion, high temperatures, corrosion, electrical conductivity, EMI shielding, release properties, and repair of worn parts.

Nearly any material may be plasma sprayed, and since the substrate temperature can be properly controlled to stay below 250°F, there’s no fear of overheating that causes warping or deformation to the part being coated.

The MBI Difference

At MBI we apply advanced plasma-spray coatings on your surfaces to meet application requirements regarding wear, release, heat, corrosion, oxidation, or other properties.

The “plasma release” properties of MBI’s TRACLON family of coatings create durable, extreme non-stick surfaces with traction control (non-slip). TRACLON coatings have the highest degree of non-stick known to any industry.

We employ industry-proven, high-energy Plasma spray systems (Sulzer Metco 3MB, 7MB and 9MB) to create various metallic & ceramic coatings. They are produced by applying plasma spray injected with our proprietary polymer mix, resulting in a high-performance ultra-release surface with non-slip properties.

Common Applications

  • Roll Surfacing

  • Textile & Fiber Parts

  • Friction Discs

  • Finish Rolls

  • Doctor & Feed Rolls

  • Groove Rolls

  • Hot (Heater) Plates

  • Let Down Rolls

  • Rolling Guides

  • Crimper Sleeves

  • Crimper Rolls

  • Seal Areas

  • Pump Sleeves

Key Advantages

One of the most popular functions of Plasma spray is producing ceramic coatings that are hard, extremely wear-resistant, high temperature resistant, and inert. They vastly outperform alternate methods, such as chroming, hardening, anodizing, etc.

Ceramic coatings offer versatile surface finishes. They can be found on a cross-grained (matte) finish of 80-300 Ra. widely used on textile parts applications or ground and super-finished surface of below 5 Ra. used for surfacing rolls and seal areas.

Let’s Work Together

Whether you need to enhance the performance of your equipment or repair worn-down surfaces, MBI Coatings can help. Put our advanced surface engineering to work in your business.

Contact us today to learn more.

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