Lauetstrasse 13 • CH-8112 Otelfingen • Tel +41 (0)44 844’25’50 • Fax +41 (0)44 844’24’92 • info@buehrer-ag.ch  

 

Welcome to the coating specialists!

We have since 1965 experience in the flaming technology. Today, we use newest robot technology in the spraying process with wire and powder. Metal spraying, mechanical engineering and sandblasting is our core business. We repaired already many complicated machine parts more economically with electric-arc spraying process, than this would have been possible with a new creation. When may we work on your parts?

Important advantages by using coating processes

No expensive new parts!

Shorter time to market!

No distortion of the workpiece!

Interesting material mating (e.g. steel on aluminum)!

Increase of the parts lifetime by high-wearing materials!

Flexibility with onsite metal spraying and

deposition welding!

Cheap and fast!

Notice: We expanded and moved !

Now we can offer the following innovations to you:

Abrasive blasting area with a size of 6 x 3.5m

Hangar crane for a max. weight of 5t

Newest electric-arc spraying plant

Coating of shafts up to a length of 4m and a weight of 5t

Convince yourself from the advantages of metal spraying with a sample order.

Ranges of application of metal spraying

Re-establishment of worn out machine parts

Wear resistancy

Surface improving

Corrosion protection

Improvement of the electrical and thermal conductivity on contact points

Electrical and thermal isolation

Metal spraying processes

We work with the following processes:

Electric-arc spraying (EASP) with wire

Flam spraying (FLSP) with wire or powder

Characteristics

The layers of electric-arc process are characterized by a outstanding adhesion, yet not reached in the flame spraying. The spraying particles weld with the basic material.

Arbitrarily strong layers from 0.2mm to 20mm can be laid on.

The sprayed coatings can hardly be differentiated by colour from the basic material.

Good machinability of the oxide-poor sprayed coatings.

Electric-arc sprayed coatings have approximately 3 times higher strength and smaller contraction strain than flaming sprayed coatings.

Metal sprayed coatings are micro porous, which has big advantages for sliding bearings and Simmerring seats.

Independently the basic material can all materials be coated e.g. babbitt metal on aluminium

For further information we are happy to answer your questions.

Typical applications of metal spraying

These workpieces are particularly suitable for metal coating:

Eccentric shafts, cam shafts, crankshafts

Guide rails, guide ways, setting wedges

Brake disks, V-belt pulleys

Roles, rollers

Cross beams, ball and socket bearings

Piston rods, pin, axles

Plunger, piston, valves

Pinion shafts, worn shafts

Firm and sliding bearing seats

Simmering and sliding seats

Drillings

Examples of redone parts

Worn parts from cast steel. Right wave covered with masking tape and sand blasted, left finished coated bearings with aluminium bronze (CuAl 8). Aluminium parts with improved bearing quatity. Roll with new coating Coqwheel with hard coating Parts coated with rust free steel. Gear shafts Newly coated bearing parts Parts coated with Osu-60/l (13% chrome-plated steel) and polished. Crankshaft repair with flame or electric-arc spraying process. Anodensubporte: Aluminium coated wit copper (Cu) for low electric restistance Repair of huge wave shaft (wrong cut). Parts up to 4m and 1.9t can be coated! Crosshead from grey cast iron bearing surfaces coated with babbitt metal on tin basis (SnSbCu 7 4). Robot in coating action. Automated process for series. Hard coating 70HRc Electric-arc spraying head

Repair

We repair your worn machine parts!

Examples

Firm and bearing seats

Simmering and sliding seats

Piston rods, pin, axles, waves

Outside and inside seats

Guide rails

Eccentric shafts, cam shafts

Drillings etc..

Important advantages

No distortion (workpiece does not heat up)

Large selection of materials!

Wedge courses and drillings can for coating be taped off, no rework!

Interesting material mating! (e.g. AlBz on grey cast iron)

Good workability of the sprayed coatings. We offer turning and cylindrical surface grinding.

Fast delivery!

 Competent consultation! Call us. We gladly advise you and give you a concrete offer!

Use of coatings with metallization systems:

General wearing parts:

Rollers, grip arm, guidance, rims, measurer, pan bottoms, forms, extrusion, shears, pliers, roles, coils, gas bottles, hydraulic parts, camp, spindles, knuckle, crosshead, plunger, piston, valves, brake disks, V-belt pulleys, eccentric shafts, cam shafts, crankshafts, cross beams, ball and socket bearing, waves, piston rods, pin, axles, pinion shafts, , shafts guide rails, guide ways, setting wedges

Parts for different functionalities like:

Corrosion protection, electrical conductivity, improved sliding qualities, repeated service life increase, corrosion resistance, wear-resisting quality, oxidation protection, high temperature protection, re-establishment of the original dimension, abrasion resistance, preventing protection, improved corrosion resistance, new surface, non-adhesive, transfer of energy, isolation

Parts with resistance against:

Grain abrasion, friction, cavitation, particle erosion to 1000°C temperature load, chemical attacks, electricity, heat corrosion, wear, abrasion, erosion, cavitation, atmospheric corrosion, screen electromagnetic radiation, chemical corrosion, screen against disturbances by radio frequency

Parts with improvement of:

Soldering ability, optimization of the adhesion, appearance, weight saving (combination of different materials), balance by structure of weight, machinability

Parts of engines, transmissions, pumps, fans, turbines:

Construction machines, boat engines, diesel engines, petrols engines, gas engines, drive unit, compressor, transmission case bearing seats, engine repair, engine maintenance, camp, axles, seals, engine component repair of passenger car, truck. General automobile and boat industry, crane installations, agricultural machines, aviation, railway, ship and steamer parts, steam valves

