Arcspray 528E-BL4-ICC

Introducing the ARC528E-ICC

Introducing the NEW ARC528E-BL4-ICC system – the latest advancement in arcspray technology.

This upgraded system builds on the trusted ARC528E platform, now equipped with a high-performance brushless 4-wheel drive motor for superior wire feed control.

Paired with the robust and reliable S245/345-ICC-BL constant current energiser, this setup delivers stable, repeatable performance across a wide range of spray applications.

The energiser features intelligent closed-loop control and user-friendly interface software, allowing seamless adjustment between open and closed loop operation.

Designed for demanding environments, this system offers enhanced control, process consistency, and flexibility—ideal for high-throughput, precision coating tasks.

ERW tube weld seam repair
LPG cylinder spraying
Capacitor spraying
Multivoid aluminium tube
Paper mill rolls
Railway tracks
Subsea riser pipes
Pantograph brushes
Steel vessels
Non-stick cookware
Steel reinforcing bars
Construction Piles

New S245-ICC-BL and S345-ICC-BL sealed energisers
Closed Loop Current = simplicity / reliability
Inbuilt pistol control system
Integrates to production machinery
Safety interlocks
Anti-corrosion and engineering wires
Easy to maintain = lower downtime
Uses wires 1.2mm to 3.17mm
Quick release supplies option for fast pistol changeover
Wire dispense from reels, coils or drums

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Met-Cell

Introducing the MET-CELL

A complete automated thermal spray system for any process, designed with modular packages to create a turnkey solution to meet your production needs.

Knowledgeable Cell Design
Premium Performance & Quality
Integrated Technology

MET-CELL is a modular turnkey solution that adapts to all your thermal spraying needs

MET-CELL has been designed to ensure that automating your production process is as easy and cost-effective as possible, whilst maintaining exceptional coating results. Each cell can be individually configured using versatile, modular packages and options. Whatever material, MET-CELL is flexible to adapt to your production needs and thermal spraying processes and deliver repeatable, quality coatings at an improved rate.

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MET-CLAD

Introducing the MET-CLAD

Laser cladding falls into the group of processes commonly known as hard-facing.

The laser cladding process is a method of applying a fully dense, metallurgically bonded and virtually pure coating which can be used to increase the wear resistance, corrosion resistance or impact performance of metallic components. In some cases, all three of the properties can be improved.

The process utilises a precisely focussed high power laser beam to create a weld pool into which a metallic powder is applied. The powder, which is carried by a stream of inert shielding gas, is blown coaxially through the laser beam.

The highly accurate nature of the laser beam allows fully dense cladding with minimal dilution (<5%), yet with a perfect metallurgical bond. Numerous coatings can be applied, the composition of which can be designed to combat the failure mechanisms associated with each component.

The NEW Metallisation MET-CLAD laser cladding system is a stand-alone product that can be used to apply laser clad coatings. The control console offers mass-flow control of the laser shielding and powder feed gas for repeatable cladding. The laser can also be housed and controlled within the cladding console. All operations of the cladding process are controlled via a touchscreen panel. The interface to the operator is very simple to understand and runs on a familiar Windows interface.

The control console enables control of the laser, cooling system, gases and interfaces with the powder feeder, laser head and external automation such robot and/or turntable/lathe etc. – all from the one touch screen.

As standard, the control console includes a built in, 3kW, 19″ rack mounted diode laser. 3kW is chosen for its compact size and is generally considered to give manageable capabilities for a wide range of cladding applications. Larger capacity lasers can be integrated but will have their own enclosure.

The laser cladding head supplied as standard is a co-axial, conical head system giving excellent precision and efficiency. An optional camera can be supplied to view down the centre of the laser and show the weld pool as the cladding process is underway.

Complete turnkey packages can also be offered with booths, robots and automation.

Down hole stabilisers (WC/Ni)
High temp process rolls, hardness & corrosion resistance, valve lips and seats (Cobalt 6)
Valve balls/seats, process rolls, waste incineration boiler parts, oil refinery process plant (NiCrMo)
Coal and ore crushing hammers / wear plates / sand valves (WC/Ni)
Valve balls/seats, process rolls, boiler components, waste incineration boiler parts, hydraulic rods, down hole stabilisers (FeCrB)

Fully dense, high quality coatings with low dilution
Mass flow control of process and powder feed gases = repeatability
Easy to use, intuitive operator interface
3kW diode laser – suitable for most cladding operations
PC control with touch screen
Recipes or manual parameter setting
Manual or automatic operation

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Met-PCC(HVOF)

Introducing the Met-PCC(HVOF)

The Metallisation Met-PCC(HVOF) system is the latest development to our range of HVOF systems.

