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Highlights from the History of Sulzer Metco

Sulzer Metco Today and In The Future
Today, as throughout our history, our customers challenge us to provide solutions that will help them improve the value and service performance of the components they produce or require for their own operations. We are dedicated to earn their loyalty through commitment, service and innovation that will keep our customers at the forefront of their fields by providing the advantages they need in today’ s competitive climate

The broad range of surface technologies offered by Sulzer Metco and the experience we possess to reliably apply those technologies guarantees our customers the very best surface solutions. Beyond the surface, Sulzer Metco quality and know-how is evident in our manufacture of critical components for select markets. We provide highly effective solutions to the toughest of customer problems with our unique range of strategic processes, and we are available at every step with comprehensive support services.

2004 — Sulzer Metco Acquires OSU Maschinenbau GmbH
The acquisition of OSU Maschienbau GmbH, located in Duisburg, Germany, has enabled Sulzer Metco to increase its arc spray equipment, zinc wire and zinc-alloyed wire product offering and expand market reach, particularly in the corrosion market. The OSU Maschinenbau product portfolio, which had primarily been available only in Europe prior to the acquisition, became available for worldwide distribution through Sulzer Metco' s global distribution network.

2004 — Sulzer Metco Acquires Ambeon
With the acquisition of the Ambeon Division of Westaim in Canada, Sulzer Metco further expanded the materials business. Now operating as Sulzer Metco ( Canada) Inc., the company is a global provider of customized nickel-based materials for the power generation and aero industries. These materials are also used in electronic applications. The acquisition strengthens the Sulzer Metco thermal-spray materials offering and expands the portfolio in the area of honeycomb structures, electronic shielding, and hardfacing materials.

2004 — Sulzer Metco Acquires WOKA GmbH
In January 2004, Sulzer Metco acquired WOKA GmbH, a family-owned carbides manufacturer in Germany. This step strengthened the materials business by widening the Sulzer Metco offering of thermal spray coating and welding materials. Renamed to Sulzer Metco WOKA GmbH, the acquisition opened new market opportunities for Sulzer Metco with markets mainly in the paper industry, oil and gas sectors, earthmoving and machine tool industries.

2002 — Sulzer Metco Acquires DB Thin Films
In December 2002 Sulzer Metco acquired DB Thin Films LLC, based in Woonsocket, Rhode Island, USA. Now operating under the name of Sulzer Metaplas ( US) Inc., the company continues to be a provider of customized surface coatings using the PVD ( Physical Vapor Deposition) technology for both decorative and functional applications. The acquisition will enable Sulzer Metco' s Thin Film unit, represented by Metaplas Ionon, to expand its service offerings in the large North American market.

2002 — Sulzer Metco Acquires Euroflamm Select, Inc.
In 2002 Sulzer Metco acquired Euroflamm Select, Inc. ( formerly Select Powertrain Technologies, Inc.) in Dayton, Ohio, U.S.A. Euroflamm Select develops, manufacturers and distributes carbon-based friction products used in powertrain applications for the automotive industry such as synchronizer rings, clutch discs and other gearshift components. The acquisition cemented the close and successful joint activities of Euroflamm GmbH in Germany, a Sulzer Metco company and Euroflamm Select, Inc.

2001 — Sulzer Metco Acquires Metaplas-Ionon GmbH and EuroFlamm GmbH
Metaplas Ionon GmbH provides customized system solutions and high-quality surface treatment services, thus expanding the Sulzer Metco portfolio of surface technologies. Metaplas Ionon offers three advanced processes: IONIT® plasma nitriding and plasma nitro carburizing for wear protection of metallic components; IONIT OX® , a combination of gas nitriding, gas nitro carburizing, plasma activating and oxidizing for corrosion and wear protection and improved surface properties and MAXIT® , a PVD coating process for high wear resistance and low friction.

The acquisition of EuroFlamm GmbH expands Sulzer Metco’ s coating service capabilities. Euroflamm provides thermal spray coating services for a variety of industries including state-of-the-art coatings for automotive powertrain components, coverings for paper machinery, thermal and wear coatings for the power generation industry, naval coating applications and wear / anti-frictional coatings for consumer articles.