Various parts

Bearing surfaces of roll pin, anchor axles, impeller shafts, knuckle, bars, hard surfaces, plunger, piston guidance, structuring of a heat barrier, shoes, applications on pressing and shrinking seats, antifriction bearing seats, beds, improvement of the heat conductivity, guide ways, repair of crankshafts, main and connecting rod bearing places, excavator wave, augers, fans, bearing seats, creation of a not wettable surface, non-adhesive coatings, self-lubricating layer systems, rough profiles for the increase of the sliding friction value, protection against sparking, creation of a micro-porous, self-lubricating surface, making a controllable wear possible to the "self fitting", resistant surface, roughen surface, high coefficient of friction, porous coatings, formation of an electrical isolation, improvement of the wettability, increase of the electrical conductivity, not magnetic intermediate layers, structure of reflector surfaces, anti-corrosive coatings with different materials

Parts of the different industries like

Machine tool industry, textile industry, agriculture, construction industry, metallurgy, automobile industry, aviation, printer industry, mining industry, shipbuilding, energy engineering and production, hydraulics, medicine etc.

Layer types of metal spraying

The area of application of metal spraying is very broad. With the new coating, new functions are independently of the base material possible:Possible kinds of layer Soft and hard coatings Resistance against wear Resistance against grain abrasion Resistance against hard surfaces Resistance against friction Resistance against chemical corrosion and atmospheric corrosion Resistance against heat corrosion Resistance against erosion Resistance against abrasion Resistance against oxidation (soldering ability improves) Resistance against electricity Resistance against cavitation Increase of electrical conductivity Increase of the sliding qualities Increase of the transfer of energy Increase of the isolation Improvement of the machinability Weight reduction Screen against electromagnetic radiation Screen against high frequencies Tungsten carbide sliding surfaces High temperature protection Self-lubricating layer systems Non-adhesive coatings Increase of the sliding friction value Customized layer development New surface (appearance and aesthetics) Preventing protection layer Re-establishment of the original dimension

Your advantages

Re-establishment of worn out machine parts Expensive timeconsuming new preparations are void Shorter down-times No distortion of the workpiece Interesting material mating (e.g. steel on aluminum) Variable layer thickness possible No rework by covering of unwanted coating places Increase of the service life by high-wear materials New layer function selectable independently to base material Good workability of the sprayed coatings Flexibility by onsite metal spraying and deposit welding Time and cost saving Electric arc spraying is our specialityNearly all materials can be coated by metal spraying in the electric-arc process as for example aluminum, cast iron, plastics, textiles or wood. The base material plays thereby a subordinated role. A outstanding advantage of metal spraying is the distortion-free coating with all metals available as wire.

How does Electric arc spraying works?

Electric arc spraying is a thermal spraying process that uses an electric arc between two consumable electrodes of the surfacing materials as the heat source. A compressed gas atomizes and propels the molten material to the workpiece. The two consumable electrode wires are fed by a wire feeder to bring them together at an angle of approximately 30 degrees and to maintain an arc between them. A compressed air jet is located behind and directly in line with the intersecting wires. The wires melt in the arc and the jet of air atomizes the melted metal and propels the fine molten particles to the workpiece. The power source for producing the arc is a direct-current constant-voltage welding machine. The wire feeder is similar to that used for gas metal arc welding except that it feeds two wires. The gun can be hand held or mounted in a holding and movement mechanism. The part or the gun is moved with respect to the other to provide a coating surface on the part. Electric-arc spraying characteristics Layer thickness: 0.3mm – 20mm HardeningMetal: up to 70 HRC Wire: 1.6mm, 2.0mm, 2.5mm Zerreissfestigkeit: 3 times higher as with flame sprayed layers Colour: almost no difference from base material Refining: Turning, grinding, polishing,... Cost: CHF/dm² (depending on spraying process, layer thickness etc.) Examples Isolation Purpose Isolation Object Turbocharger inlet shovel Material Chrome-plated steel Coating Ceramic(s) in the flaming spraying process Wear protection Purpose Longer service lives Object Part from mixer Material Chrome-plated steel Coating 13% CR steel/Ledurit 76 both 50% in the electric-arc spraying process coated Wear protection Purpose Longer service lives Object Bowl Material Chrome-plated steel Coating AMCO bronze in the electric-arc spraying process Transfer of energy Purpose Pneumatic cylinder copper upcoating Object Pneumatic cylinder Material Anticorodal Coating AMCO bronze in the electric-arc spraying process Further workpiece examples or typical applications.

Workflow

Preparation of the workpiece for the new coating, degreasing and sandblast with aluminium oxide. Coat depends upon application. Grinding the workpieces. Packed and storage Portions which may not be coated must be covered with masking tape or non-adhesive color. Spraying a wear protection OSU-60/L Cr 13%. Finish process with cylindrical surface grinding or turning. Storaged palette ready for transport Best thanks for your order!

Metal spraying with use of roboter technology

 We automated electric-arc spraying with a special developed plant. Like that we can faster spray series of workpieces for you with an even coating without clouding effect. Programming the robot you can of course let up to us. We can offer higher quality as with hand spraying possible.

Abrasive blasting

 Within the range of abrasive blasting work we can offer following services to you:

Surface cleaning of colour and rust

Glass or plexiglass unpolish

Chromium-plated steel glass bead blasting

Different blast grains and grain size

Surfaces from rough to fine

Plants

Abrasive blasting booth

Automatic bar machine

Drum automat

Abrasive blasting cab

Most diverse parts can be worked on with the plants.

Rework

Further service for all sand blasted parts:

Corrosion protection

Coating in the electric-arc spraying process

Materials:

Zinc,

Aluminum, CrAl...

With our specialized knowledge we are happy to find for you the solution of abrasive blasting problems even with sample sand blasting. Please require an offer. We have short time delivery.

Automatic bar machine

Bars and pipes: max to diameter 240 x 6000mm Blast grain: Aluminium oxide Roughness: N7 to N8 With this plant (6 nozzles) we can economically sand blast bars up to 6m length - regularly without clouding effects.

