Senkron Surface Technologies – High Customer Satisfaction A Leader in Its Industry.

Processes

At Senkron Surface Technologies, we develop coating processes optimized for each application area based on modern manufacturing techniques and international standards. By offering customized solutions tailored to our customers’ needs, we enhance surface durability and provide sustainable added value to production processes.

HVOF (High Velocity Oxy-Fuel) Coating

HVOF coating is based on the principle of burning a mixture of fuel gas (such as propane, hydrogen, or kerosene) and oxygen under high pressure, then expelling the combustion gases through a nozzle at supersonic speed. The coating powder is injected into this high-velocity gas stream and impacts the surface at speeds of 800–1000 m/s. As a result, a mechanically dense, high-surface-density coating with strong adhesion is applied to the component.


Gas flow rate: 800–1000m/s
Flame temperature: ~3000°C
Typical bond strength: >70MPa
Surface density: Very high (sealed structure, low void ratio)
Hardness: 1100–1600HV (depending on coating material)

Tungsten carbide (WC-Co, WC-Co-Cr)
Chromium carbide (Cr₃C₂-NiCr)
Nickel-based superalloys
Stainless steel, molybdenum, special metal mixtures

High hardness, wear and erosion resistance
Long life and sealing with high surface density
Low heat input to the part → minimum deformation
High surface quality even with thin coatings
Suitable for parts with fine tolerances

Wire drawing reels, pulleys and guide rollers
Valves, pistons, die faces, shafts
Energy, defense, automotive and general industrial applications

Flame Spray Coating

Flame spray coating is based on melting a coating powder or wire-form material in a flame produced by a mixture of combustible gas (typically acetylene or propane) and oxygen, then spraying it onto the surface. This method is preferred for large surface areas and applications with low to moderate performance requirements due to its low equipment cost and ease of use.


Flame temperature: ~2800–3200°C
Particle velocity: 30–100m/s
Typical bond strength: 10–30MPa
Coating thickness: 100–500 microns

Soft metals (aluminum, zinc, bronze)
Low alloy steel wires
Ceramic powders (Al₂O₃ etc.) – with limited performance
Plastic and polymer based powders (PTFE etc.) – in special applications

Equipment cost is low, maintenance and operation are easy
Large and complex surfaces can be coated quickly
Corrosion protection (e.g. galvanic protection with zinc coating)
Suitable for jobs requiring thin coatings and temporary protection applications

Zinc and aluminum coatings against surface corrosion (sheet metal, pipe, construction parts)
Low-cost surface repair in agricultural and construction machinery
Insulation plates, lubrication or filling purposes in light-load-carrying parts

Arc Spray Coating

Arc spray is a thermal spray method based on melting two conductive metal wires using an electric arc, then atomizing and spraying the molten material onto the surface with compressed air. Since the wire-form material is low-cost and readily available, this technique offers an economical, fast, and efficient solution for coating large surface areas.


Coating temperature: 3500–4000°C (electric arc temperature)
Particle velocity: 50–150m/s
Typical bond strength: 20–40MPa
Coating thickness: 100–1000 microns

Carbon steel and stainless steel wires
Aluminum, zinc, bronze, copper
Molybdenum, nickel alloys
Zinc-aluminum (sacrificial coatings)

Cylinder, roller, shaft and drum surfaces
Bearing areas and surfaces worn out of tolerance
Corrosion preventive applications in ship and marine parts
General maintenance and overhaul processes
Low-cost and accessible application thanks to consumables in wire form
Provides time savings on large surfaces with high coating speed
Low heat input offers safe application for parts with risky repair by welding
A suitable alternative for filling and measuring processes on worn surfaces
Suitable for field applications with mobile equipment

Plasma Spray (APS – Atmospheric Plasma Spray) Coating

Plasma spray coating is based on the principle of creating a high-temperature plasma jet by ionizing gases (such as argon, helium, or hydrogen) using an electric arc. The coating powder is injected into this plasma stream and sprayed onto the surface. The temperature of the plasma jet can reach up to 15,000 °C, allowing for the effective processing of hard-to-melt ceramic powders.


Plasma temperature: 10,000–15,000°C
Particle velocity: 200–500m/s
Coating thickness: 50–500 microns
Typical bond strength: 30–60MPa

Ceramics: Al₂O₃ (alumina), Cr₂O₃ (chromium oxide), TiO₂ (titanium oxide), ZrO₂–Y₂O₃ (zirconia)
Metals and alloys: MCrAlY, NiCr, molybdenum
Non-stick coatings


Provides special surface properties such as electrical insulation, thermal barrier or non-stick
Allows processing of ceramic-based materials
Can be applied without damaging the part geometry (low thermal effect)

Textile machinery: rollers, yarn guides, reels
Food and packaging industry: non-stick ceramic coatings
Energy and turbine equipment: thermal barrier layers
Surfaces requiring electrical insulation
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