Thermal spraying systems

The perfect thermal spraying for crankcases

With the development of the G500TS thermal spraying system, GROB meets the requirements of modern engine development and offers customers in the automotive industry complete manufacturing lines for the production of aluminum crankcases with thermally sprayed cylinder bore surfaces.

The G500TS production cell offers convincingly simple integration into the flexible GROB system solutions for combustion engines and covers the cylinder bore surface with a wafer-thin steel coating as part of the overall process. Top notch technology for your efficient manufacturing facility!

Advantages

Reduced engine weight

High wear resistance

Good friction characteristics between piston ring and cylinder bore surface

Potential for high charging levels

Less blow-by

High resistance to aggressive fuels

Favorable cost-benefit ratio

Reduced fuel consumption

GROB thermal spraying methods

Wire method

The GROB wire method gives you a favorable thermal spraying material, a high degree of process reliability and simple material conveying: A transport gas centrifuges fine droplets of a molten steel wire onto the cylinder bore surface, where they instantly solidify into a wafer thin layer.

Powder method

The GROB powder method offers advantages such as high flexibility of the material and a tried and proven process: A powder is fused by means of electrical current and a plasma gas. Unlike the wire method, a powder conveyor is required here.

GROB thermal spraying system in detail

Feeding the thermal spraying material

Conveying from wire drum or spindle possible
Ergonomic wire drum change
Integrated wire straightening station or alternatively a powder conveyor
Integrated fill level control

Gas management

High-precision mass flow control of the gases to guarantee process quality
Gas sensors in the system for guaranteed safety
Integrated compressor for compressed air supply without affecting the compressed air system

Noise protection cabin

System noise level ≤ 75 dB(A)
Lock for material exchange

Exhaust system

High-performance extraction of gases and dusts
Automatic cleaning of the filter
Dusts collected in drum or big-bag

Automation

Integrated part changer
Loading by gantry or robot

Thermal spraying mechanism

Gas-cooled, high-energy plasma torch
Optimized machine design for guaranteed long tool life
Automatic torch cleaning device
Automatic monitoring of the plasma and particle beam