The Met-PCC(HVOF) system applies all of the simple control / operator interface features of our previous HVOF and Plasma systems. The ‘–L’ version can be interfaced with our own MET-JET4L pistol and/or other non-Metallisation liquid fuel pistols. The ‘-G’ version can be interfaced to a range of non-Metallisation gas fuelled HVOF pistols.

The Met-PCC(HVOF) system has re-packaged the control elements and utilised the latest technology to optimise functionality and reliability. At the front end, the operator interface utilises an intuitive Graphical User Interface (GUI), including the option to integrate video images into the display. The interface runs on a familiar touchscreen Windows PC platform with Intel Dual Atom processor which is great for usability, integration and communication. Behind the scenes, the latest PLC runs the system with communication between devices via the reliable Ethernet protocol.

As you would expect from a system of this standard, the gases/fluids are all mass-flow controlled for optimum repeatability of coatings. All spray parameters can have real-time trending on the system.

The result is a truly unique, compact design, flexible, easy to operate HVOF system, backed up by Metallisation’s 90 year+ industry experience and support.

Hard-chrome plate alternative
CGL mill rolls
Oil/Gas valves
Paper rolls
Suspension components
Landing gear
Hydroelectric turbines
Automotive valves
Wire drawing blocks

Mass flow control = repeatability
Easy to use operator interface
Liquid fuel = thick, low stressed coatings
Various pistols can be used
High hardness, low oxide level coatings
PC control with touch screen
Optional keyboard control
Unlimited recipes and parameter recording
Low running costs compared to hydrogen fuel
High bond strength and low porosity coatings

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Met-PCC(PLAS)

Introducing the Met-PCC(PLAS)

The Metallisation Met-PCC(PLAS) is the latest development to our Atmospheric Plasma Spray (APS) systems.

The Met-PCC(PLAS) system applies all of the simple control / operator interface features of our previous Plasma and HVOF systems but now allows the use of the Metallisation 50kW PLA5000 pistol and/or non-Metallisation plasma pistols. 50kW pistols use a single power source with an additional power source added for 80kW systems.

The Met-PCC(PLAS) system has re-packaged the control elements and utilised the latest technology to optimise functionality and reliability. At the front end, the operator interface utilizes an intuitive Graphical User Interface (GUI), including the option to integrate video images into the display. The interface runs on a familiar touchscreen Windows PC platform with Intel Dual Atom processor which is great for usability, integration and communication. Behind the scenes, the latest PLC runs the system with communication between devices via the reliable Ethernet protocol.

The result is a truly unique, compact design, flexible, easy to operate Plasma system, backed up by Metallisation’s 90 year+ industry experience and support.

Print rolls / Analox rolls
Paper rolls
Mechanical Seals
Aerospace engine
Aerospace airframe
Wire Drawing Capstans
Automotive valves
Base Coat to Non-Stick Surfaces such as Teflon

Mass flow control of primary, secondary and carrier gases = repeatability
Easy to use, intuitive operator interface
Inverter power supply = stability
PC control with touch screen operator interface
Optional keyboard control or operator interface unit
Manual or fully sequenced start-up, operation and shut-down
Various straight, angled and extension pistols can be used
Safety interlocks to prevent running without coolant and gases
Argon or Nitrogen primary and Nitrogen, Helium or Hydrogen secondary gases
Unlimited recipes and parameter recording
Other powder feeders/power sources can be interfaced

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Deflected Flame Spray Extension

Introducing the deflected flame spray extension

The Metallisation deflected flame spray extension has been developed as a direct result of customers requirements to apply a quality coating in difficult access areas. The initial requirement was for spraying onto pipe runs in the petro-chemical industry where the access between pipes and near pipe supports or other structures was limited. The extension unit fits directly onto the Metallisation flame spray pistols.

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MK74-PCC Auto Flame

Introducing the MK74-PCC

The Metallisation MK74-PCC is a fully automatic flamespray system with mass flow control, which offers the ability to produce the highest quality, repeatable coatings.

The system provides a fully automatic sequence of flame, powder feed and purge. Fault sensors check for loss of flame, stoppages or powder out and can interlock to external automation to stop production and request assistance. These features ensure continued operation, improved coating quality and minimised downtime.

The system is PC controlled with distributed I/O, for extreme reliability, comprising a touch screen HMI (with optional keyboard), mass flow control gas box and pistol.

Aerospace.
Abradables.
Thermal barriers.
Spray/fused coatings.

Mass flow control of Oxygen, Fuel Gas and Air = repeatability.
Easy to use, intuitive operator interface.
PC control with touch screen.
Optional keyboard control or operator interface unit.
Unlimited recipes and parameter recording.
Manual or fully sequenced start-up, operation and shut-down.
Safety interlocks to prevent running without Nozzle Air.

