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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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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Arcspray 528E-ACD

Introducing the Arc528E-ACD

The New Metallisation Arc528E-ACD system offers the ultimate in reliability and precision for ultra-high throughput, demanding production applications with anti-corrosion coatings.

Wire drive is supplied at the proven heavy-duty pistol by a new, powerful brushless AC Inverter motor, through a robust gearbox and drive roller system. The high-performance pistol incorporates proven Metallisation technology, including a unique, constant geometry (CG) head. This ensures smooth and consistent spray quality and minimal downtime when changing consumable spares.

The high throughput ARC528E-ACD pistol connects to one of two new Metallisation PLC controlled energisers, either 1000A or 1500A rated.

The drive unit controller is now internally mounted within the energiser for improved reliability. The industrial spec. PLC offers reliability and easier maintainability, enabling the system to be fully integrated with production equipment such as ductile iron pipe processing plants.

Ductile Iron Pipes
LPG cylinder spraying
Railway tracks
Subsea riser pipes
Construction Piles
Wind Towers
Large Monopiles

New brushless AC drive motor
New sealed energiser = easy to maintain
1000A or 1500A energiser = high production rates
Robust proven design = greater reliability
Uses 2.3mm to 4.76mm wires without changing drive rollers
Uses 2.3mm to 4.76mm wires without changing drive rollers
High capacity power electronics
High throughput = quicker production
Wire dispense from reels, coils or drums
Quick release supplies option for fast pistol changeover

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Arcspray 701(16)-CL

Introducing the Arc701/S700(16)

The Metallisation Arc701/S700(16) twin wire arc spray system is a unique blend of ability and innovation. It brings together the proven performance of our Arc700 pistol plus the very latest technological advances. For instance, the new S700(16) energiser still offers high spray rates for reduced spraying times over large areas but is now combined with closed loop current control. This enables the operator to set the spray current independent of wire type before starting the job, enabling easier setup and protection of the system from over-current.

The control function is now controlled by a simple PLC which ensures improved reliability as less component parts are required. It also makes fault finding simple using a standard multimeter with the I/O for the PLC. The S700(16) energizer features sealed electronics for excellent reliability in the harshest of spray environments.

The design also allows for multiple customer-specific packaging options for the wire drive and dispense. In one option, for example, the unit is neatly mounted on the energiser, leaving it free to swivel and follow the operator when spraying. Other options include floor or trolley mounting of the wire drive unit.

The drive unit is very robust, ensuring supreme reliability in the most arduous of site conditions. The lightweight, hand-held pistol incorporates proven Metallisation technology, including a unique, constant geometry (CG) head. This ensures smooth and consistent spray quality and minimal downtime when changing consumable spares. Various packaging options, including an extended site trolley, allow the energiser to be sited up to 25m from the pistol spraying area. Alternatively, the drive unit can be mounted neatly on the energiser, leaving it free to swivel and follow the operator when spraying.

Structural steelwork
Offshore/oil & gas
Shipbuilding/marineBridges (concrete and steel)
Vessels and enclosures
Wind turbine towers
Steel reinforcing bars
Large anti-corrosion

Closed-loop current = simplicity / reliability
New sealed energiser = reliability
High throughput = less spray time
Easy to maintain = lower downtime
Uses wires from 2.3mm to 3.17mm
Push system
Drive to pistol distance = 5m
Energiser to pistol distance up to 25m
Designed and suited for anti-corrosion applications
Lightweight pistol
Robust design = greater reliability
Wire dispense from reels, coils or drums

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