Sand blasting cab

Cab size: Partial size: max. 1200 x 1000mm Blast grain: Aluminium oxide, glass beads, glass pellet Roughness: N6 to N12 Owing to integrated turntable and reinforcement also larger and heavier parts can be sand blasted efficiently! Kinds of blast grain:Chill castingBlast grain from cast irons for roughening up, descaling, derusting and clearing away surfaces.Cast steelSharp-edged blast grain from recompensed high coal steel with long service life and high breaking strength. Steelgrit is used for cleaning with excellent surface finish, for pretreatment before enamelling, painting and coating. Due to the hardness impurities themselves they are removed under difficult conditions. Spherical blast grain from recompensed high coal steel with long service life and high breaking strength. Steelshot is used for cleaning and shot-peening.CorundumSharp edged, abrasives alumina with continuous cleaning and erosion effect. Been suitable to remove hard layers and for surface activation before coating metallic and non-metallic materials.Glass beadsGlass beads consist from a mineral and of a synthetic portion. They are particularly suitable for obtaining silk matte effects on high-grade steel sheet metals.Ceramic(s) beadsCeramic(s) beads consist of a mineral and of a synthetic portion. Opposite glass beads they exhibit a substantially higher service life and the surface are less size sensitive.Plastic granulatesPlastic is a synthetic blast grain, suitable particularly for plastic and soft parts as well as sensitive forms.

Abrasive blasting booth

We have a large blasting booth, so we can clean also larger special parts for you. Booth size: 6x3.5m Weight: max 1.5t Blast grain: Aluminium oxide Roughness: N9 Pump Careful blasting work on bones Drum automat Small parts can economically be sandblasted in the drum automat. Small parts: up to 1kg Blast grain: Aluminium oxide, glass beads, glass pellet Roughness: N7 to N9 Drum for the workpieces

Mobile repairs

 With our driving workshop we can onsite apply a new coating with the electric-arc process or use deposition welding.

We offer to you:

Mobile metal spraying

Mobile deposition welding

Mobile electric arc sprayings is used where a transport of the workpiece is impossible (e.g. fixed carrier). The base material of the part which can be coated plays a subordinated role, since different material combination are possible.

Deposition welding

 Deposition welding is particularly used with the repair of bad drillings and can even be applied onsite. Too large or damaged drillings can be welded up and worked on again on measure.

Which drilling can be repaired with the mobile deposition welding plant?

Drillings with a diameter of 50-200mm and a depth of up to 300mm.

Which advantages do I have?

New preparations are avoided, repair is more economical

Timesaving, because we can come to you; we are mobile and fast

Example of a welded up drilling

For better recognition is the drilling cut open

 Mechanical refinement

 We have the possibility to even work on odd sized workpieces.

What are your parts like?

Machinery

Turning lathe conventionally:

Boehringer Goeppingen VDF type E 560

Point length: 2'500 mm

Peak height over bed: 300 mm

Peak height over carriage: 200 mm

Accessories: Steady rest

Grinding machine (internal and external) conventionally:

Fortuna (redone)

Point length: 750 mm

Peak height: 180 mm

Download sprayable material data sheet

 The list of the newest sprayable materials in tabular form

download here:

 S prayable materials (German only)

 Sprayable materials (German only)

 Factsheet of Buehrer AG (PDF document)

 How to find Buehrer AG, Otelfingen

Feedback und Comments

About you Forename Surname* Company Street/ Nr. PC/ City Phone Email Adress* Feedback by ...? ? Call email My interest: Metal spraying Sand blasting Engineering How do you know us? Internet Friends Swisstech exebition different Comment? ??? How can we start working for you?Usually after a telephone or email we get a drawing by fax or email.With the received drawing and purpose of workpiece we can give you an offer.Why not try with a sample order our service? BÜHRER AGLauetstrasse 13CH-8112 OtelfingenTel +41 (0)1 844 25 50Fax +41 (0)1 844 24 92info@buehrer-ag.chwww.buehrer-ag.ch

History of the Buehrer AG

1964 Richard Buehrer founded the company as a private firm. Already in the first years not only the flaming and powder spraying process was used, but also the new electric-arc process, characterised by a outstanding adhesion, a good cutting property and a 3 times higher strength.

1974 With the purchase of turning lathe and cylindrical-surface grinding machine now also the necessary finishing could be implemented.

1988 The private firm was converted into a corporation.

1994 Martin Buehrer took over the management. The company name changed to BUEHRER AG.

1998 Investment into the robot technology. New large surfaces with a regular layer are possible.

1999 Because of a short-circuit the whole workroom burned out. After only one month of intensive reorganization it could be coated again. With a " day of the open door ", we celebrated the reopening of the enterprise with our customers.

2001 On 18 March Richard Buehrer, founder and board of directors president of the BUEHRER AG, died after short serious illness.

2002 Moving into the larger premises to the Lauetstrasse in Otelfingen, where we work with the newest electric-arc spraying plant and a ABB robot for you.

Martin Bührer

Managing director

Certified Mechanical Engineer

mb@buehrer-ag.ch

Environmental protection

We put also great importance to the environment. Metal dust is collected separately and recycled.

We fulfill also the highest requirements to pure air regulations with the newest filter system installed.

Where ever waste can be avoided, we act accordingly.

Glossary

 This Lexikon should give some help referred to metal spraying questions.

A

Abradable coatings

Coatings which are designed to be abraded by a mating surface to form a tight gas or air seal, while retaining good erosion resistance.

Abrasive blasting

A process for cleaning and roughening a surface by means of an abrasive directed at high velocity against the work piece.

Acetylene

Unsaturated aliphatic hydrocarbon gas. Used as a fuel gas in combustion thermal spray processes, welding and cutting. Acetylene has the highest flame temperature and requires the smallest amount amount of oxygen to form a neutral flame.

