flame spray company profile 2016

02/16

Company Profile

In 1969 Flame Spray was established as the first Italian job shop to actively promote Thermal Spray coating technologies and activities.

Today it is an international benchmark for applications in these markets: Energy, Oil & Gas, Printing, Steel, Transport, Aerospace.

Beyond Thermal Spray, Diffusion coatings, Slurry coatings, Cladding and Welding are today commonly applied processes at Flame Spray.

The Company’s well established know how is developed daily in the research and production center of Roncello (Italy) and also in the excellence production sites of Montefino (Italy), Szada (Hungary), Varazdin (Croatia) and Fountain Inn (USA)

The new Shop in the Shop sited in Morra de Sanctis (Avellino), in partnership with Ema (Rolls Royce Group), will be the key of success in the Aeronautic market.

Technology and Company

Background

Energy Oil & Gas Printing Steel Transport Aerospace

Markets at Flame Spray


Weld OverlaySlurry Diffusion

All thermal spray processes rely on the same principle of heating a feedstock (powder or wire), accelerating it to high velocity and then allowing the particles to strike the substrate.Particles will then deform and freeze onto the substrate.The coating is formed when millions of particles are deposited on the top of each other.Those particles are bonded to the substrate by either mechanical or metallurgical bonding.

Slurry technique consists in the application of a corrosion resistant inorganic coating operating at temperatures up to 600 °C.This coating protects metals from corrosion on the basis of galvanic principle.These coatings are qualified for several industrial applications.

Diffusion Aluminizing has proven to be a cost effective way to increase the resistance of metals from corrosion and oxidation.Flame Spray proprietary technologies are optimized to be applied on components of different geometries, dimensions and materials

Coating technologies at Flame Spray

Thermal spray

Weld overlay provides protective welded layers with high thickness and optimized metallurgical bonding.This technology is mainly used for highly corrosive environments.


Market. Turnover. People

IGT

Energy- not IGT (incl. renewable and fossil)

Oil and Gas

Paper, cardboard and printing

Aeronautic

Systems

General engineering

2000 12,2 mil €

2005 25,3 mil €

2010 37,1 mil €

2011 41,0 mil €

2012 47,5 mil €

2013 50,0 mil €

2014 54,0 mil €

2015 62,0 mil €

Turnover trend

Oil & Gas - MTM Valves

< 2002 2004 2006

APS + HVOFTBCMCrAlYWearAbradable

BrazingHoneycombBlade tipsPlates

Diffusion aluminizing

Internal aluminizing

on cooling passagesSlurry / Gel

2008

Welding

Cascade Plasma

2012

Cold Spray

2013

Technologies

Technologies

Cold Spray

20142010 2011

Internal HVOF

Pt/Al Coatings

2016

HVAF

R&D Excellences

R&D Internal Developments

• implementation of 3D Optical Scan system to check the coating thickness, where standard NDT are not possible.

• Introduction of Spray Watch Camera for continuous process

monitoring.

• Installation of a SEM-EDX system(Scan Electron Microscopy – Energy Dispersive X-ray analysis)

R&D Projects

Since 15 years Flame Spray attend to several European Projects including:

• H2IGCC coordinated by ETN• LOWBRASYS coordinated by BREMBO• MACPLUS coordinated by CSM

8

Iso 9001 Certified

Fountain Inn, South Carolina, USACoating Application Center

Roncello, ItalyHeadquarters R&D DepartmentGeneral EngineeringCoating and machine job-shop

Varazdin, CroatiaCoating Application Center

Montefino, ItalyCenter of excellence for Printing Machines Applications

Szada, HungaryCenter of excellence for Turbogas Coating Applications

Weiherhammer, DeutschlandFlame Spray shop-in-the-shop at BHS Corrugated

Morra de Sanctis, ItalyCenter of excellence for Heat Treatments and Aeronautical Applications

Flame Spray around the world

Profile

Flame Spray Italy

• Headquarters

• Large production capacity

• Productions for all the markets

• Tools and booths to handle also very large parts

• First development of technologies

• Center for training and technology transfer

• Founded in 1969 • Covered surface: 14.500 m2

• Headcount (Dec ’15): 184• Applied technologies

• Thermal spray (APS + HVOF +Internal HVOF, HVAF, Cold Spray,)

• Slurry for compressor blades• Arc, CMT and PTA cladding• Diffusion aluminizing• Vacuum Heat treatment/brazing• Chemical stripping

• Equipment• 23 Spray booths with APS, Cascade

Plasma, HVOF and Wire spray (max size 12 m x 6 m x 5 m)

• 6 environmentally controlled slurry booth• 4 air + 2 Argon furnaces• Fully equipped Laboratory • ISO 9001 and ISO 18000 certified

Flame Spray Roncello ItalyResources

Flame Spray Hungary

Profile• Center of excellence for IGT and aerospace market

• Integrated production line (TS, Diffusion Coating, brazing, HT)

• Structured organization with

scheduling tools

• Specific engineering group

for part oriented process development

• Qualified for aerospace

(ISO 9001, NADCAP, S-1000)

• Founded in 2002• Covered surface : 8.500 m2

• Headcount (Dec ’15): 117• Available technologies

• Thermal spray (APS + HVOF)• Heat treatment• Slurry for compressor blades• Diffusion aluminizing• Honeycomb brazing• Shot peening• Welding/Weld overlay• PT/Al Coatings

