Fusionbond®: Engineered Coating Performance for Demanding Applications
Fisher Barton’s FUSIONbond® process delivers high-performance coatings engineered for extreme environments. Designed with engineers in mind, FUSIONbond® combines advanced materials with precision thermal processing to create coatings that outperform traditional methods in durability, adhesion, corrosion and wear resistance.
SEM Data of Ripening of Precipitates as Function of Heat Treat
Advanced Metallurgical Bonding
Metallurgically bonded coatings are based on Ni, Co, or Fe alloys, enriched with boron and silicon to reduce the alloy’s melting range. Fusionbond® is a heat treatment process that utilizes precise time, temperature, at atmosphere controls resulting in a strong metallurgical bond between the coating and the substrate
- Thermal Spray Deposition followed by a proprietary heat treatment process
- Enhanced diffusion between the coating and the substrate for high adhesive strength, resulting in durable coatings that can take impacts without chipping
- Dense coatings with low porosity (<1%) and low permeability result in highly corrosion resistant coatings
Superior Wear Resistance
FUSIONbond® coatings are engineered to resist abrasive wear, even under the most punishing conditions. This precision heat treatment process maximizes the coatings wear performance by optimizing the precipitation and growth of hard complex carbides in a ductile metal matrix, providing tough wear resistant coatings.
- Optimized microstructure for maximum wear resistance.
- Wear resistant complex carbides anchored into a ductile metal matrix.
- Nearly 2x wear performance of competitive coatings.
Why FUSIONbond® Outperforms Traditional Coatings
Many coatings achieve high hardness and low porosity yet still fail prematurely in service. Fusion Bond™ addresses the root cause: microstructure, not just surface properties.
FUSIONbond® creates a controlled balance of hard phases that maximizes wear resistance while maintaining consistency across parts and batches. Compared to HVOF and laser cladding, Fusion Bond™ produces:
- Significantly extended wear life — up to 7× improvement with identical material chemistry
- Consistent performance across part sizes and geometries
- Lower part‑to‑part variation, reducing unexpected failures
- Improved lifecycle economics, even when upfront cost is higher
Rather than selecting coatings based solely on hardness values or initial price, Fusion Bond™ enables customers to optimize for service life, reliability, and total cost reduction.
Versatile Applications
FUSIONbond® is trusted across industries where reliability and longevity are critical:
- Agricultural components
- Chemical processing
- Oil & Gas
- Construction equipment
Each application benefits from the same robust coating chemistry and deposition technique, tailored to meet specific performance requirements.