Alloying Element

Any metallic element added during the making of steel for the purpose of increasing corrosion resistance, hardness, or strength. The metals used most commonly as alloying elements in stainless steel include chromium, nickel, and molybdenum.

Alloy Steel

An iron-based mixture is considered to be an alloy steel when manganese is greater than 1.65%, silicon over 0.5%, copper above 0.6%, or other minimum quantities of alloying elements such as chromium, nickel, molybdenum, or tungsten are present. An enormous variety of distinct properties can be created for the steel by substituting these elements in the recipe. Addition of such alloying elements is usually for the purpose of increased hardness, strength or chemical resistance.

Acid Steel

Steel melted in a furnace with an acid bottom and lining and under a slag containing an excess of an acid substance such as silica.

Annealing

Heating to and holding at a suitable temperature and then cooling at a suitable rate, for such purposes as reducing hardness, improving machinability, facilitating cold working, producing a desired microstructure, or obtaining desired mechanical, physical, or other properties.

Arc Welding

A group of welding processes wherein the metal or metals being joined are coalesced by heating with an arc, with or without the application of pressure and with or without the use of filler metal.

Aluminising (Thermal Spray Method)

Thermal sprayed coatings of aluminium usually on substrates of steel or nickel chromium alloys which are subsequently heat treated to aluminise the surface.

Amorphous

noncrystalline, or devoid of regular structure.

Apparent hardness

The value obtained by testing a coating or sintered material with standard indentation hardness equipment.

Arc Wire Spraying

A thermal spray process where two electrically conducting wires are brought together to form an electric arc. Molten material formed in the arc is projected by a compressed gas stream towards the work piece to form a coating.

Argon (Ar)

Monatomic noble gas, atomic number 18, one of the most inert elements. Commonly used as a plasma gas for plasma spraying and providing inert environments for many processes.

B

Basic Steel

Steel melted in a furnace with a basic bottom and lining and under a slag containing an excess of a basic substance such as magnesia or lime.

Binder

A cementing medium used in producing composite or agglomerate powders.

Blasting

A pressurised stream of particlulates (ceramic, plastic, metal, , etc.) applied on a surface to clean, peen or abrade.

C

Carbon Steel

Steel that has properties made up mostly of the element carbon and which relies on the

carbon content for structure. Most of the steel produced in the world is carbon steel.

Carrier gas

Usually nitrogen or argon gas that carries powder into the thermal spray process.

Cavitation

The formation and rapid collapse within a liquid of cavities or bubbles that contain vapour or gas or both.

Chromium (Cr)

An alloying element that is the essential stainless steel raw material for conferring corrosion resistance. A film that naturally forms on the surface of stainless steel self-repairs in the presence of oxygen if the steel is damaged mechanically or chemically, and thus prevents corrosion from occurring.

Coating

The application of a layer of material onto the surface of a substrate.

Composite Coating

Mixture of two or more materials. Many thermal spray coatings could be considered as composites.

Corrosion

Chemical or electrochemical reaction between a material and it's environment which results in deterioration in the properties of the material.

Corrosive wear

Wear in which chemical or electrochemical reaction with the environment is significant.

Corrosion

The gradual degradation or alteration of steel caused by atmosphere, moisture, or other agents.

Cementite

A compound of iron and carbon, known chemically as iron carbide and having the approximate chemical formula Fe3C. It is characterized by an orthorhombic crystal structure. When it occurs as a phase in steel, the chemical composition will be altered by the presence of manganese and other carbide-forming elements.

Chromium-Nickel Steel

Steel usually made by the electric furnace process in which chromium and nickel participate as alloying elements. The stainless steel of 18% chromium and 8% nickel are the better known of the chromium-nickel types.

D

Detonation Gun

A thermal spray process in which the coating material is heated and accelerated to the workpiece by a series of detonations or explosions from oxy-fuel gas mixtures.

E

Elasticity

The property of certain materials that enables them to return to their original dimensions after an applied stress.

Erosion

Removal of material from a surface due to mechanical interaction between that surface and a fluid, a multicomponent fluid, or impinging liquid or solid particles.

Electric Arc Furnace (EAF)

Steelmaking furnace where scrap is generally 100% of the charge. Heat is supplied from electricity that arcs from the graphite electrodes to the metal bath. Furnaces may be either an alternating current (AC) or direct current (DC). DC units consume less energy and fewer electrodes, but they are more expensive.

Electric Arc Spraying (EASP)

Electric Resistance Welded (ERW) Pipe

Pipe made from strips of hot-rolled steel which are passed through forming rolls and welded. While seamless pipe is traditionally stronger and more expensive than comparable ERW pipe, ERW technology is improving and the technique now accounts for approximately 48% of OCTG shipments by tonnage.

F

Fatigue wear

Wear of a solid surface caused by fracture arising from material fatigue.

Ferritic

The second-largest class of stainless steel, constituting approximately 25% of stainless production.

Ferritic stainless steels are plain chromium steels with no significant nickel content; the lack of nickel results in lower corrosion resistance than the austenitics (chromium-nickel stainless steels). Ferritics are best suited for general and high-temperature corrosion applications rather than services requiring high strength. They are used in automotive trim and exhaust systems, interior architectural trim, and hot water tanks. Two of the most common grades are type 430 (general-purpose grade for many applications, including decorative ones) and type 409 (low-cost grade well suited to withstanding high temperatures).

Ferroalloy

A metal product commonly used as a raw material feed in steelmaking, usually containing iron and other metals, to aid various stages of the steelmaking process such as deoxidation, desulfurization, and adding strength. Examples: ferrochrome, ferromanganese, and ferrosilicon.

Ferrochrome

An alloy of iron and chromium with up to 72% chromium. Ferrochrome is commonly used as a raw material in the making of stainless steel.

Ferrous

Metals that consist primarily of iron.

