The Hydropower sector is consistently combating challenges caused by the impacts of hard particles on the surface of renewable energy components, such as the erosion of hydro turbine parts. In addition to erosion and abrasive wear, renewable energy components can also be subjected to high levels of corrosion caused by acid or alkaline water conditions.
To help hydropower companies tackle these challenges, HVOF thermal spray can be used to create dense HVOF tungsten carbide or chromium carbide coatings, which has been tested vigorously and proven to effectively protect surfaces from erosion and corrosion.
Working with the wind energy sector, we support renewable energy technologies in ensuring optimal operation of wind turbine components in a number of challenging situations.
For instance, electrically conductive coatings for renewable energy can be created from metals such as Zn, Al, Cu, along with their alloys. These custom-made coatings are then applied to glass fibre composites and carbon fibre, helping to protect blades of wind turbines from the disastrous effects of a lightning strike.
Highly corrosion resistant alloys coatings can be sprayed to mechanical parts by arc spray. These range from Zn-Al to highly corrosion resistant alloys such as Hastelloy, in an effort to protect them from salt water corrosion.
Meanwhile, to combat the mechanical wear of bearings and transmission components, wear resistant alloys such as Tribaloy, Stellite, WC and ceramics (Aluminium Oxide and Chrome Oxide) are applied using a combination of HVOF thermal spray and plasma spraying techniques.
Last, but not least, for many transmission units in the wind-powered renewable energy sector, controlled and consistent coefficients of friction are crucial. For this, we apply duplex coatings with arc sprayed bond coats and plasma sprayed carbides.
Unsurprisingly, the mechanical components of renewable energy technologies used to convert tidal energy are consistently subjected to combined corrosive-erosive wear. We help companies extend the lifespan of these active components and reduce the need for costly maintenance intervals by applying a dense protective HVOF tungsten or chromium carbide coating to the surfaces.
The combustion products used for biomass energy generation are the biggest culprits when it comes to common causes of boiler tube corrosion and erosion. To support renewable energy generation processes in the biomass sphere, we apply corrosion and erosion resistant alloys using established thermal spraying techniques.
These protective coatings for renewable energy are usually made from metal alloys or chromium carbide – alloy composites to ensure the most cost-effective combination of boiler tube performance and durability.
Using mainly the HVOF thermal spray process, Inconel, Chromium Carbide and Tungsten Carbide coatings can be applied to protect the components of renewable energy technologies against the corrosive and erosive effects of the aggressive environment they are subjected to in hydrothermal applications.
Fuel cells are another area of the renewable energy field where we can offer a range of solutions. For example, plasma sprayed oxide ceramic coatings provides renewable energy components with electrical insulation which offers excellent resistance to high temperature thermal cycling.
Specialised Atmospheric Plasma Spraying (APS) also prevents cell cathode poisoning by coating the equipment with LSM, LSCF and MCO materials designed to prevent chromium from evaporating, interconnecting and poisoning the SOFC cathode.
For renewable energy processes where a dense electrolyte is needed, such as the production of Solid Oxygen Fuel Cell (SOFC), we offer a range of thermal sprayed zirconia-based oxide ceramic coatings. Thanks to their increased durability, wear and corrosion resistance, as well as their higher dielectric strengths and conductivity, ceramics make robust and cost-effective coatings for renewable energy applications.
Our team is at the core of our business. It’s their extensive knowledge of coatings specifically for the renewable energy sector that enables us to offer our clients cost-effective and innovative solutions to their problems. In addition to our routine services, we are also involved in Research & Development projects for global leaders in the Automotive, Marine and Aluminium industries.
We pride ourselves on exceptional customer focus across all departments – we make sure to keep our clients informed and meet our deadlines, so they can rest assured that they can always rely on our word.
Contact us to discuss your bespoke solution.