Thermal Spray & Metalizing | Donaldson Industrial Dust, Fume & Mist

Overview

Donaldson Torit® dust collectors are in hundreds of thermal spray applications worldwide.

Our advanced Ultra-Web® fine fiber filtration technology is supremely suited for applications involving thermally generated fume, especially when installed in a Donaldson Torit dust collector selected for your application.

Thermal Spray or Metalizing is a group of coating processes which deposits finely divided metallic or non-metallic materials in a molten or semi-molten condition on a surface/substrate to form a coating. The coating material may start out in the form of a powder, ceramic rod, wires, or even molten materials. The process has the potential to generate very small particulate often referred to as “fume”. This thermally generated fume can be smaller than one micron in diameter, and uniform in size making collection a challenge.

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Products

Applications

Thermal Spray Coating Process

Powder Feedstock -> Powder Particle Melting (Gas or Electric Heating) -> Molten Particle Acceleration -> Particle / Substrate Impact -> Coating

Processes Involving Thermal Spray

The thermal spray processes involve such heat that the process produces a very fine dust (fume), typically sub-micron in size and very uniform. Some of the materials used in thermal spray applications have associated adverse health effects, and defined minimum exposure limits set for them, which necessitates effective dust collection.

Following are terms for typical thermal spray processes that produce fumes needing to be controlled:

Flame Spray Powder Flame Spray
Wire Flame Spray High Velocity Oxy / Fuel Spraying (HVOF)
Cold Spray Plasma Arc Spray
Electric Arc Spray

Related Processes Producing Contaminants—Surface Preparation and Finishing Operations:

Abrasive blasting
Grinding
Wet machining

Special Considerations

Many metal fume dusts are combustible and those operations generating or handling metal fumes can require special mitigation efforts to minimize fire and explosion risks. Standards such as NFPA 654 can provide guidance for those who generate and handle these types of dusts. See the Donaldson Dust Collectors and Combustible Dust Strategies brochure.

Metal fume dusts may also have identified adverse health impacts, and special mitigation strategies may be required to limit occupational exposure below levels OSHA or other health organizations have established for these materials.

Collectors In Use

Model	Product Family	Use
DFO 3-36 with 36 Cyclone Pre-Separator	Cartridge Dust Collector	Electric Arc Thermal Spray
Downflo Oval (DFO) 4-16	Cartridge Dust Collector	Metallizing
(7) DFT 4-48	Cartridge Dust Collector	Plasma Arc Spraying
Downflo Oval (DFO) 3-18	Cartridge Dust Collector	Powder Flame Spraying