Flame hardening

The localised surface heating of a medium carbon steel by an impinging gas flame so that the temperature is raised above 900oC. The part is quenched (or self-quenches by virtue of the remaining cool bulk of the component) and tempered to produce a hard martensitic structure at the surface.

Flame spraying (FLSP)

A thermal spraying process in which the particles are heated and accelerated in a flame (combustion flame, plasma flame). Old term for thermal spray process. FLSP was the first thermal spraying process. It use 2760 ºC (5000 ºF) oxyacetylene flame to melt the targets which may be powders, rods, or wires.

Friction

The reaction force resulting from surface interaction and adhesion during sliding. The friction Coefficient is defined as the friction force divided by the load.

G

Galvanized Steel

Steel coated with a thin layer of zinc to provide corrosion resistance in underbody auto parts, garbage cans, storage tanks, or fencing wire. Sheet steel normally must be cold-rolled prior to the galvanizing stage.

Galvanic corrosion

Accelerated corrosion of a metal because of an electrical contact with a more noble metal or nonmetallic conductor in a corrosive electrolyte.

Granular powder

Particles having approximately equidimensional nonspherical shapes.

Grinding

The removal of material by the use of fixed abrasives like grinding wheels or emery paper.

Grit blasting

A pressurised stream of hard metal or oxide grit material used to clean and roughen surfaces prior to coating.

H

Hardening

Process that increases the hardness of steel, i.e., the degree to which steel will resist cutting, abrasion, penetration, bending, and stretching. The increased endurance provided by hardening makes steel suitable for additional applications. Hardening can be achieved through various methods, including (1) heat treatment, where the properties of steel are altered by subjecting the steel to a series of temperature changes; and (2) cold working, in which changes in the structure and shape of steel are achieved through rolling, hammering, or stretching the steel at a relatively low temperature.

Hardness test

A test designed to assess the resistance to penetration from a load. The surface is indented under a defined load and the depth or area of penetration is measured.

Helium (He)

Monatomic noble gas, Most inert element, atomic number 2. Used as a plasma gas in plasma spraying.

High Velocity Oxy-fuel Spraying (HVOF)

A Thermal spray process. The spray powder particles are injected into a high velocity jet formed by the combustion of oxygen and fuel, heated and accelerated to the workpiece.

Hydrogen

Diatomic gas, atomic number 1, The lightest element, very reactive and powerful reducing agent. Used as a secondary plasma gas in the plasma spraying process and as a fuel gas in combustion thermal spray processes (CWS, CPS and HVOF).

I

Induction hardening

The localised surface heating of a medium carbon steel by an induction coil so that the temperature is raised above 900oC. The part is quenched (or self-quenches by virtue of the remaining cool bulk of the component) and tempered to produce a hard martensitic structure at the surface.

Heat Treatment

Altering the properties of steel by subjecting it to a series of temperature changes. To increase the hardness, strength, or ductility of steel so that it is suitable for additional applications. The steel is heated and then cooled as necessary to provide changes in the structural form that will impart the desired characteristics. The time spent at each temperature and the rates of cooling have significant impact on the effect of the treatment.

High-Carbon Steel

Steel with more than 0.3% carbon. The more carbon that is dissolved in the iron, the less formable and the tougher the steel becomes. High-carbon steel's hardness makes it suitable for plow blades, shovels, bedsprings, cutting edges, or other high-wear applications.

Impurities

Elements or compounds whose presence in a material is undesired.

Indentation Hardness

The resistance of a meterial to indentation. This is the usual type osf hardness test, in which a pointed or rounded indenter is pressed into a surface under a substantially static load.

Induction Hardening

A process of hardening a ferrous alloy by heating it above the transformation range by means of electrical induction, and then cooling as required.

Iron

(Chemical symbol Fe.) Element No. 26 of the periodic system; Atomic weight 55.85. A magnetic silver white metal of high tensile strength, ductile and malleable. Melting point of pure iron about 2795 (degrees) F. Chemically iron is chiefly base forming. The principal forms of commercial iron are steel, cast iron and wrought iron.

J

K

Kerosene

Liquid fuel used in some HVOF thermal spray processes.

L

Life Cycle Costing

An accounting method of costing where expenses are allocated over the life of the product. Life cycle costs are often lower for stainless steel than for alternatives despite a higher initial outlay, because stainless products generally last longer and require little maintenance.

Low-Carbon Steel

Steel with less than 0.005% carbon is more ductile (malleable): It is capable of being drawn out or rolled thin for use in automotive body applications. Carbon is removed from the steel bath through vacuum degassing.

Localized corrosion

Corrosion at discrete sites, for example, pitting, crevice corrosion, and stress corrosion cracking.

M

Machinability

The relative ease of machining a metal.

Malleabilizing

A process of annealing white cast iron in such a way that the combined carbon is wholly or partly transformed to graphitic or free carbon or, in someinstances, part of the carbon is removed completely.

Manganese

(Chemical symbol Mn.) Element No. 25 of the periodic system; atomic weight 54.93. Lustrous, reddish-white metal of hard brittle and, therfore, non-malleable character. The metal is used in large quantities in the form of Spiegel and Ferromanganese for steel manufacture as well as in manganese and many copper-base alloys.

Matalloid

Element intermediate conductivity between the true metals and non-metals. Arsenic, antimony, boron, tellurium, and selenium, etc., are generally considered metalloids; frequently one allotropic modification of an element will be non-metallic, another metalloid in character. Obviously, no hard and fast line can be drawn.

Mechanical Properties

The properties of a material that reveal its elastic and inelastic behavior where force is applied, thereby indicating its suitability for mechanical application; for example, modulus of elasticity, tensile strength, elongation, hardness, and fatigue limit.

Mechanical Working

Plastic deformation or other physical change to which metal is subjected, by rolling, hammering, drawing., etc. to change its shape, properties or structure.

Medium-Carbon Steel

Contains from 0.30% to 0.60% carbon and less than 1.00% manganese. May be made by any of the standard processes.

