Thermal spray Thermal spray

Technology , concept and Technology , concept and Hard chrome Replacement Hard chrome Replacement

ApplicationsApplications

Spraymet Surface Technologies Pvt Ltd Spraymet Surface Technologies Pvt Ltd Bangalore and Pune Bangalore and Pune spraymet@gmail.comspraymet@gmail.com

Spraymet Background Spraymet Background

Started in 1996, by Sulzer Metco/Advani Oerlikon Manager with 18 years Started in 1996, by Sulzer Metco/Advani Oerlikon Manager with 18 years experience in thermal spray and welding experience in thermal spray and welding

Objective : To provide TOTAL Objective : To provide TOTAL SURFACE TECHNOLOGY SOLUTIONS :SURFACE TECHNOLOGY SOLUTIONS :

PRODUCTS : PRODUCTS : Equipment and Materials for thermal spray , PTA cladding Equipment and Materials for thermal spray , PTA cladding

SERVICES : Thermal spry : Plasma , HVOF, Metallizing SERVICES : Thermal spry : Plasma , HVOF, Metallizing

PTA : Co and Ni alloy cladding PTA : Co and Ni alloy cladding

For Repair and OEM coatingsFor Repair and OEM coatings

Spray shop : 1998 Bangalore Spray shop : 1998 Bangalore

Spray Shop : 2013 Pune Spray Shop : 2013 Pune

SPRAYMETSPRAYMET

PRODUCTS AND SERVICESPRODUCTS AND SERVICES

Some of the industries presently served are Some of the industries presently served are

AutomotiveAutomotive Piston rings, Synchro ring, Rocker arm pin, etc. Piston rings, Synchro ring, Rocker arm pin, etc.

Steel Steel CRM rolls,Briddle rolls, Sink rolls, Guide rolls, etc.CRM rolls,Briddle rolls, Sink rolls, Guide rolls, etc.

Pulp and Paper Pulp and Paper Rewinder rolls,Traction rolls, Various sleeves & shaftRewinder rolls,Traction rolls, Various sleeves & shaft

Pump and valve Pump and valve Plungers, sleeves,Wedges, Seat rings, Balls for globe valves. Plungers, sleeves,Wedges, Seat rings, Balls for globe valves.

Turbine and power Turbine and power Thermal barrier coating , blade coating, inconel weld repair Thermal barrier coating , blade coating, inconel weld repair rotor bearing area repair rotor bearing area repair

Oil and Gas Oil and Gas Metal seated Slab gate and seat, Ball and seat, BOP Rams,Metal seated Slab gate and seat, Ball and seat, BOP Rams, CRA cladding of flow areas. CRA cladding of flow areas.

Facilities Facilities Bangalore Bangalore

ROBOTIC Plasma(2) , HVOF(2), Wire Metallizing , PTA, ENP, ROBOTIC Plasma(2) , HVOF(2), Wire Metallizing , PTA, ENP, Blasting and other auxillary opeartions /capacities like : Blasting and other auxillary opeartions /capacities like :

Crane : 10 Tons Grinding : 800diaX6mts Diamond belt super Crane : 10 Tons Grinding : 800diaX6mts Diamond belt super finsihsing finsihsing

PUNEPUNE ROBOTIC HVOF, Wire Metallizing , (ENP) Blasting and other ROBOTIC HVOF, Wire Metallizing , (ENP) Blasting and other

auxillary opeartions /capacities like : auxillary opeartions /capacities like : Crane : 2 Tons, Surface Grinding and Lapping Crane : 2 Tons, Surface Grinding and Lapping

TheoryTheory

How thermal spray works and its place How thermal spray works and its place amongst other surface treatment amongst other surface treatment processes ? processes ?

COMMON SURFACE COMMON SURFACE TREATMENT METHODSTREATMENT METHODS

Plating – Hard chrome,Anodising, ENP etcPlating – Hard chrome,Anodising, ENP etc

Thermal Spraying – Plasma , HVOFThermal Spraying – Plasma , HVOF

Weld Cladding –TIG,PTA,Laser Weld Cladding –TIG,PTA,Laser

Gas Nitriding /Plasma nitriding Gas Nitriding /Plasma nitriding

Physical Vapor Deposition TechnologyPhysical Vapor Deposition Technology

How coating bonds?How coating bonds?

