The metal-additive system provides an accurate and effective means of achieving repairs, restoration, sealing and corrosion protection. In particular, it is said to offer advantages where thinner, lighter and more complex components are utilised – typically, for example, in the engine manufacturing and repair sectors.  

Nick Gilfillan, Dycomet UK managing director, comments: “The concept overcomes issues such as stress, distortion and porosity that are often associated with traditional welding and thermal spraying. He explains that the gas dynamic design is centred on creating a supersonic gas flow 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.  

“The acceleration in the airflow means the particles deform as they hit the substrate, changing the composition of the surface via a process of plastic deformation.  However, there is no risk of high temperatures causing melting which, potentially, leads to material weakening or distortion,” adds Gilfillan.  

Dycomet UK beloeves that, compared with other means of applying metal coatings, the benefits of this method – discovered during experiments for re-entry into Earth’s atmosphere – are clear-cut. Applications such as corrosion repair can be to any thickness and can be fully machined, while there is no distortion and little 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, low compressibility and low porosity all combine with high electrical and thermal conductivity to achieve high quality results. Even the restoration of thin-wall and heavily corroded parts is feasible. Heavily corroded or worn high-content magnesium alloys are also easily repairable with the system.  

Dycomet is offering two alternative systems – a high pressure option and a choice of portable low pressure units. The former is suitable for larger structures or work pieces and is typically used in a fixed installation, often in conjunction with a production line facility. The low pressure units can be automated or operated via a hand-held spray gun and can be taken directly to the point of application, requiring connection only to an air end 240V electrical supply.

The low pressure system is well suited for applications in a range of metals including aluminium, zinc, copper and nickel as well as tin, gold, silver and platinum.  Importantly, combinations of metals can also be worked with cold spray technology. The low substrate temperatures ensure no risk of HAZ (heat affected zones) that can arise with high temperature alternatives. The high pressure system is applicable to all metals, glass and ceramics including specialist substrates such as stainless steel, titanium, molybdenum and MCrAly.

Research laboratory

The availability now of Dycomet’s new application research laboratory adds a further dimension to the system’s capability. It is designed to provide both an application development consultancy service and to operate as a facility to undertake trials for equipment sales.  

“This enables us to assess both equipment and materials and apply them to application parameters that match the customer’s requirements,” adds Nick Gilfillan.  He points out that the UK-based unit can also call on support from the company’s main European facility in the Netherlands which has a built-in high pressure system available for trials for UK and Irish clients.

“The success of the technology is based on its performance capability and the advantages that it offers over alternative methods whilst at the same time opening up greater opportunities for users,” concludes Gilfillan. “We believe that the addition now of the dedicated laboratory facility in this country will enhance our services to customers and will add to the growing list of successful installations of both the high pressure and low pressure systems.”