Frequently Asked Questions

Cost-effective and ideal for large surfaces, thermal spray abradable coatings and thermal barrier coatings can be applied to most metals. A great choice to advance sustainability efforts within your facility, they can restore or repair worn parts and extend service life. These processes utilize materials such as powders, wires or rods that are fed through special guns. The materials are heated or melted, then sprayed in a gas stream onto a substrate. Benefits include wear, abrasion and corrosion resistance during exposure to high temperature environments. Thermal spray coatings are used in a wide variety of industries including aerospace, oil and gas, food processing, paper, packaging and transportation.

There are several types of thermal spray processes. Each has different properties and is applied using different methods.

Flame Spray

Plasma

High Velocity Oxygen Fuel (HVOF)

Twin Arc

Traditional thermal spray coatings have many benefits, but it can be difficult to narrow them down to one coating that has all the properties needed in your particular application. Magnaplate’s PLASMADIZE® composite coatings offer the additional benefits of infused polymers, dry lubricants, metals and/or ceramics to achieve desired properties. These include operating in temperatures up to 1,000 F, exceptional wear resistance, hardness and release, and USDA/FDA compliance. PLASMADIZE® coatings can be applied utilizing advanced techniques of robotic deposition for consistent, repeatable results on large volume, complex parts.

Yes. We developed PLASMADIZE® options specifically for effective release of adhesive tapes, hot melt glue and similar sticky substances.

Yes. One of our PLASMADIZE® coatings was formulated for exceptional PVC release and wear-resistant properties in applications up to 500 F.

PLASMADIZE® coatings can be applied in substantial thicknesses, starting at .002 to .010 inch, to extend a part’s service life.

PLASMADIZE® coatings can be used to combat corrosion from many chemicals used in the pulp and paper, fertilizer, paint and printing ink industries to name just a few. These include many acids, alkalis, most organic solvents, chlorides, sulfites, thiosulfates and bleaching chemicals. Surfaces can be cleaned with just water, often eliminating the need for harsh cleaners or detergents. PLASMADIZE® can also resist the pH range encountered in many washdown solutions.

Yes. We offer versions of PLASMADIZE® that comply with the FDA’s CFR 21 175.300.

The part’s size and complexity and the desired coating thickness play large roles in determining cost. Due to the nature of application methods, deep internal holes can present challenges. Specialized techniques can be developed to spray into certain holes, and this will affect pricing. Masking can be a time-consuming step, also adding to overall cost. A wide variety of raw materials such as powders and gases are used in these coatings, and their prices vary.

Depending on the type of coating and part configuration, we can process parts up to 20 by 10 by 10 feet with a weight limit of 4,500 pounds.

Polymer coatings are various types of chemicals applied to a substrate utilizing a spray, spin dip, electrostatic or fluidized bed technique. Designed for many ferrous and non-ferrous metals, they are used to protect against corrosion or to provide non-stick properties at high temperatures. Polymer coatings have been around for about 100 years, and are found in countless consumer and commercial products such as cookware and medical devices.

LECTROFLUOR® coatings surpass the properties of conventional polymer coatings to protect ferrous, non-ferrous and mixed metal parts in harsh environments. A significant advantage with LECTROFLUOR® is that each coating can be tailor-made to meet specific requirements. Coatings within the LECTROFLUOR® family offer excellent release properties and low COF along with UV, chemical and corrosion resistance. They have exceptional electrical properties and can endure a broad service temperature range. Ideal applications include pumps, valves, sealing dies, molds, housings, rolls and stirring equipment. Each LECTROFLUOR® type provides specific characteristics and benefits, such as being able to withstand washdown cleaning agents or the durability needed for rubber molding. Specialized application techniques have been designed to resist potential microcracking and provide pinhole-free coatings. We utilize a variety of polymers and fluoropolymers such as ETFE, FEP, PTFE, PFA or dry lubricants in our LECTROFLUOR® coatings to impart the properties necessary to combat the conditions your parts encounter.

Yes. One of our LECTROFLUOR® coatings, with a thickness range of 0.0005 to 0.0015 inch, was formulated specifically to provide exceptional PVC release and wear-resistant properties in applications up to 500 F.

Yes. Many of our LECTROFLUOR® coatings comply with USDA and FDA codes for use in the food, pharmaceutical and packaging industries on parts such as hoppers, augers, rollers and seal bars.

Our LECTROFLUOR® family of coatings utilizes a wide variety of raw materials, and pricing varies. Each of these materials requires a particular method of application, with some more time-consuming than others. Some LECTROFLUOR® processes require heat curing, so oven cure time is a price factor. Masking also affects overall costs, as this is a labor-intensive aspect of any job. Part configuration, such as those with deep holes or complex geometries, also always factors into cost.

