THERMAL SPRAYING

SELECTED REFERENCES

Lufthansa Technik AG, Hamburg (DE)
Industry:
Aerospace
Technology:
Thermal Spraying
Process:
Plasma
Torch:
F6
Year of construction:
2007

GTV dual coating center for repair coating of engine parts using HVOF and plasma process.

 

Component recognition is realized by a scanning system and the operator receives automatic suggestions for selecting and positioning the optimal component fixture.

Flowserve Flow Control GmbH, 
Ettlingen (DE)
Industry:
Energy
Technology:
Thermal Spraying
Process:
Plasma, HVOF & Flame Spraying
Torch:
F6, K2, Top Gun, Diamond Jet, 6PII
Year of Construction:
2008

GTV coating center for coating of ball valves using plasma, HVOF and powder flame spraying process.

 

The coating center consists of 3 pcs. work spaces and a robot cell, which allows continuous work
in one work space each. Component diameters of 150 mm - 1,200 mm can be processed by the handling system.

Kurt Zecher GmbH, Paderborn (DE)
Industry:
Printing industry
Technology:
Thermal Spraying
Process:
Plasma
Torch:
F6
Year of construction:
2010

GTV coating center for coating of anilox rolls using plasma process.

 

In order to change between bond coat and ceramic layer, an F6 torch with injector changer is used. This enables a semi-automatic switching between the powder and coating type.

Technische Universität Berlin, Berlin (DE)
Industry:
Research / universities
Technology:
Thermal Spraying
Process:
Vakuum plasma „thin film“
Torch:
F6 / EPI
Year of construction:
2010

GTV coating center for coating of various components for research purposes using vacuum plasma process. 

 

A modified KUKA robot with multi-station satellite table is mounted in the vacuum tank. The minimum operating pressure is 1.5 mbar.

Georgsmarienhütte GmbH, 
Georgsmarienhütte (DE)
Industry:
Steel
Technology:
Thermal Spraying
Process:
Arc spraying
Torch:
Shark 1000
Year of construction:
2011

GTV coating system for coating of support rolls for steel rolling mills using arc spraying process.

 

A special feature is the in-door installation of the filter system, which is designed according to ATEX.

N.N.
Industry:
Electrical
Technology:
Thermal Spraying
Process:
Plasma, Arc spraying
Torch:
Delta, Shark 400
Year of construction:
2015

GTV coating center for coating of stainless steel tubes using multi-anode plasma and arc process. 

 

The components are automatically fed into the system by a conveyor belt. The coating process is carried out automatically in 2 different coating rooms. Masking of components and cleaning of masks is done fully automatic.The transport within the coating center is carried out by 2 pcs. picker and placer. The coated components are transported out of the center again by a conveyor belt.

Autocraft Drivetrain Solutions Ltd., Grantham (GB)
Industry:
Automotive
Technology:
Thermal Spraying
Process:
RSW
Torch:
RSW
Year of construction:
2012

GTV coating center for internal coating of engine blocks using RSW technology.

 

The coating is used to repair grey cast iron blocks using a primer coat.

SKF Österreich AG, Steyr (AT)
Industry:
Miscellaneous
Technology:
Thermal Spraying
Process:
Plasma
Torch:
F6
Year of construction:
2013

GTV coating center for coating rings using plasma process.

 

The coating cell is alternately loaded and unloaded with rings by 2 robots through an airlock. The automatic component fixture serves simultaneously as a rotation unit and masking during the coating process under a fixed torch.

Heraeus Materials (Materion), 
Shanghai (CN), Hanau (DE)
Industry:
Glass
Technology:
Thermal Spraying
Process:
Plasma 
Torch:
Delta
Year of construction:
2010 - 2015

GTV coating center for coating of sputter targets using multi-anode plasma process.


A special feature is the coating that is several centimeters thick, realised using special internal water cooling of the component carrier.

Robert Bosch LLC, Anderson (USA)
Robert Bosch GmbH, Bamberg (DE)
Industry:
Automotive
Technology:
Thermal Spraying
Process:
Plasma
Torch:
F6 TWIN
Year of construction:
2013 - 2021
(12 systems in total)
 

GTV mass production coating center for coating of SE sensors using plasma and plasma suspension process.

 

The components are fed into the process using a GTV multi-station indexing table. Loading and unloading of the indexing table is realised with a special loading system. Specially modified powder canisters allow a continuous filling of powder during the spray process.

 

 

SMS Group, Bhubaneswar (IN), Mönchengladbach (DE), Belo Horizonte (BRA), Shanghai (CN), Tscheljabinsk (RU)
Industry:
Steel
Technology:
Thermal Spraying
Process:
HVOF, arc spraying
Torch:
K2, JP5000, LDU
Year of construction:
2012 - 2016

GTV coating center for coating of large components for steel production using HVOF and arc process.

