Flame Spray or Thermal Spray Welding

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I have never even heard of this, before.  I wondered if anyone works with this and how common it is in the real world?I did find this under Wikipedia:http://en.wikipedia.org/wiki/Thermal_sprayingI wonder if this was one of those inventions that resulted accidentally?TxDoc's Photos Lincoln SP175 PlusLincoln Power Mig 256Lincoln 250 LX Spool Gun Lincoln Precision Tig 225 Hypertherm 600 KMG 2x72 Belt GrinderBaldor 812RE Grinder
Reply:Nope, thermal spray welding is intentional.  Another member named CastWeld has some good examples of using thermal spray Oxy-Fuel welding to repair and build up cast iron surfaces.  I saw it used experimentally to hard surface stamping dies.  Not really for production dies, more for rapid prototyping so they could quickly change a die surface and make a few more prototype parts.Benson's Mobile Welding - Dayton, OH metro area - AWS Certified Welding Inspector
Reply:At this time, we have this company spray welding inside one of or coal boilers.  They hard surface wear areas on our water walls, ID fan runners, coal chutes and super heater tubes.  In some places we will pad weld the area first then have them coat over the area.  They use what looks like a miller wire feeder to spray the wire.  I am not sure if they use any kind of shield gas or not.  The areas are blasted with steel grit before spraying.  Once put on you sure don't want to grind on that area.  It is very tough.  http://www.metallicbonds.com/Dan D.
Reply:Both of the vids are thermal spray, I flame spray which requires a high preheat. This is not really a welding process, its a bonding process more similar to brazing. The cold process as above vids has a weaker bond than the higher heat spraying. I repair cracked cast iron heads with the high heat process, the colder process would leak- but is faster and is much lower heat input and works well in the above applications. I think the process was used first in Germany before WW2.PeterEquipment:2  old paws2  eyes (that don't look so good)1  bad back
Reply:They used to have a process similar to coat steel with aluminum or zinc.  Kind of like zinc plating, but for large structures already built, like bridges. I've looked into it, it was out of my price range.
Reply:I appreciate the replies.  I had run across this, accidentally.  Pretty amazing process. Again, thanks for the info, I learned something new from this.TxDoc's Photos Lincoln SP175 PlusLincoln Power Mig 256Lincoln 250 LX Spool Gun Lincoln Precision Tig 225 Hypertherm 600 KMG 2x72 Belt GrinderBaldor 812RE Grinder
Reply:If you think that's good, try this oneProbably has been here before I thought it was fun.
Reply:Gonna resurrect this thread cause I did a search before posting on the topic. This is kind of the bread and butter of my trade, mouldmaker. Was curious to see how many on here do it,  or even know about it.
Reply:I have used metal spray .It is very limited and better just to use weld build up.Great video 📹 Dave

Originally Posted by TxDoc

I have never even heard of this, before.  I wondered if anyone works with this and how common it is in the real world?I did find this under Wikipedia:http://en.wikipedia.org/wiki/Thermal_sprayingI wonder if this was one of those inventions that resulted accidentally?
Reply:I've done a little spray metal or metalizing, it can be used for building up shafts to restore diameter, it also has use for adding a spray "ceramic" for wear areas.NRA LIFE MEMBERUNITWELD 175 AMP 3 IN1 DCMIDSTATES 300 AMP AC MACHINELET'S GO BRANDON!"Those who would give up essential Liberty, to purchase a little temporary Safety, deserve neither Liberty nor Safety.” BENJAMIN FRANKLIN
Reply:We use it on the seams of glass moulds. Colmonoy is harder than the cast iron so it holds up better. It gets chipped or rolled from wear so we spray weld it to repair. Brass molds we tig with castolin eutectic xx rods. Thermal spray welding is pretty obscure so happy to see some still use it. These videos dont really show our process. Ours is much more pinpoint. Imagine adding like a 1/16 inch piping on a  90° corner.Last edited by Roland11; 3 Days Ago at 08:46 PM.
Reply:Maybe I will see if I can get some vids of our process.Last edited by Roland11; 3 Days Ago at 08:48 PM.
Reply:

Originally Posted by TxDoc

I have never even heard of this, before.  I wondered if anyone works with this and how common it is in the real world?I did find this under Wikipedia:http://en.wikipedia.org/wiki/Thermal_sprayingI wonder if this was one of those inventions that resulted accidentally?