Spray Lab

Spray Laboratory, which processes and analyses thermal spray powders, is at the heart of our application engineering. Over 25 years ago, we created a laboratory for our AMPERIT® thermal spray powders. Today it is a development laboratory with state-of-the-art equipment. The lab carries out high velocity oxygen fuel spraying (HVOF), plasma spraying and cold-gas spraying. The PTA welding system on site supports our AMPERWELD® product range.

Amperit Spray Laboratory

Our thermal powder spraying activities focus on developing and optimizing thermal spray powders, establishing spray parameters and assessing coating properties. Our high-tech laboratory has the capacity to analyze bond strength, wear, friction, cavitation and corrosion of coatings. In addition, we are able to analyze surface roughness, metallographic structure and hardness of coatings.

The constant exchange of information between users and manufacturers is our interface between theory and practice. We take advantage of our small-scale systems during the development phase to produce customized test batches of powders by spray-drying, sintering, atomization, grinding and blending. The Spray Lab then processes these test batches under near-real-world conditions. Our analytical laboratories in production plants supply the physical and chemical powder properties which are finally recorded in the customer specifications

H.C. Starck’s main laboratory is certified according to DIN EN ISO 9001 and – since 1995 – has been accredited as a testing and calibration laboratory according to DIN EN ISO/IEC 17025, gaining it the recognition by the world’s leading manufacturers of airplane engines and turbines.

Technical equipment

Spraying systems:

  • High velocity oxygen fuel spraying (HVOF): JP-5000, DJ Hybrid
  • Atmospheric plasma spraying: F4, 7/9 MB
  • Cold gas spraying: Kinetiks 4000
  • PTA welding: Eutronic GAP 3002

Testing systems:

  • A wide variety of optical microscopes
  • Corrosion testing (ASTM B 117 salt spray test, electrochemical corrosion)
  • Cavitation testing
  • Bondstrength testing 
  • Wear analysis (pin-on-disk tribometer)
  • Wear analysis (ASTM G65, JIS H 8503)
  • Surface roughness measurement
  • Hardness analyses (micro- and macro-hardness)

Smaller-scale systems for developmental products:

  • Spray dryer
  • Sintering furnaces (vacuum, H2, air)
  • Atomization (for metals and alloys)
  • Blending and grinding units