Coating formationCoating formation

Features of thermal spray Features of thermal spray

Wide Materials Choice Wide Materials Choice

Metals , Alloy blends, carbides,ceramics..Metals , Alloy blends, carbides,ceramics..Uniform Coating Thickness - 0.02 to few mmUniform Coating Thickness - 0.02 to few mm

Selective coating capability by masking Selective coating capability by masking

In situ coating capability- paper /powerIn situ coating capability- paper /powerCoatings with high perfomance :60Rb-72Rc Coatings with high perfomance :60Rb-72Rc

No metallurgical change in Base materialNo metallurgical change in Base material

Benefits of Thermal SprayingBenefits of Thermal Spraying

Low Capital Investment - Compared to a plating and Low Capital Investment - Compared to a plating and vacuum coating installation.vacuum coating installation.

Competitive Application Costs – Selective coating allows Competitive Application Costs – Selective coating allows cost controlcost control

When parts are large enough and the coating When parts are large enough and the coating performance requirement is high, thermal spraying performance requirement is high, thermal spraying becomes very cost competitive. becomes very cost competitive.

Environmental : Most importantly the effluent treatment Environmental : Most importantly the effluent treatment plant is not required. All required is a good dust plant is not required. All required is a good dust collector.collector.

Schematic of thermal spray processesSchematic of thermal spray processes

Plasma Spraying ProcessPlasma Spraying Process

A high temperature plasma stream is created by non-transferred plasma A high temperature plasma stream is created by non-transferred plasma arc within the torch.  Many gases may be ionized this way, argon or arc within the torch.  Many gases may be ionized this way, argon or nitrogen with small additions of hydrogen and helium are popular choices.nitrogen with small additions of hydrogen and helium are popular choices.

In an ionized gas, free electrons have been stripped from the atoms and In an ionized gas, free electrons have been stripped from the atoms and recombination releases very significant thermal energy.  The plasma recombination releases very significant thermal energy.  The plasma stream can reach temperatures of 10,000-50,000 degrees Fahrenheit.stream can reach temperatures of 10,000-50,000 degrees Fahrenheit.

SURFACE COATING

HVOF (High Velocity Oxygen Fuel) spray processHVOF (High Velocity Oxygen Fuel) spray processSURFACE COATING

HVOF (High Velocity Oxygen Fuel) spray processHVOF (High Velocity Oxygen Fuel) spray process

The HVOF thermal spray process uses the high The HVOF thermal spray process uses the high pressure (8-10bar)combustion of gases, such as pressure (8-10bar)combustion of gases, such as propane, propylene, hydrogen, or a liquid fuel such as propane, propylene, hydrogen, or a liquid fuel such as kerosene. kerosene. The process creates a very high velocity >1200m/s The process creates a very high velocity >1200m/s Propel the particles at near supersonic speeds ~800-Propel the particles at near supersonic speeds ~800-1000m/s1000m/sHigh impact force results in Bond strength >12000PSIHigh impact force results in Bond strength >12000PSI

SURFACE COATING

Comparison of Thermal spray ProcessesComparison of Thermal spray Processes

HVOF carbide coating

Typical micrographTypical micrograph

Evaluation of coatingsEvaluation of coatings

Micro Hardness HV 0.3Micro Hardness HV 0.3

Porosity ASTMPorosity ASTM

Micrograph 400X voids, oxides etcMicrograph 400X voids, oxides etc

Bond strength ASTM C 663Bond strength ASTM C 663

Bend test Bend test

Salt Spray Test Salt Spray Test

Surface rough nessSurface rough ness

Reports and Documentation Reports and Documentation

Powder composition Powder composition ( WcCoCr 86/10/4 for slab gate and seat) ( WcCoCr 86/10/4 for slab gate and seat)

Coating Hardness HV 0.3( On cuopon) Coating Hardness HV 0.3( On cuopon)

Bond test at IMR SingaporeBond test at IMR Singapore

Bend test ( at request and as per customer criterion) Bend test ( at request and as per customer criterion)

Porosity test at NABL Lab Porosity test at NABL Lab

Salt spray ( at request) on test result enclosed upt 700 Salt spray ( at request) on test result enclosed upt 700 hours hours

Demention report 100%Demention report 100%

Flatness ( Light Band) sampling as per customer Flatness ( Light Band) sampling as per customer

DP ( NDT) test : sampling as per customerDP ( NDT) test : sampling as per customer

Bend Test ReportBend Test Report

Adhesion Strength report as per Adhesion Strength report as per ASTM C 633 ASTM C 633