 

The robot mounted on a JET axis enables linear high-speed coating with a traverse speed of up to 3.2 m/s.

Krebs Korrosionsschutz GmbH, 
Rostock (DE)
Industry:
Oil and offshore
Technology:
Thermal Spraying
Process:
Arc spraying
Torch:
2 x Shark 1000
Year of construction:
2016

2 pcs. twin wire arc coating systems with automatic suction unit for coating of monopiles for off-shore wind turbines.

 

The components are up to 60 m in length and up to 10 m in diameter and the coating length is about 30 m. The entire spraying equipment is travelling along the component and can be moved after spraying.

Schlie Hydraulik-Service GmbH, 
Hamburg (DE)
Industry:
Miscellaneous
Technology:
Thermal Spraying
Process:
Wire flame spraying
Torch:
107K
Year of construction:
2016

GTV coating center for repair coating of components using wire flame spraying process.

 

The handling system can pick up various component dimensions with rotational symmetry. The system is loaded and unloaded through the 90° angle sliding gate system using an on-site hall crane.

N.N.
Industry:
Automotive
Technology:
Thermal Spraying
Process:
Plasma, Arc Spraying 
Torch:
Delta RE, Penta, Shark 400 RE 
Year of construction:
2014 - 2017

GTV mass production coating system with a total of 8 systems for coating of components for electric vehicles.

 

The coating is carried out in various steps using plasma and arc process, including 2 laser systems for pre- and post-processing of the components. The systems are connected by an automated transport system. An MES system is used for process data acquisition and quality control.

Robert Bosch GmbH, Stuttgart (DE)
Industry:
Automotive
Technology:
Thermal Spraying
Process:
HVOF 
Torch:
Top Gun Suspension 
Year of construction:
2017 

Pilot system for suspension spraying with KUKA robot, turn-tilt table and extraction system.

 

The suspension is fed to the process using the GTV suspension feeder. The coating system can process either aqueous or solvent-based suspensions.

KBA-Industrial Solutions AG & Co.KG, Radebeul (DE)
Industry:
Printing industry
Technology:
Thermal Spraying
Process:
Multi-anode-plasma, grit blasting
Torch:
Delta
Year of construction:
2014 and 2016

GTV coating center for coating of printing rolls using multi-anode plasma process.


The GTV Delta injector changer ensures automatically switching between bond and top coat. A GTV NIR (Near InfraRed) sensor measures particle temperature and velocity online.

TLS Anilox GmbH, Salzkotten (DE)
Industry:
Printing industry
Technology:
Thermal Spraying
Process:
Plasma, HVOF
Torch:
F6, K2
Year of construction:
2016

GTV coating center for coating of anilox rolls using plasma and HVOF process.

 

Due to the inclined arrangement of the lift gates, the handling systems can be folded out alternately and the components can be changed ergonomically using a hall crane. A robot travers system is mounted behind the two roller handling systems. Thus, the coating process can be carried out in both spray rooms.

Heidelberg Manufacturing Deutschland GmbH, Amstetten (DE)
Industry:
Printing industry
Technology:
Thermal Spraying
Process:
HVOF, grit blasting
Torch:
K2
Year of construction:
2007 and 2016

GTV coating center for coating of printing rolls using HVOF process.

 

The jet axis for the robot is equipped with an edge detection system and enables linear high-speed coating at a traverse speed of up to 3.2 m/s. The system automatically recognizes the component sections to be coated linearly.

GfE Fremat GmbH, Brand-Erbisdorf (DE)
Industry:
Glass
Technology:
Thermal Spraying
Process:
Plasma
Toch:
Penta
Year of construction:
2016

GTV Penta system for coating of sputter targets using multi-anode plasma process.

 

The 5-fold radial powder injection enables high powder feed rates (up to 500 g/min) with simultaneously high deposition rates and thus significantly reduced process times. The Penta torch is especially developed for coating of large components and replaces several standard plasma torches.

Buderus Guss GmbH, 
Biedenkopf-Ludwigshütte (DE)
Industry:
Automotive
Technolog:
Thermal Spraying
Process:
HVOF 
Torch:
K2, Diamond Jet 
Year of construction:
2018

GTV mass production coating center for coating of brake discs using HVOF process.

 

The system is loaded with pallets by the operator through the loading station. The handling, coating and output of the brake discs are carried out automatically by 3 robots. An MES system is used for process data acquisition as well as for QM tasks.

Aerotech Peissenberg GmbH & Co. KG, Peissenberg (DE)
AT Engine Mexico, Hermosillo (MEX)
Industry:
Aerospace
Technology:
Thermal Spraying
Process:
Plasma, HVOF
Torch:
F4, K2
Year of construction:
2018

GTV dual coating center for coating of aerospace components using plasma and HVOF process.