Melting Range

The range of temperature in which an alloy melt; that is the range between solidus and liquidus temperatures.

Metal

An opaque, lustrous, elemental substance that is a good conductor of heat and electricity and, when polished, a good reflector or light. Most metals are malleable and ductile and are, in general, denser than other substances.

Metallising

Is a recommended repair method for large damaged or uncoated areas of a galvanized item.

Metal Spraying

A process for applying a coating of metal to an object. The metal, usually in the form of wire, is melted by an oxyhydrogen or oxyacetylene blast or by an electric arc and is proficted at high speed by gas pressure against the object being coated.

Microhardness

The hardness of a coating as measured on a microscopic scale. Can show the hardness of individual phases within the coating and avoid the effects of porosity.

Microstructure

The structure of a prepared surface of a metal as revealed by a microscope at a magnification greater than ten diameters.

Molybdenum (Mo)

An alloying element used as a raw material for some classes of stainless steel. Molybdenum in the presence of chromium enhances the corrosion resistance of stainless steel.

Modulus of Elasticity

A measure of the rigidity of metal. Ratio of stress, within proportional limit, to corresponding strain.

Molybdenum

(Chemical symbol Mo) Element No. 42 of the peridic system; atomic weight 95.95. Hard, tough metal of grayish-white color, becoming very ductile and malleable when properly treated at high temperatures.

N

Nickel (Ni)

An alloying element used as a raw material for certain classes of stainless steel. Nickel provides high degrees of ductility (ability to change shape without fracture) as well as resistance to corrosion. Approximately 65% of all nickel is used in the making of stainless steel.

Nickel Silver

Copper base alloys that contain 10-45% Zn. and 5-30% Ni.

Nickel Steel

Steel containing nickel as an alloying element. Varying amounts are added to increase the strength in the normalized condition to enable hardening to be performed in oil or air instead of water.

Nickel plating

The electrolytic deposition of nickel to form a corrosion barrier or to reclaim a worn part. Can also include hard ceramic particles to from a wear resistant composite coating.

Nitrogen

Diatomic gas. Used as a primary and secondary gas in plasma spraying. Inert to most materials, with some exceptions like titanium.

Non-Ferrous Metals

Metals or alloys that are free of iron or comparatively.

Normalizing

A heat treatment applied to steel, Involves heating above the critical range followed by cooling in still air. Is performed to refine the crystal structure and eliminate internal stress.

O

Overheating

Heating a metal or alloy to such a high temperature that its properties are impaired. When the original properties cannot be restored by further heat treating, by mechanical working, or by combination of working and heat treating, the overheating is known as burning.

Oxidation

The addition of oxygen to a compound. Exposure to atmosphere sometimes results in oxidation of the exposed surface, hence a staining or discoloration. This effect is increased with temperature increase. Loss of electrons by a constituent of a chemical reaction. (Also refers to the corrosion of a metal that is exposed to an oxidising gas at elevated temperatures.)

Oxygen

Gas used to support combustion of fuel gases in combustion thermal spray processes. Achieves much higher flame temperatures than using air.

Oxide

Compound of oxygen with another element.

P

Particle size

The controlling lineal dimension of an individual particle as determined by analysis with sieves or other suitable means.

Plasma Spraying (PSP)

A thermal spraying process in which the heat source is a plasma flame. Similar to flame spraying, PSP however produces 16,650 ºC (30,000 ºF) heat for melting powders and yet the surface temperature of the substrate rarely exceeds 150 ºC (300 ºF).Plasma Transferred Arc (PTA)

Porosity

The presence of pores or voids in a coating, usually expressed as a percentage by volume.

Powder Metals

Fabrication technology in which fine metallic powder is compacted under high pressure and then heated at a temperature slightly below the melting point to solidify the material. Primary users of powder metal parts are auto, electronics and aerospace industries.

Precipitation Hardening (PH)

A small group of stainless steels with high chromium and nickel content, with the most common types having characteristics close to those of martensitic (plain chromium stainless class with exceptional strength) steels. Heat treatment provides this class with its very high strength and hardness. Applications for PH stainless steels include shafts for pumps and valves as well as aircraft parts.

Permalloy

Nickel alloys containing about 20 to 60% Fe, used for their high magnetic permeability and electrical resistivity.

Plating

A thin coating of metal laid on another metal.

Polished Surface

The finish obtained by buffing with rouge or similar fine abrasive, resulting in a high gloss or polish.

Polishing

Producing a specularly reflecting surface.

Propane

Aliphatic hydrocarbon gas used as a fuel gas in thermal spray processes.

Propylene

Hydrocarbon gas used as a fuel gas in thermal spray processes. Higher flame temperature than hydrogen and propane.

Q

Quality Control

All aspects of the control of the spraying process including the surface preparation, spraying, control of thickness deposited and the oxide and porosity levels, surface finish.

Quench Hardening (Steel)

A process of hardening a ferrous alloy of suitable composition by heating within or above the transformation range and cooling at a rate sufficient to increase the hardness substantially. The process usually involves the formation of martensite.

Quenching

Rapid cooling.

R

Reduction of Area

The difference, expressed as a percentage of original area, between original cross-sectional area and that after straining the specimen.

Rockwell Hardness (Test)

A standard method for measuring the hardness of metels. The hardness is expressed as a number related to the depth of residual penetration of a steel ball or diamond cone (brale) after a minor load of 10 kilograms has been applied to hold the penetrator in position. This residual penetration is automatically registered on a dial when the major load is removed from the penetrator. Various dial readings combined with different major loads, five scales designated by letters varying from A to H; the B and C scales are most commonly in use.

S

Sealing

A process which, by absorption of a sealer into thermal spray coatings, seals porosity and increases resistance to corrosion of the underlying substrate material.

Shrinkage

A decrease in dimensions of a coating during processing.

Shrinkage stress

The residual stress in a coating caused by shrinkage during processing.