Porocity and Hardness ReportsPorocity and Hardness Reports

Main class of Materials Main class of Materials

SURFACE COATING

Major properities Major properities

  HVOF COATING OPTION FOR HARD in Oil and gas Industry

Carbides Process Hardness Thickness Notes

1 Tungsten carbide/Cobalt 88/12 or 83/17

HVOF 1100 to 1350 HV 0.3

150-200 to Microns

Dense and hard Coatings wear, Applications for temperatures up to 450 Deg C

2 Tungsten carbide/Cobalt/Chromium86/10/4

HVOF 1100 HV to 1350 Hv 0.3

150-200 to Microns

Improved oxidation andcorrosion protection overWC-Co and WC-Ni.

3 Tungsten carbide/Chrome carbide/Nickel 70/23/7

HVOF 1000 to1200 HV 0.3

150-200 to Microns

Superior oxidation andcorrosion properties thanother tungsten carbide based material

4 Tungsten carbide+NiCrBSi50/50 , 65/35

HVOF 1000 to 1300 Hv 0.3

150-200 to Microns

A blend of Tungsten carbide and NiCrBSi for fretting wear, erosion, abrasion

5 Chrome carbide /NiCr (75/25)

HVOF 850-1100 HV 150-200 to Microns

Good and lower cost replacement for Hardchrome temp resistance 850 C

Ceramics

6 Aluminium Oxide Plasma Spray 55 to 60 RC 200 Mirons High purity Alumina ceramic coating with good wear and corrosion resi. But brittle .

7 Chrome Oxide

Plasma Spray 65-72 Rc 200 microns Better coating than Allumina with good wear and corrosion resi. But brittle.

Hardness ComparisonHardness Comparison

Abrasion Comparison Abrasion Comparison

Salt Spray test results of Wc/Co/Cr HVOF coating Salt Spray test results of Wc/Co/Cr HVOF coating HVOF coatings sustain > 2000 Hrs ( sub sea applicaions ) HVOF coatings sustain > 2000 Hrs ( sub sea applicaions )

vs Hard Chrome 200 hrsvs Hard Chrome 200 hrs

ACCOUSTIC CHAMBERSACCOUSTIC CHAMBERS

JP 5000 HVOF JP 5000 HVOF

Metal seated gate vlave Metal seated gate vlave Pune plant facility Pune plant facility

Metal seated - Seat rings Metal seated - Seat rings

Other coponents oil and gas Other coponents oil and gas Plug carbide coating

Control valve plug -stellited

Ball and seat TC coated and match lapped Mud Rotor : Repaired and Tc coated + super polished

BOP Piston rod carbide coated BOP Piston rod carbide coated and Groundand Ground

HVOF coated BOP Piston rod DP Tested – Passes HVOF coated BOP Piston rod DP Tested – Passes RDP/LPT test RDP/LPT test

Frac Pump plungers Frac Pump plungers

Super finish 0.05 Ra Super finish 0.05 Ra

PROGRESSIVE PUMP ROTORCARBIDE COATED and super polised ( Earlier this application was Hard chrome)

Carbide coated and Ground Gate ValveCarbide coated and Ground Gate Valve( Replacement for Nitriding ) ( Replacement for Nitriding )

20” Ball tungsten carbide coated – Metal Seated Severe service application .

Plunger Ceramic coated Plunger Ceramic coated

Gas compressor piston rod. Gas compressor piston rod. Wc+CrC coated Wc+CrC coated

DP( NDT) test on HVOF coating DP( NDT) test on HVOF coating

S P R A Y M E TS P R A Y M E T

ContactContactBangalore : Bangalore :

A 413, 9A 413, 9thth main, 2 main, 2ndnd stage, Peenya Indl Area,Bangalore 560058, stage, Peenya Indl Area,Bangalore 560058,Tel/Fax ; 080- 28364565 E mail : Tel/Fax ; 080- 28364565 E mail : spraymet@gmail.com , , S S Joshi : 9916903701S S Joshi : 9916903701

Pune : Plot 244, Sector 7 , PCNTDA, MIDC Bhosari , Pune Pune : Plot 244, Sector 7 , PCNTDA, MIDC Bhosari , Pune Tel : 8149046272 E mail : spraymetpune@gmail.com Tel : 8149046272 E mail : spraymetpune@gmail.com

Thank you Thank you

SURFACE COATING