Nick Gilfillan, managing director of Dycomet UK, explains: “Centred on a portable, low pressure gas dynamic design, the concept overcomes issues such as stress, distortion and porosity that are often associated with traditional welding and thermal spraying, and has already provided proven benefits in a wide range of applications across Europe.”

 

Gilfillan believes that by bringing the technology to manufacturers and engineers in Ireland and the UK, the company is opening up new possibilities in applications such as repair, restoration, sealing and corrosion protection, to electrical conductivity and bespoke specialist needs.  

“Importantly,” adds Gilfillan, “the system can be used with a range of substrates. This includes not just metals such as aluminium, cast iron, steel and copper, but even glass, ceramics and – currently in development – plastic and composite materials.”

Dycomet UK attributes this capability to the technology behind the design. The system is centred on creating a supersonic airflow into which metal particles are injected.  This produces high levels of kinetic energy to create a rapid build-up of metal which is not simply added to the surface but actually becomes structurally integral with the substrate.

 

Gilfillan says: “The acceleration in the airflow means the particles deform as they hit the substrate, changing the composition of the surface yet without the risk of high temperatures causing melting which, potentially, leads to material weakening or distortion.” 

Applications, such as corrosion repair, can be to any thickness and can be fully machined. Dycomet says there is no distortion or oxidisation of either the substrate or the coating. Moreover, because a localised spray jet is used, adjacent areas remain unaffected by the operation. Excellent adhesion, cohesion and optimised porosity characteristics are claimed and these combine with high electrical and thermal conductivity to achieve high quality results – even the restoration of thin-wall parts is feasible. 

“Dycomet UK is making two units available – single and twin-chamber options – neither of which weighs more than 18kg.  Each requires connection to single-phase 240V electrical and six bar air supplies, together with location adjacent to an extraction facility – all commonly available in a vast number of manufacturing and engineering environments,” continues Gilfillan. “The system can be put to use with only minimal training and guidance, which we are also happy to provide.”

For manual operation, a hand held nozzle is used to direct the spray towards the part in question, although the company points out that the system can also be incorporated into automatic facilities.

The company’s involvement with Dymet systems, and particularly Dycomet, arose via the Bridge Organisation – well-established in the specialist field of automotive re-manufacturing and which now fully owns Dycomet UK.

“Bridge has always been committed to seeking out new methods of working – a commitment that is increasingly important as thinner, lighter, more highly accurate and complex components are seen increasingly with modern engines,” continues Nick Gilfillan. “The metal deposition capability of the Dymet unit clearly addresses these issues – to the extent that we were keen, and are now delighted, to become a distributor throughout Ireland and the UK.”

With full access to Dymet’s research and development capability in Europe – soon to be enhanced by a new laboratory facility in the UK – and with a high pressure system expected later this year, Dycomet UK is committed to moving the technology forward.