 

The components are safely fed to the process using a two station turn table to enable almost continuous coating.

Autoneum Management AG, 
Winterthur (CH)
Industry:
Automotive
Technology:
Thermal Spraying
Process:
Special
Torch:
Special torch
Year of construction:
2019

Special equipment for plastic coating of automotive products using modified air heaters.

 

To support a series process, powder hoppers with a respective volume of 8 liters were developed, which switch over automatically depending on the filling level. A program-dependent powder switch diverts the material that has not been fed into the process into a collecting container when the torches are withdrawn from the workpiece.

MTU Maintenance GmbH, Hannover (DE)
Industry:
Aerospace
Technology:
Thermal Spraying
Process:
Plasma, HVOF
Torch:
F4, K2, JP5000
Year of construction:
2020

GTV dual coating system for coating of aerospace components using plasma and HVOF processes.

 

The components are safely fed into the process via a turning table to enable almost continuous coating. To save valuable floor space, the main components of the spraying technology were installed on a stable platform that is part of the sound insulation cabin.

Heidelberg Graphic Equipment 
Shanghai Co., Ltd, Shanghai (CN)
Industry:
Printing industry
Technology:
Thermal Spraying
Process:
HVOF, grit blasting 
Torch:
K2
Year of construction:
2021 

GTV coating center for coating printing rollers using HVOF process.

 

The robot jet axis is equipped with edge detection on the program side and enables linear coating in the high-speed process at a traverse speed of up to 3.2 m/s. The system automatically detects the component sections to be linearly coated.

Siemens AG, Berlin (DE)
Industry:
Energy
Technology:
Thermal Spraying
Process:
Plasma
Torch:
Delta, F4
Year of Construction:
2021

GTV coating center for fully automatic coating of turbine blades using multi-anode plasma and conventional plasma processes.

 

The components are loaded into the GTV transport system and automatically recognized. Stored recipes independently initiate the required actions such as component weighing, pre-heating, coating, post-heating and quality control. At the end of the process, the GTV system provides the component in the desired condition for further processing.

IWB Werkstofftechnologie GmbH, 
Chemnitz (DE)
Industry:
Miscellaneous
Technology:
Thermisches Spritzen
Process:
HVOF
Torch:
K2
Year of construction:
2021

GTV coating center for coating different components using HVOF process.

 

The GTV robot JET axis, which has been proven for decades, is used for flexible coating of components on the GTV roller spraying bench as well as an add-on turntable. The spindle drive, turntable drive and suction hood are each designed as an external robot axis, thus enabling high-precision coating even of components with complex geometries.

Fraunhofer Anwendungszentrum für Großstrukturen in der Produktionstechnik, Rostock (DE)
Industry:
Research / universities
Technology:
Thermisches Spritzen
Process:
Plasma, arc spraying
Torch:
Delta, Shark 400 HV
Year of construction:
2021

GTV Dual Coating Center for the coating of various components with the purpose of developing coating systems and qualification for the industry using the two high-performance spraying systems GTV-APS-DELTA (multi-anode plasma process) and GTV-arc Sparc 400HV (arc system with high-speed setup).

 

The entire system is arranged on two floors, one above the other, to save space. Due to a special design of the GTV filter it is possible to fulfill the ATEX requirement even for an indoor installation and to carry out the complete installation in an existing building.

Impact Innovations GmbH / 
University of Glasgow (DE / ENG)
Industry:
Research / universities
Technology:
Thermal Spraying
Process:
Cold gas
Torch:
Impact Cold-Spray-Gun 
Year of construction:
2021

With its partner Impact Innovations GmbH, GTV has also been supplying cold gas spraying equipment for several years.

 

Here, the core competence of Impact is combined with the know-how of GTV to realize a comfortable turnkey installation for the customer. The system realized in this project is used for research purposes in various fields.

Howden Turbo GmbH, Frankenthal (DE)
Industry:
Energy
Technology:
Thermal Spraying
Process:
HVOF
Brenner:
K2
Baujahr:
2021

GTV coating center for coating different components using HVOF process.

 

The components can be mounted either on the GTV roller spraying bench or on the multi-station satellite table. This enables a very wide and flexible range of products to be processed.

Nova Werke AG, Effretikon (CH)
Industry:
Miscellaneous
Technology:
Thermal Spraying
Process:
HVOF, Plasma Suspension
Torch:
K2, F6
Year of construction:
2021

GTV plant technology also allows existing GTV coating centers to be upgraded to include additional coating processes.

 

In this project, an existing GTV-HVOF-K2 coating system was upgraded to include the GTV plasma suspension process. The entire system is conveniently operated from the main control panel.