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Met-PCC(MK66E) Auto Flame

Introducing the MK66E-PC

The NEW Metallisation MK66E-PC is a fully automatic flame spray system with mass flow control, which offers the ability to produce the highest quality, repeatable coatings. The system provides a fully automatic sequence of ignition, main flame and wire feed. The wire feed is capable to be stopped during spraying without melting the wire back into the nozzle, even when left for extended periods. Fault sensors check for loss of flame, wire stoppages or wire out and can interlock to external automation to stop production and request assistance. These features ensure continued operation, improved coating quality and minimised downtime.

The system is PC controlled with distributed I/O, for extreme reliability, comprising a touch screen HMI (with optional keyboard), mass flow control gas box, and compact, electric drive pistol.

Molybdenum coatings on train axles
Robotic spraying
Heater tracks on wing/rotor leading edges
Ceramic seal areas
Tube mills

Mass flow control of Oxygen, Propane Fuel Gas and Air = repeatability
Easy to use, intuitive operator interface
PC control with touch screen
Optional keyboard control or operator interface unit
Unlimited recipes and parameter recording
Manual or fully sequenced start-up, operation and shut-down
Safety interlocks to prevent running without Nozzle Air.
Interface to external control systems/robot automation.

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MK74 Powder Flame

Introducing the MK74

Weighing only 1.85kg (4Lb), the Metallisation MK74 powder spray pistol can be hand held or machine mounted to spray a wide range of powders. Its robust construction will ensure long periods of trouble-free operation.

The MK74 is easy to ignite and has excellent flame stability, thanks to its nozzle system. A special air cap narrows the spray pattern to densify the coating which is particularly beneficial when spraying ceramics where very high deposit efficiencies can be achieved.

The MK74 can spray ceramic coatings as well as self fluxing alloys and all other metallic powders.

Small engineering repairs
Spray/fused coatings
Shaft reclamation
Self fluxing alloys for extremewear applications
Glass mould plungers
Steel mill table rolls

High deposit efficiency
Dense coatings
Quiet operation
Sprays ceramics and metals
Simple to use
Suitable for spray/fuse coatings
Powder vibrator option for poor flowing powders
Optional remote powder feeder
Can spray some plastics
Economic coatings

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MK61-FS Wire Flame

Introducing the MK61-FS

The Metallisation MK61-FS is an oxygen-acetylene fuelled flamespray system, primarily for spraying engineering coatings of steels, bronzes, copper and importantly, molybdenum. The lightweight, robust pistol offers the possibility to reclaim damaged parts for small to medium sized applications. Molybdenum can also be sprayed with the MK61-FS as a soft bond coat through to a very hard, wear resistant coating. The MK61-FS system can be used for anti-corrosion coatings where propane is not readily available. The ‘FS’ stands for Free-Standing as the new control board can be free standing or wall mounted to suit all site or in-house applications.

Extended supplies package options are being increasingly used to maximise efficiency when working on large job sites such as refineries, petro-chemical sites and offshore structures. The extended supplies packages, up to 50m from cylinders to pistol, allows the cylinders to be remotely located whilst the operator moves around the job with just the pistol and occasionally moving the control panel. The length of supplies is limited by the pressure of the acetylene. Longer supplies are possible with the propane fuelled MK73-FS as well as faster spray rates for corrosion coatings.

New in 2014 is a more ‘site friendly’ control panel. It is more robust and offers further protection to the flowmeter and ARF unit. It can be wall mounted or will free-stand on the floor. The flow of hoses is neater than the previous unit.

Engineering coatings
Reclaiming parts
Bearing and seal surfaces
Wear coatings
Molybdenum
Fine coatings with low heat input

Stop/start version allows operator to stop spraying and leave the flame lit (e.g., whilst inspecting or moving the work piece)
Wire sizes 1.5mm to 4.76mm (3/16”) to suit many application and coating requirements
Suitable for Engineering wires, steels, copper and bronzes plus anti-corrosion materials.
Spreader and non-spreader versions to allow detail work or larger areas to be sprayed efficiently
New, free standing or wall mounted control panel with Safety shut-off valve
Optional panel mounted oxygen regulator for long supplies setups
Variable wire speed control
Two stage air cap gives optimal setting for lighting and spraying
Rugged construction combined with light-weight and balance for ease of handling
Variety of hose lengths to suit each application
Flow meters for optimal setting of parameters and fault finding
Flow meters include large pointers for ease of checking from a distance
Air Regulator and Filter (A.R.F.) unit supplies motor air, nozzle air.
Optional deflected extensions for access to difficult to spray areas (anti-corrosion wires)
Variety of wire dispense methods and packaging available

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