Shot peening

The bombardment of a component surface with steel or ceramic shot. Produces a residual compressive stress in the surface and improves fatigue and stress corrosion performance.

Shroud

A gaseous and/or mechanical or physical barrier placed around the spraying process designed to reduce the ingress of air into the system and so reduce oxidation of the of the materials being sprayed.

Sintering

A process that combines iron-bearing particles, once recovered from environmental control filters, into small pellets. Previously, these materials were too fine to withstand the air currents of the smelting process and were thrown away. The iron is now conserved because the chunks can be charged into the blast furnace.

Stainless Steel

The term for grades of steel that contain more than 10% chromium, with or without other alloying elements. Stainless steel resists corrosion, maintains its strength at high temperatures, and is easily maintained. For these reasons, it is used widely in items such as automotive and food processing products, as well as medical and health equipment.

Stress Corrosion Cracking (SCC)

Slow growth of cracks in stainless steel caused by the combined effect of mechanical stress and exposure to a corrosive environment.

Scleroscope Test

A hardness test where the loss in kinetic energy of a falling metal tup, absorbed by indentation upon impact of the tup on the metal being tested, is indicated by the height of rebound.

Shore Hardness Test

Same as scleroscope test.

Silicon

Chemical symbol Si. Element No. 14 of the periodic system; atomic weight 28.06. Extremely common element, the major component of all rodks and sands; its chemical reactions, however, are those of a metalloid. Used in metallurgy as a deoxidizing scavenger. Silicon is present, to some extent, in all steels, and is deliberately added to the extent of approximately 4% for electric sheets, extensively used in alternating current magnetic circuits. Silicon cannot be electrodeposited.

Silicon Steel

Steel usually made in the basic open-hearth or electric furnace, with about 0.50-5.% silicon, other elements being usually dept as low as possible. Because of high electrical resistance and low hysterisis loss, silicon sheet and strip are standard in electric magnet manufacture.

Sintering

Converting powder into a continuous mass by heating to a temperature considerably below fusion, usually after preliminary compacting by pressure.

Skin

A thin surface layer that is different from the main mass of a metal object, in composition, structure or other characteristics.

Soldering

Joining metals by fusion of alloys that have relatively low melting points -- most commonly, lead-base or tin-base alloys, which are the soft solders. Hard solders are alloys that have silver, copper, or nickel bases and use of these alloys.

Solution Heat Treatment

A process in which an alloy is heated to a suitable temperature long enough to allow a certain constituent to enter into solid solution and is then cooled rapidly to hold the constituent in solution. The metal is left in a supersaturated, unstable state and may subsequently exhibit age hardening.

Spot Welding

An electric-resistance welding process in which the fusion is limited to a small area. The pieces being welded are pressed together between a pair of water-cooled electrodes through which an electical current is passed during a very short interval so that fusion occurs over a small area at the interface between the pieces.

Spray chamber

A chamber in which the spraying process is carried out. It may merely be an acoustic chamber for plasma spraying or a vacuum chamber for vacuum plasma spraying.

Surface preparation

Cleaning and roughening the surface to be sprayed, usually by grit blasting. This is to increase the adhesion of the coating to the substrate.

Surfacing

The application of a coating or cladding to a surface to impart a change in its surface behaviour.

Steel

An iron-base alloy, malleable in some temperature range as initially cast, containing manganese, usually carbon, and often-other alloying elements.

Strain

A measure of the change in the size or shape of a body, referred to its original size or shape. Deformation produced on a body by an outside force.

Stress Relief

Low temperature annealing for removing internal stresses, such as those resulting on a metal from work hardening or quenching.

Stress Relieving

Heating to a suitable temperature, holding long enough to reduce residual stresses and then cooling slowly enough to minimize the development of new residual stresses.

Structure

The arangement of parts; in crystals, expecially, the shape and dimension of the until cell, and the number, kinds and positions of the atoms within it.

T

Terne

Sheet steel coated with a mixture of lead and tin. Terne principally is used in the manufacture of gasoline tanks, although it also can be found in chemical containers, oil filters and television chassis.

Tolerances

A customer's specifications can refer to dimensions or to the chemical properties of steel ordered. The tolerance measures the allowable difference in product specifications between what a customer orders and what the steel company delivers. There is no standard tolerance because each customer maintains its own variance objective. Tolerances are given as the specification, plus or minus an error factor; the smaller the range, the higher the cost.

Tempering

In heat treatment, re-heating hardened steel to some temperature below the A1 temperature for the purpose of decreasing hardness and/or increasing toughness. The process also is sometimes applied to normalized steel.

Thermal barrier coating

A coating forming an insulating barrier to a heat source to protect the substrate.

Thermochemically formed coatings

A painted, dipped or sprayed chromium oxide based coating consolidated by repeated deposition and curing cycles (about 500oC).

Thermal spraying

A process in which coating material is heated and accelerated from a spray torch towards the workpiece. The deposited material forms a coating on the surface.

Tin

Chemical symbol Sn. Element No. 50 of the periodic system; atomic weight 118.70. Soft silvery white metal of high malleability and ductility, but low tensile strength; melting point 449 (degrees) F., boiling point 4384 (degrees) F., yielding the longest molten-state range for any common metal; specific gravity 7.28. Principal use as a coating on steel in tin plate; also as a constituent in alloys.

Tinning

Coating with tin, commonly either by immersion into molten tin or by electro-deposition; also by spraying.

Titanium

Chemical symbol Ti. Element No. 22 of the periodic system; atomic weight 47.90; melting point about 3270 (degrees) F.; boiling point over 5430 (degrees) F.; specific gravity 4.5. Bright white metal, very malleable and ductile when exceedingly pure. Its principal functions as an alloy in the making of steel. High strength and good corrosion resistance.