Depending on the type of coating and part configuration, we can process parts for polymer coatings up to 18 by 8 by 6 feet. These processes have a weight limit of 4,500 pounds.

Titanium nitride physical vapor deposition (TiN PVD) is a complex process performed in a chamber in a vacuum environment. The resulting gold-colored coating is a strong, thin, uniform and extremely hard surface layer. These coatings can be applied to many ferrous and non-ferrous metals including steel, titanium, and even aluminum. Unlike chemical-based processes, PVD can be used on parts with sharp edges, or those requiring extremely tight tolerances. PVD coatings have better wear and abrasion resistance than stainless steel, and can greatly extend the service life of parts.

MAGNAGOLD® and GOLDENEDGE® are Magnaplate’s enhanced TiN PVD coatings that provide wear and abrasion resistance beyond conventional PVD processes. These surface treatments are applied in low temperatures, preventing distortion or loss of hardness of metal parts. MAGNAGOLD® and GOLDENEDGE® can operate in a wide range of temperatures (-360 to +800 F), are resistant to impact forces, and are well suited for parts with tight dimensions. Benefits include chemical resistance, low COF, hardness up to an equivalent of Rc 85, and non-stick properties. These coatings resist most acids, alkalis, fluxes, solder and weld spatter. MAGNAGOLD® is ideal for tooling such as drill bits, punches, dies and electronics. GOLDENEDGE® is intended for sharp-edged parts such as blades, knives, grinders and slicers. This coating has a fine grain structure as a result of its low temperature application, and produces a thin, dense, hard surface with a low COF that minimizes wear of cutting edges.

PVD (Physical Vapor Deposition) is a process in which titanium raw materials are evaporated in a vacuum. The vapor reacts with nitrogen, and is then condensed back into a solid film on the substrate. CVD (Chemical Vapor Deposition) involves the use of raw materials in gaseous form in the process. The gas byproducts from CVD can be hazardous and flammable. CVD is performed at extremely high temperatures of 1,800+ F, which can distort metal parts, requiring vacuum heat treating to restore the hardness of the substrate.

Both coatings can be applied in a thickness of between 0.00004 and 0.0002 inch.

Yes, both MAGNAGOLD® and GOLDENEDGE® are FDA compliant for food contact applications.

The PVD chamber is not designed to hold many parts at one time. As with any coating job, factors such as the complexity and configuration of the part, if masking is needed, and deep holes will all affect costs.

Due to the nature of this process, and the necessity of fixturing parts within the PVD chamber, we recommend you contact us to discuss your application in detail.

Thin dense chrome is an electroplating process which creates a chrome coating thinner and denser than standard chrome plating. These coatings offer protective benefits for parts including increased hardness, low COF, as well as corrosion, wear and abrasion resistance. This is also an ideal coating choice for parts in a high temperature environment.

Magnaplate’s DYNALOY® surface treatment offers a higher level of corrosion resistance than standard thin dense chrome. Due to the coating’s low processing temperature, parts can be coated at any time in their service life without adversely affecting the base material’s properties. DYNALOY® has a hardness of 72 Rockwell, and can withstand operating temperatures up to 1,600 F. It is compatible with most ferrous metals, and has an attractive matte silver finish. It creates a thin microstructure with precise reproduction of substrate’s original surface morphology. Since DYNALOY® is so thin and uniform, even on edges, there is no need for grinding or machining steps after coating. Applications include automation, packaging and hydraulic equipment, conveyors, pumps, valves, punches, bearings and a wide variety of tooling and space components.

Unlike conventional hard chrome plating, DYNALOY® is void of micro-cracks. During hard chrome plating, micro-cracks can occur when internal stress exceeds the tensile strength of the hard and brittle chromium. Stresses do not have an opportunity to build up with DYNALOY® , primarily because the coating is so thin. No micro-cracks means enhanced corrosion resistance with DYNALOY® .

While the base metal’s properties such as hardness and porosity can impact individual results, DYNALOY® can resist attack by most organic and inorganic compounds.

No, application of a DYNALOY® coating will not affect tolerances due to its extremely thin and uniform nature, with a thickness range of 0.0001 to 0.0003 inch.

DYNALOY® is an economical process for any size order. Parts with complex geometries, and those that require masking would add to overall costs. With DYNALOY® , there is no need for machining or grinding after coating, eliminating the time and expense of those operations.

Depending on the type of coating and part configuration, we can process parts up to 3 feet x 4 feet x 3 feet, with a weight limit of up to 400 pounds.