2000 — Sulzer Metco Acquires Eldim and Interturbine Coatings B.V.
Continuing its focus on flight and power turbine applications, Sulzer acquires Eldim and Interturbine Coatings BV, of Lomm, Netherlands. Integrating both companies into Sulzer Metco, Interturbine Coatings BV becomes Sulzer Metco Coatings BV. Eldim’ s high-quality seal and honeycomb technologies supplement Sulzer Metco’ s existing abradable and braze markets, while the EB/ PVD coating capabilities of Sulzer Metco Coatings BV is a logical step in the expansion of Sulzer Metco’ s coating services business in Europe. Eldim supplies solely to the aerospace industry and specializes in conventional machining and manufacturing of gas turbine blades, vanes, seals and sheet metal fabrications.

1998 — Sulzer Metco Acquires QCoat
Further expanding European market penetration of coating services, Sulzer Metco acquired QCoat, Ltd in Stalybridge UK. Well-situated in Cheshire, QCoat specializes in thermal spray coating services and surface finishing / machining services of pump and compressor components for the oil and gas equipment market, as well as print machine rolls and embossing rolls for the paper machinery market.

1995 — Salzgitter Acquired by Sulzer Metco
Located in northern Germany, Sulzer Metco acquired the Salzgitter coating facilities in 1995. Now known as Sulzer Metco Component Services GmbH, these facilities are well-suited to the handling of heavy and large components such as paper, printing, textile and steel machinery. Sulzer Metco Component Services GmbH is also capable of processing turbine blades and vanes.

1994 — Sulzer Acquires Metco and Sulzer Metco is Born
In September, 1994, Sulzer acquires Metco and integrates all materials and surface technologies companies under the name of Sulzer Metco. The integration results in a strong, globally-positioned company, well-suited to the thermal spray supply and service needs of a wide variety of major industries, including aerospace, automotive, power generation, pulp and paper, printing, medical and textile industries.

1991 — EPI is Acquired by Sulzer
The addition of Electro-Plasma Inc., in 1991, reinforces Sulzer as the global leader in low-pressure plasma spray technology. By this time, the Sulzer surface and materials technologies companies hold a strong position at the forefront of plasma spray material and equipment design, development and manufacturing.

1989 — Metco Introduces the Diamond Jet® HVOF ( high velocity oxygen fuel) Process
For the first time, customers can purchase an economical, in-house HVOF spray system that rivals the quality of proprietary processes, previously available only as more expensive coating services. Metco improves its Diamond Jet resources with the introduction of the DJ 2600 Hybrid air cap and several choices of fuel gases, in 1992. The Diamalloy family of materials continues to expand.

1986 — AMI Acquired By Sulzer
Continuing its focus on materials and surface technologies, Sulzer acquires AMI. Not only did the acquisition increase Sulzer’ s product portfolio to include thermal spray and braze materials, but it gave Sulzer a greater foothold in the U.S.A., as well. In 1988, AMI became known as Sulzer Plasma Technik, with AMDRY® being retained as the product trade name.

1985 — Sulzer, a Swiss Firm, Acquires Plasma Technik AG
Continuing a consolidation trend in the thermal spray industry, Sulzer takes control of Plasma Technik AG. The purchase of Plasma Technik gave Sulzer four Plasma Technik contract spray facilities in Wohlen, Switzerland, Florida, U.S.A., which opened in 1979, England, which opened in 1984, and Singapore in 1985. For Sulzer, the materials and surface technology business was a good fit and in line with much of its R & D efforts.

1973 — Electro-Plasma Inc. ( EPI) Founded In California, U.S.A.
By isolating the spray gun and part of the handling equipment in a low pressure chamber, Eric Muehlberger invented a highly practical method of producing high-quality plasma coatings in near " as-cast" condition. Known as LPPS® systems, these chambers produce coatings with optimal adhesion, reduced stress and added durability, ideal for the aerospace and medical implant industries.

1973 — Metco Expands into Mexico, the Southern Hemisphere and Japan
Metco begins to look globally again after the merger, and forms a joint venture with Daiichi-Jitsugyo in Japan. Sales offices are subsequently set up in Australia, Brazil, Singapore and Mexico. At this point, Metco offers the most complete range of thermal spray equipment and materials of any company.