Tungsten

Chemical symbol W. Element No. 74 of the periodic system; atomic weight 183.92. Gray metal of high tensile strength, ductile and malleable when specially handled. It is immune to atmospheric influences and most acids, but not to strong alkalis. The metal is used as filament and in thin sheet form in incandescent bulbs and radio tubes. Forms hard abrasion. Promotes hardness and strength at elevated temperatures.

U

V

Vacuum or Low Pressure Plasma Spraying

Plasma spraying carried out in a chamber which has been evacuated to a low partial pressure of oxygen. It is then usually partially backfilled with argon to avoid the possibility of forming a glow discharge.

Vanadium

Chemical symbol V. Element No. 23 of the periodic system; atomic weight 50.95. Gray-white, hard metal, unaffected by atmospheric influences or alkalis but soluble in most strong acids; melting point 3119 (degrees) F.; boiling point about 6150 (degrees) F.; specific gravity 5.87. It cannot be electrodeposited. Its principal functions as an alloy in the making of tool steels. (1) Elevates coarsening temperature of austenite (promotes fine grain). (2) Increases hardenability (when dissolved) (3) Resists tempering and causes marked secondary hardening.

W

Wire spraying

A thermal spray process whereby the supply for the coating material is fed into the gun in the form of a continuous wire.

Wear

Loss of material from a surface by means of some mechanical action.

X

Y

Z

Zinc (Zn)

Chemical Symbol Zn. Element No. 30 of the periodic system; atomic weight 65.38. Blue-white metal; when pure, malleable and ductile even at ordinary temperatures; melting point 787 (degrees) F.; boiling point 1665 (degrees) F., specific gravity 7.14. Can be electrodeposited; it is extensively used as a coating for steel and sheet zinc finds many outlets, such as dry batteries, etc. Zinc-base alloys are of great importance in die casting. Its most important alloy is brass. Thermal spray coatings of zinc or zinc alloys (eg Zn/Al, Zn/Sn) provide galvanic corrosion protection.

 

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Thermal Spraying, Metal Spraying, Flame Spraying, Hard Chrome, Abrasion Resistance, HVOF, Roll Coating

Here you receive again an overview of the Buehrer AG. Our enterprise exists for over 43 years and we are particularly in coating metals specialized. The basis of our success is based on high-end quality, well-trained employees and modern equipment and technologies (HVOF, metal spraying, surface technique, mechanical engineering, sandblast technology, surface refinement, flame spraying (wire flame spraying, powder flame spraying), plasma spraying, electric arc spraying, thermal coating and surface treatment). So that the metals keep their longevity, we offer you excellent abrasion resistance methods, thermal coatings, corrosion protection and hard chrome. We can choose from various procedures and techniques (sandblasting, protection coatings (erosion, oxidation, impact wear, corrosion, abrasion) and robot roll coating) and can further process your parts: Ask Buehrer AG for optimal and individually cut solutions!

With our sophisticated procedures and experience we can prepare also complicated machine parts, which is often more favourable, as a new production. Because of our long-term know-how we are your perfect partner if you have questions to: HVOF, metal spraying, electric arc spraying, thermal coating, surface coating, hard chrome, sandblast technology, surface treatment, surface refinement, flame spraying (wire flame spraying, powder flame spraying) and abrasion-wear protection. Our products of technologically high level can help your enterprise to more success. Likewise we are expert with the following topics: Sandblast, surface refinement, plasma spraying, robot roll coating and resistance protection, protecting coatings against erosion, oxidation, impact wear, corrosion and abrasion. We put also great importance to the environment. We fulfill also the highest requirements to pure air regulations with the newest dust filter system installed. We look forward to your order.

Wherever waste can be avoided, we recycle and use modern air cleaner. On our website you can check out yourselves our products and services: HVOF, metal spraying, electric arc spraying, thermal coating, surface coating, hard chrome, sandblast technology, surface treatment, surface refinement, flame spraying (wire flame spraying, powder flame spraying) and abrasion-wear protection. The variety will impress you. You like a personal discussion to find the best solution? We will inform you about our extensive services (sandblast technology, surface refinement, HVOF, metal spraying, mechanical engineering, surface technique, flame spraying (wire flame spraying, powder flame spraying), plasma spraying, electric arc spraying, thermal coating and surface treatment. We focus on quality and are a customer-oriented service provider for all sorts of coatings (e.g. roll coating). Our success, we maintain a close customer relationship over years.

Our service range (HVOF, metal spraying, surface technique, hard chrome coating, sandblast technology, surface refinement, flame spraying (wire flame spraying, powder flame spraying), plasma spraying, electric arc spraying, thermal coating and surface treatment) is under a constant quality control. We make sure that only absolute perfectly manufactured or repaired parts leave our factory. Experiences of many years, professional quality work are the principle of our successful enterprise. You can profit from our services (sandblast, surface refinement, plasma spraying, robot roll coating and resistance protection, protecting coatings against erosion, oxidation, impact wear, corrosion and abrasion. Here we offer the service of an extensive consultation, which you receive naturally at any time. We are your competent partner in the range of coatings. We would like to gain your confidence by accepting your criticism in order to develop ourselves for further achievement of objectives.

It is a challenge for us to meet exactly your requirements of different kinds of coatings. Therefore no trouble is too huge to improve our achievements in surface refinement, HVOF, mechanical engineering, metal spraying, surface technique, sandblast technology, flame spraying (wire flame spraying, powder flame spraying), plasma spraying, electric arc spraying, thermal coating and surface treatment. We constantly renew and revise our techniques and would like that everyone can afford our offers such as sandblast, surface refinement, plasma spraying, robot roll coating and resistance protection, protecting coatings against erosion, oxidation, impact wear, corrosion and abrasion. For this reason we compiled a concept for we can offer a fair price performance ratio of our products to you.

You look for an enterprise, were quality, precision and competence stands in first place? Then you are absolutely right by contacting Buehrer AG. We like to know about your ideas and requirements.