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A metal object can be surface coated on the exposedarea to achieve high wear, corrosion resistance, or thermal insulation. Surface coating can also be used to repair damagedparts. Complete part replacement is then unnecessaryand this refurbishment effectively extends the lifetime of the part.
This coating is used to produce magnetic, wear- and corrosion-resistant, and high-strength products, where temperature stability is important. Surface coating encompasses many different deposition techniques where the use of alloys based on cobalt powders is common, such as HVOF (High-Velocity Air Fuel), laser cladding, and plasma transferred arc (PTA).
Stellite coatings can be obtained by many deposition techniques: plasma transferred arc (PTA) is certainly an optimal choice that gives thick, dense coatings, but thermalspray techniques like high velocity oxy-fuel (HVOF) are also widely used to deposit such materials.
The present study investigates wear and mechanicalproperties of Stellite 6 deposited by cold spray in comparison to PTA-deposited Stellite 6, aiming to obtain a very dense coating without the dilution zone typically resulting from PTA weld surfaces.
Flame spraying is a coating process using heat. A flame produces heat which is used to melt the thermal spray material, normally in powder, wire, or ceramic rod form. The molten particles are then propelled onto the surface to be sprayed, compressed air is used on the wire flame spray so that the molten particles are atomized and then propelled onto the substrate. When using the powder flame spray, the metal or ceramic powder particles are softened by the flame, then this softened powder is sprayed onto the surface to be coated by the use of the flame gases through the nozzle.
With the wire flame spray process, the wire spray material is melted in a gaseous oxygen-fuel flame. The fuel gas can be acetylene, propane or hydrogen. The wire is fed concentrically into the flame, where it is melted and atomized by the addition of compressed air that also directs the melted material towards the workpiece surface.
This coating process is based on the same operational principle as the wire flame spray process, with the difference that the coating material is a spray powder. Thus, a larger selection of spray materials is available, as not all spray materials can be manufactured in wire form. In Ceramic coating, the feedstock material is fed continuously to the tip of the spray gun where it is melted in a fuel gas flame and propelled to the substrate in a stream of atomizing gas. Common fuel gas is acetylene. Air is typically used as the atomization gas. Equipment: Ceramic coatings on pump equipment Name of the part: Ceramic Coated Sleeves and Plungers
A major expense associated with pump operation is the replacement of sleeves/plungers. Wear on these components necessitates:
Abrasion, Corrosion, and friction are the main causes of the problem The Solution we provide Coatings that provide a long-lasting wear-resistant surface using ceramic oxides or metallic carbides. We have a robotic Plasma transferred arc system (PTA) and flame spray equipment to apply coatings of tungsten carbide in a nickel chrome boron matrix and chromium oxides. The coating thickness is selected based on application wear potential and varies from 0.5mm to 1.5mm in thickness. For severe wear applications, PTA coated sleeves last longer. The Compositions used in ceramic coating are Chromium oxide, Alumina Titanium, Zirconia, Nickel alloys, Aluminium Bronze. Industries in which these parts are used are Thermal power plants, Sugar industries, Oil and gas sector and chemical process plants. These are our major consumers.
Plasma arc welding (PAW) is an arc welding process similar to gas tungsten arc welding (GTAW). The electric arc is formed between an electrode (which is usually but not always made of sintered tungsten) and the work piece. The key difference from GTAW is that in PAW, by positioning the electrode within the body of the torch, the plasma arc can be separated from the shielding gas envelope. The plasma is then forced through a fine-bore copper nozzle which constricts the arc and the plasma exits the orifice at high velocities (approaching the speed of sound) and a temperature approaching 28, 000 °C (50, 000 °F) or higher. Arc plasma is the temporary state of a gas. The gas gets ionized after the passage of electric current through it and it becomes a conductor of electricity. In an ionized state, atoms break into electrons(-) and ions(+) and the system contains a mixture of ions, electrons, and highly excited atoms. The degree of ionization may be between 1% and greater than 100% i.e.; double and triple degrees of ionization. Such states exist as more electrons are pulled from their orbits.
The energy of the plasma jet and thus the temperature is dependent upon the electrical power employed to create arc plasma. A typical value of temperature obtained in a plasma jet torch may be of the order of 50000 °F (28000 °C) against about 10000 °F (5500 °C) in an ordinary electric welding arc. Actually, all welding arcs are (partially ionized) plasmas, but the one in plasma arc welding is a constricted arc plasma.
Plasma arc welding is an arc welding process wherein coalescence is produced by the heat obtained from a constricted arc setup between a tungsten/alloy tungsten electrode and the water-cooled (constricting) nozzle (non-transferred arc) or between a tungsten/alloy tungsten electrode and the job (transferred arc). The process employs two inert gases, one forms the arc plasma and the second shields the arc plasma. Filler metal may or may not be added.
Polyether ether ketone (PEEK) is a high-temperature, high-performance thermoplastic special engineering plastics. It has good mechanical properties and resistance to chemicals, resistance to abrasion, resistance to hydrolysis and other properties. Its light weight, self-lubricating properties, good flow properties and processing properties can be filled with carbon fibre, graphite, molybdenum disulphide, etc. to further improve the lubricating properties and mechanical strength.
Cladding is a welding procedure that puts weld metal on the surface of the work, as opposed to joining two pieces of material. Generally, this is used for corrosion resistance or wear resistance and frequently a different material is used for the clad than for the base metal. In hot wire welding, the power supply controls the heat of the filler wire prior to its introduction into the weld puddle. Arc energy that would usually go into melting the wire provides more penetration, while heating of the wire almost to the melting point by a separate power supply increases deposition beyond that possible with standard cold wire TIG. In cladding applications where the part is rotated, the hot wire solution can result in weld deposition that approaches MIG speed, but with TIG quality. Laser cladding is realized either as wire (laser hot wire cladding) or powder cladding. The laser beam creates a molten pool at the workpiece surface, to which is simultaneously added the laser coating material (wire or powder) molten by the laser. The exposure time is short, which creates only a short delay as the cooling is quick. The result is a layer that is connected with the basic material metallurgically. It is tougher than those coatings created by thermal spraying, and compared to hard chromium plating, for example, it is harmless to health, too.
Advantages:
Oxy-acetylene welding torch with powder hopper and injection venturi mounted between a gas mixture and nozzle Powder falls through flame on a workplace where weld pool is maintained and the continuous bead is laid down. Spray and fuse use high heat to increase the bond between the thermal spray coating and the substrate of the part. Unlike other types of thermal spray, spray and fuse create a metallurgical bond between the coating and the surface. This means that instead of relying on friction for coating adhesion, it melds the surface and coating material into one material. Spray and fuse are the difference between adhesion and cohesion.
Spray and Fuse Benefits
Spray and Fuse Materials
Spray and fuse are the best for.
