For many years Clemco Denmark has been a supplier of metallization systems from Ozu Hessler in Germany.

Today in the modern arc spray process, the raw material in form of a pair of metallic wires (electrodes) is melted by an electric arc. This molten material is atomized by a cone of compressed air and propelled towards the object to be metallized. The molten spray solidifies immediately on the component surface forming a dense, strongly adherent coating suitable for corrosion protection or component reclamation. The deposits possess a higher degree of bond strength than most other thermally deposits and the use of compressed air and electricity alone mean immense savings in gas costs compared to gas-flame metallizing.

Zinc/alu applied this way provides corrosion protection to steel for decades longer than paint alone. Zinc and aluminum are the most commonly used materials for metallizing steel structures and has the advantage to provide a highly resistant corrosion protection of steel exposed to rough conditions like for example salt water.

To be able to safely and effectively metallizing objects of steel, the process has to be carried out in a suitable metallizing booth which has the statotory ventilation flow. Before setting up a metallization booth you must apply for approval by the relevant environmental authorities. Clemco Denmark designs and builds complete booths for metallization with proper ventilation volume and lighting to perform the metallization safely and effectively.

You can read more about our booth solutions here.

When chosing a zinc/alu metallization system for corrosion protection it is important to find out how many squaremeters you need to metallize per hour. The most popular of our Osu Hessler metallization systems has a capacity from 300 to 600 Amps and is capable of metallizing about 30-100 m2. per hour depending on the operator's skills and the layer thickness to be applied.

With an Osu Hessler 600 Ampere metallization system, you can metallize approx. 100m2 per. hour with a zinc coating thickness on 80 micron and with a setting of about 575 Ampere on the system. It is assumed that the roughness of the item is 8-12 Ra and the purity meets Sa 2½ standard. We recommend to use a zinc wire of 2.5 -3.0 mm in diameter, containing 85% zinc and 15% aluminum. This mixture of wire creates the least amount of dust.

  • The gun from OSU Hessler is sturdy and built to withstand very dusty operating conditions
  • All parts are easy to replace and renew by the user without any help from the supplier
  • A strong DC-motor guarantees high torque and reliable feeding of metallization wire within the spray capacity
  • The cable kit is made of lightweight air-cooled cables with great flexibility. The cable Kit provides cooling air for atomization, separate cable for DC wire-feed motor, control cable and two wires insulated with Teflon® cores with connection to the gun


We recommend setting up the metallization system outside the cabin where the work takes place, to avoid metallization dust inside and outside the plant. The metallization hose is together with the gun passed through a sealed hole into the cabin. Osu Hessler’s metallization guns are equipped with a safety feature interrupting the metallization process, if the operator drops or loses the gun while metallizing.

If you are interested in metallizing with robot we deliver metallization systems with a capcity up to 1500 Apm.

Read more about our robotic metallizing solutions here.

If you want some more information about our metallization systems please contact our sales department on +45 70 13 10 30


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