1970 — Plasma Technik AG Founded In Wohlen, Switzerland
The Swiss husband and wife team of Herbert and Marlies Nussbaum, understanding that a higher degree of process control and automation was needed for plasma spray technology, focused on developing sophisticated plasma spray equipment that provided excellent repeatability and coating accuracy. They produced highly efficient systems with throughput capable of high-volume production and low rejection rates.

1969 — Metco Produces and Markets Electric Arc Wire Spray and 10E Gun
Successful introduction of the Type RG Electric Arc Spray System completes Metco’ s portfolio in thermal spray manufacturing. This first system had 500 amp maximum power output, and was capable of spraying 11-gauge wire. The 10E Metallizing Gun was first offered for improved hardware life and better maintenance.

1968 — AMI Founded in Troy, Michigan
Dick Gillman founds Alloy Metals Incorporated ( AMI) in Michigan, U.S.A. AMI’ s gas atomization operations produce the AMDRY® line of powdered materials. AMI produces the first MCrAlY ( Metal-Chromium-Aluminum-Yttrium) materials by dry gas atomization process for high-temperature needs of flight gas turbines.

1960 — Metco Becomes Metco Inc., Markets Water-Cooled Plasma Flame Gun
A name change and a 200 for 1 stock split started Metco’ s decade with a bang. Metco introduces the Type MB plasma gun and plasma spray system, marking the advent of a commercially viable process to thermal spray ceramics, refractories and other high-temperature materials. Metco’ s product portfolio appropriately expands to include a wide variety of powders suitable for the plasma process. In 1964, Metco introduced Metco 404 self-fluxing, exothermic, nickel aluminide powder – first in a family of composite spray materials excellent for base coats and product build-up.

1956 — Metco Markets the ThermoSpray Powder Gun and Self-fluxing Alloy
The Type-P ThermoSpray® Powder Gun for spraying refractory ceramics, self-fluxing alloys and tungsten carbides makes its debut. Sprasteel® LS was also developed in 1956.

1948 — Metco Expands Into Europe
Metco establishes its first subsidiary in the UK, followed shortly thereafter by offices in Germany, Austria and Holland. The new Type-L Gun cut compressed air use by 60% , bringing modern metallizing within reach of the smallest shop. Gas flow meters and Sprabond wire – a molybdenum alloy for smooth surfaces – were introduced.

1938 — Metco Introduces Type-E Gun With Improved Wire Spray Rates
Featuring easily adjusted " fast" and " slow" speeds for spraying soft or hard metals without the need for gear changes, the E-gun was rapidly embraced for its economical, high-speed metallizing rates. The E-gun could spray 3.2 mm ( 1/ 8 inch) wire – a larger diameter than previously used – with lower air consumption. Also introduced were the company’ s first materials, Metcoloy ® 1 and Metcoloy 2, both stainless steel wires. Metcoloy 2 is still marketed today.

1933 — Rea Axline Founds Metallizing Engineering Company ( later METCO)
In the midst of the worst economic depression ever in the United States, Rea Axline, a recent California Institute of Technology graduate, founds a small shop in Jersey City, New Jersey to sell wire spray equipment for corrosion control and repair of simple machine elements. The company started with 5 employees and included two of Rea’ s talented associates from Cal Tech.

1909 — Schoop Invents Thermal Spray
In the early 1900s, Max Ulrich Schoop, of Zurich, Switzerland experiments with the spraying of lead and zinc metals for protective coatings. In 1909, Schoop obtained a patent covering the use of a combustion process ( oxygen fuel) to melt wire and direct it to a substrate. Schoop’ s second patent, in 1911, incorporated an electric arc as a production heat source. Thus, the technology of thermal spraying was begun. During its early application, the metallizing process was used mainly for corrosion protective coatings.

In 1917, Schoop received the John Scott Award. Created in 1834, the John Scott Award honors " the most deserving" inventors. Schoop received the award for " Schoop' s Metal Spraying Process" . Recipients have included Mme. Marie Curie, Guglielmo Marconi, the Wright brothers and Thomas Edison. In 1994, Mr. Schoop was inducted into the Thermal Spray Hall of Fame.