Printing machines mirror the art of precise manufacturing and adjusting of fast moving and heavy components with an accuracy of few micrometers. In order to meet the challenge of fast and high quality printing combined with a long lifetime of the machines, the core components transporting the print substrate and the different kinds of ink and other liquids needs to be coated, what is done more and more by applying thermal spray processes. The main requirements cover wear and corrosion resistance as well as suitable wetting and special needs like the ability of laser engraving. Moreover, the coatings are post processed to achieve a sufficiently low surface roughness combined with an appropriate microstructure resulting in a fine structure if laser engraving is considered. This paper will give a review of applications, techniques and materials, which are well-established in printing industry in respect to the specific demands of the case of operation. This covers the surfaces in the printing unit namely the printing and blanket cylinders but also the inking and dampening systems.

Airline and printing industry are looking for new techniques to replace electrolytic chrome plating in their machinery because of the toxic and carcinogenic characteristics of hexavalent chromium used in the ECP. Hard chrome platings are compared to thermal sprayed coatings and different techniques are shown. The article gives examples of Hard chrome replacement in printing applications, shows activities of government, airline and textile industries. Different types of coatings, produced with different spraying techniques, are compared in wear and corrosion tests. The results lead to an economical evaluation of HVOF sprayed alternative coatings and gives a hint to the HCAT-Program.