Oerlikon Metco

Oerlikon Metco is a division of OC Oerlikon Group (SIX: OERL), the Swiss advanced manufacturing conglomerate, headquartered in Winterthur, Switzerland, and is the global leader in thermal spray coating technology — depositing metallic, ceramic, carbide, and composite coatings onto aerospace components operating under extreme heat, wear, and corrosion conditions. Founded in its modern form in 1964 (Oerlikon itself dates to 1906), Metco operates 44 service centers in 22 countries with service points co-located inside major aerospace MRO facilities.

Thermal spray is the core technology platform: High-Velocity Oxy-Fuel (HVOF) spraying deposits dense metallic coatings at 300-1,000 m/s particle velocity for maximum bond strength and minimal porosity; atmospheric plasma spray (APS) applies ceramic thermal barrier coatings (TBCs) at temperatures above the melting point of most ceramics; cold spray uses supersonic gas jets to deposit metallic powders below their melting point — enabling repair of aluminum and titanium structures without heat distortion. These processes deposit layers from 50μm to several millimeters thick.

For gas turbine engines (GE90, Trent 1000, F135, etc.), Metco's yttria-stabilized zirconia (YSZ) thermal barrier coatings on turbine blades and vanes are the enabling technology behind modern turbine inlet temperatures exceeding 1,700°C — 300°C above the melting point of the nickel superalloy substrate. Abradable seal coatings on shrouds maintain tight blade-tip clearances for aerodynamic efficiency, while MCrAlY bond coats provide oxidation resistance underneath TBCs.

Space applications include thermal protection system (TPS) coatings for reentry vehicles (ablative and insulating oxides for heat shields), protective coatings on rocket nozzle extensions and combustion chamber walls, and repair/buildup of metallic satellite structural components via cold spray. Metco's 5,000+ proprietary powder formulations — manufactured in-house — are a significant competitive moat alongside process certification to NADCAP, AS9100, and OEM-specific aerospace process specifications. Competitors include Praxair Surface Technologies (Linde subsidiary) and Bodycote's coating services division.