• Equipment: 9 APS booths, 4 HVOF booths, 2 Cascade Plasma, 2 vacuum furnaces, 4 argon furnaces, 1 air furnace, aluminizing line, 3 MIG CMT for automatic weld overlay, 1 internal aluminizing line, 1 Z-notch Mig Station

• Full equipped Laboratory with Metcut approval

• ISO 9001, 9100, 14001 and NADCAP certified

Flame Spray HungaryResources

Flame Spray Croatia

Profile

• Application center for IGT market

• Born as Shop near the Shop for

Alstom Karlovac

• Structured organization with scheduling tools

• Focused on TBC and Hardfacing coatings

for combustion components

• ISO 9001 Certified



• Thermal spray (APS + HVOF)

• Equipment: 2 APS/HVOF Large sizes (8x7x4,5m) booths

1 Large sandblasting room2 Cranes with up to 25 ton lift load

• Shop in the Shop in Weiherhammer with BHS Corrugated that is the world’s largest provider of solutions for the corrugated industry.

Equipment: 1 Hvof,2 polishing machines,1 automatic sandblasting machine

Flame Spray Croatia

Resources

Flame Spray USA

Profile• Coating center dedicated to

gas turbine applications

• All coating technologies available

• Tools and booths to handle also large parts

• Standardized coating cells to allow quick transfer of processes already qualified in Europe

• ISO 9001 Certified

Flame Spray USA

• Established in 2011• Covered surface : 7.200 m2

• Headcount: (Dec ’15) :75• Available technologies

• Thermal spray (APS + HVOF)• Heat treatment• Slurry• Diffusion aluminizing• Cold Spray• Shot peening

• Equipment:• 3 Robotized APS booths• 4 Robotized Advanced APS booths• 2 Robotized HVOF booth• 1 Robotized HVOF & advanced APS booth• 1 Robotized HVOF & Cold Spray booth • 1 Robotized advance APS & HVOF booth• 2 Argon furnaces,3 Air furnaces , Climate

controlled slurry booth,aluminizing booth, shot peening machine , large grit blasting room

Resources

Flame Spray Montefino

Profile• Coating center dedicated to

the coating and grinding of Anilox roll for printing applications.

• Tools and booths to handle also large parts

Flame Spray performs ceramic coating on anilox rolls that are laser engraved, finished and introduced on the market for flexo printing OEMs by the company Simec spa. Simec owns an experience of more 15.000 anilox rollers and sleeves for flexo market since more than 10 years.

• ISO 9001 and ISO 18000 Certified



• Thermal spray (APS +Wire Spray)• Heat treatment

• Equipment: 1 APS booth, 1 Simplex booth, air furnace

• ISO 9001, 18000 certified

Flame Spray MontefinoResources

Shop in the Shop Morra de Sanctis

Profile• Shop in the shop with Ema Spa (Rolls Royce

Group)

Flame Spray, member of Poema Network since 2014, will be responsible of vacuum heat treatment and surface coating of Aerospace and IGT components.

POEMA

(European Center for Aeronautic High Precision Casting a/k/a Polo Europeo Microfusioni Aeronautiche) is the first industrial network for aerospace investment casting components. It was established in Morra de Sanctis (Avellino, Italy) by companies that represent the excellence in technologies and processes for the production of components for aerospace engines

• ISO 9001 and ISO 18000 Certified

• Founded in 2015 • Covered surface : 1.200 m2


• APS , Heat treatment, Slurry• Equipment (Dec ’16):

• 1 APS booth• 5 vacuum furnace for aircraft blades

heat treatment • 1 furnace for Aluminising ,• 1 controlled atmosphere furnace for

heat treatment after Aluminising

Resources

Shop in the Shop Morra de Sanctis

Technology Transfer Projects

Coating on Hydro Power

PlantsBhutan

Coating on Ball Valves

Pune-India

Coating on Turbine

components Malaysia

Coating on paper rolls

Curitiba-Brazil

Coating on paper rollsTennessee

USA

Coating on Turbine

componentsFlorence-Italy

Coating on Turbine

componentsAlgeria

Coating on Turbine

componentsHungary

Cern Spinn offRenewable

energy

Furniture of Hardware and know how at OEM

On Site Coating

AT OEM FOR LOGISTIC ISSUES

• Coating on Hydro components • Coating and cladding on boilers• Coating on gas turbine components• Coating on defence components

ON SITE COATING AT END USERS FOR SERVICE PURPOSE• Cladding and thermal spray on water waste boilers (approx.15.000 m2) in

Italy, Slovakia, France, Spain, Belgium, Finland, Sweden• Coating on Geothermal Plants in Italy• Coating at Paper Rolls industry in Egypt, Germany, Hungary, Greece• Coating at Refinery in Italy

On Site Thermal Spray and Cladding on waste burners

Flame Spray Spa Headquarters20877 Roncello (Monza e Brianza) [email protected]

Coating production center

Roncello (Monza e Brianza) ItalyPh +39 039 695 7216Fax+39 039 695 331

Flame Spray Hungary Kft

Ipary Park út2111 Szada,Ph +36 28514175Fax [email protected]

Flame Spray North America Inc.

576 International Boulevard Fountain Inn,SC 29644 (USA)ph +1 864 862 2730fax +1 864 862 7465

flame spray company profile 2016

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