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Thermal Spray Coatings

The Taskmaster High Velocity Oxygen Fuel thermal spray process provides High Density coatings with almost Negligible Porosity levels. This is a result of the high particle velocities produced by a combustion driven, high speed gas jet.

This process uses an oxygen-fuel mixture. Depending on user requirements, propylene, propane, hydrogen or natural gas may be used as the fuel in gas-fueled spray systems and kerosene as the fuel in liquid-fueled systems. The coating material, in powdered form, is fed axially through the gun, generally using nitrogen as a carrier gas. The fuel is thoroughly mixed with oxygen within the gun and the mixture is then ejected from a nozzle and ignited outside the gun. The ignited gases surround and uniformly heat the powdered spray material as it exits the gun and is propelled to the work piece surface. As a result of the high kinetic energy transferred to the particles through the HVOF process, the coating material generally does not need to be fully melted. Instead, the powder particles are in a molten state and flatten plastically as they impact the work piece surface. The resulting coatings have very predictable chemistries that are homogeneous and have a fine granular structure.

These coatings can survive harsh service conditions, particularly in wear and many corrosion applications, which greatly increase component service life. The smooth, as-sprayed surface, uniform chemistry and low porosity of the coating can be finished to very smooth surface profiles.

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Features of the HVOF Spray Process:

  • Produces very clean, hard and dense coatings with fine, homogeneous structures
  • Coatings are tenaciously bonded to the substrate
  • Low to compressive coating stress allows very thick coatings
  • Excellent for wear and corrosion resistance
  • Recommended for carbide coatings and often recommended for superalloy coatings
  • Very thick coatings are possible
  • Surface finishes are generally smooth and can be used in the as-sprayed condition
  • Coatings can be ground and/or super finished
  • Work piece temperatures can be controlled to prevent changes in the microstructure. In general for optimum coating quality, temperatures should never exceed 300 degrees.

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Taskmaster Technologies Inc. offers a turnkey process, which includes robotic manipulation for control and accuracy, and years of experience in generating application procedures, that can save your company time and money. In addition, our finishing equipment allows us to meet very tight tolerance and surface finish requirements depending upon application specifications.



Taskmaster HVOF #1, Sulzer Metco DJ2700, with 9MP-DJ feeder

Taskmaster HVOF #2, Sulzer Metco DJ2700, with 9MP-DJ feeder

Taskmaster HVOF #3, TAFA, JP-8000, with Data Acquisition

Taskmaster HVOF #4, TAFA, JP-8000, with Data Acquisition

Spray Cell with Lathe to handle 72″ diameter and 288″ ( 24 feet ) long

Spray Cell with Lathe to handle 32″ diameter and 192″ ( 16 feet ) long

Internal Spray Lathe

Vertical turntable with 24″ chuck

20,000 lb capacity vertical turntable with 60″ table


Flame Spray / Spray and Fuse

Taskmaster can provide traditional low velocity flame spray coatings for many applications. Alloys for general repair and build up as well as wear and corrosion resistance are readily available. Common alloys applied are aluminum bronze, stainless steels, and nickel or cobalt base.

Many products are also designed for a secondary fusing process ( spray and fuse ) giving the coating a very strong capillary bond similar to that of brazing and eliminating the inherent porosity of the “as sprayed” product. Common applications for this process are: pistons, plungers, thermowells, and washpipes.

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TWIN WIRE ARC coatings

Wire arc coatings serve several purposes as an alternative to more expensive HVOF coatings. Common uses of wire arc coatings for corrosion protection using zinc, or zinc aluminum alloys are becoming increasingly popular. Wear resistant alloys are also useful for fast and cost effective equipment repairs.

In addition, the Wire Arc system is easy to mobilize, if on-site repairs are the best solution. Sometimes equipment repairs on large shafts, etc can be done “in place” saving teardown time and efforts.

Please enquire if you think that a wire arc coating is right for your application!


We have great capacity in terms of Twin Wire Arc equipment:

TWA #1: Sulzer Metco Smart Arc

TWA#2: Tafa 8830

TWA #3: Tafa 8830

TWA #4: Tafa 9000



Surface Blast / Shot Peen

Surface blast preparation is a critical element of our coating application performance. In addition, Taskmaster can also provide blasting services for many other applications such as:

  • Glass bead for surface decontamination or cleaning of corroded / dirty components.
  • Grit Blasting with a variety of available grit sizes and materials to create a clean, rough surface profile that enhances grip and coating bond strength .
  • Shot Peen from 110 to 780 grit sizes for stress relieving of surface tension on critical machined parts.


 New Developments:

Taskmaster is taking its HVOF coatings to a whole new dimension. With the recent purchase of a new specialized system specifically designed to spray internal bores down to 70mm in diameter, we are excited to see what new markets can be exposed, especially in the chrome replacement field. We have done extensive R & D, and continue to move forward pushing the limits of possibility. With our internal grinding, and Honing capacity, are are all set to provide turnkey service for out customers!

Currently we are providing Internal Spray coating to replace chrome / Nickel Chrome plating with amazing field results. We are confident down to about 5″ diameters dependant on lengths, but are still working hard to get quality results in smaller situati