The advantages of thermal spray technology open an increasing number of applications in several fields. However, it has to be considered that thermal spray processes contain several, partly substantial potentials of danger. As other machinery in Europe, thermal spray equipment is subject to essential health and safety requirements. This paper lists the necessary steps for the manufacturer to develop and to bring into market machinery and parts of machinery that are in conformity with the CE requirements. “CE” represents “Communauté Européenne”, the French term for the European Community. The directives, codes and legal basics, the procedure of risk assessment, the requirements to the technical documentation as well as the conditions regarding declaration and marking are discussed under the point of view of thermal spray. Some sections treat the status of modified and reconditioned machinery, the duties of users of thermal spray equipment as well as similarities and differences in the requirements in Europe to other markets.

The increasing use of HVOF (high-velocity oxy-fuel) coatings to replace hard chrome plating was initially motivated by the environmental and health risks associated with hexavalent chromium (Cr 6+ ) emissions during the plating process. Following performance optimization and proper coating selection, it has been found that the potential increase in performance and the cost/process-time reduction offered by the HVOF process often justifies its application. Recently, the use of Cr-containing alloys processed by HVOF has drawn attention to the potential release of Cr 6+ during heating of metallic chromium. For instance a new California regulation for airborne toxic control measures to reduce emission of hexavalent chromium from thermal spraying is in preparation. The present study focused on monitoring operator exposure during the HVOF spraying of WC-10%Co-4%Cr. The spraying was performed using a JP-5000 HVOF gun in a spray room in which a ventilation flow rate of 10,000 scfm was imposed. Air sampling was taken in the spray room as well as in the adjacent control room in accordance with the NIOSH 7300 and 7600 standard methods. A portable sampler attached on the operator’s chest was also used to monitor the operator exposure during a typical workday. Results indicate that even though metallic fumes of Co and Cr are present in the spray room during spraying, the hexavalent form Cr 6+ is not detected. It was concluded that an operator entering the spray room for a limited amount of time with the gun in operation would be exposed to only low fume levels that can still be reduced by wearing an appropriate respiratory mask.

Finding the time, money, and resources to train both new and existing personnel is a constant challenge. Some studies have shown that training costs can be leveraged to show a three-to-one return by both identifying and preventing problems in manufacturing environments. Many quality specifications and systems require a documented training set-up and internal round robins (RR) to validate that the teaching has provided adequate instruction. There are many keys to a successful training program such as flexibility within the work schedule, the combination of both classroom and hands-on instruction, and discipline by both teachers/students to stay the course for completion of the course work. For many technical topics, training programs outside the company work environment are available. Many of the programs mirror the worldwide accepted non-destructive testing (NDT) type of training. There is some talk of certification for many types of training. However, in many cases, it is not difficult to set up a system given the guidelines/suggestions to formulate a program. Lessons learned and some sample program outlines will be presented and discussed.

The trend in thermal spraying is more and more towards a globally uniform level of high-grade spray coatings. It is therefore extremely important that auxiliaries such as spray materials or industrial gases undergo precise examination in order to exactly define their influence. Based on their application, these auxiliary materials can always be supplied at the required purity level. In order to guarantee such high levels, the gas industry invests a great deal in analysis and supply concepts which ensure this purity from the tank or cylinder through to the point of delivery. A further point is of particular significance in today’s business world. With ever-increasing raw material prices, it is absolutely essential that spray processes are optimized to the maximum. This is not only made possible by selecting the right system, but also by choosing the right gas and gas mixture.

The GTS certificate, is the only certificate worldwide which, in addition to the quality management elements of DIN EN ISO 9001:2000, includes a personnel, process and, on request, also a product certification for thermal spraying. The rules for certification were worked out by the thermal spray users, i.e. GTS members, themselves and have proved to be very effective. Today, the GTS certificate serves as a basis for assessing a certified GTS member should inconsistencies or legal disputes arise. The certificate demonstrates that the certified company has a visible quality standard and that it also meets specified quality requirements in its day-to-day business operations.