SURFACE TECHNOLOGIES Bangalore and Pune

Surface Modification Technologies

Bangalore Plant : A 413, 9th ain, 2nd stage,Peenya Indl area

Bangalore 5600058 , spraymet@gmail.com Tel : 080-28364565 , mobile : 9916903701

Pune Plant :T 180, T Block, MIDC , Bhosari, Pune

Tel 020- 27110020 Mobile ; 8149046272

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SPRAYMET

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Various surface Modification processes

SPRAYMET

Core Surface Modification Technologies operated by Spraymet

Flame Spray : Powder / Wire Robotic Plasma Spray Robotic High Velocity Spray (HVOF) Cold Spray ( future Planning )

Cladding : PTA / TIG HWTIG /Laser ( future Planning )

Plating : Electroless ( ENP)

Nitriding ( liquid-QPQ and Gas)

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15Schematic o f

thermal spray coating

Heat source, spray gun

Acceleration Impacting Spreadening and cooling

Feedstock materials

Stick

Wire

Powder

Thermal Spray : Process Flow

Gun- Flsme/Plasma/HV

OFFlame Temp 3000-15000*C

Semi molten particle temp t

Particle velocity V ~ 400-1200m/sec

Spray dist 6-15 inches – No heat transfer to base

Grit blasted surface

Hot particle quenches @surface to give Hardness Splat ~ D= 3X

d Adhesion : Micro welding +

mechanical bonding

Practical size ~d 15-106 microns Spherical in shape

D-- = 3.5

d

SURFACE COATING

Heated particles propelled

Impact force = 1/2mv2

Concept and Schematic of

THERMAL SPRAY

Layer by layer coating builds up

Plasma spraying

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• Most versatile process in terms of range of coatings •plasma temperature: up to 15000 ºC.

• virtually all existing materials including ceramics. Flame spray 350-

500m/sec

High-velocity oxy fuel spraying (HVOF)

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Cold spraying

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• gas temperature: under the phase transition temperature ~ 800,1000C• sprayed materials: pure Al, Zn, Cu, Ni Alloys : NiCr, Cr- Carbide/NiCr

Process and prosperities comparison

Adhesion Strength (Mpa)

Processes Particle speed m/s (km/h)

Spray rate kg/h

Porosity Levels

%

Thickness capablity

mm

Flame Temp °C

Powder Flame 70 (144) 1...8 10...15 0,2...5 3000 10...30

Wire Flame 70 (144) 5...8 0,2...0,4 0,2...5 3000+1100 n. 300

Arc Spray 220 (790) 6...40 10...20 0,2...10 3000 10...30

Plasma 600 (2160) 1...6 2...8 0,2...2 16500 20...70

HVOF 800 (2880) 2...9 0,5...2 0,2...2 2800 60...120*

HVAF 800 (2880) 10...30 0,1...1,5 0,1...1.5 1800 60...120*

Detonation 900 (3240) 2...6 0,1...1,5 0,1...0.50 4500 75...120*

Characteristics of thermally sprayed coating structures(Typical Expected values)

As sprayed (3-5Ra)

Oxide-(max 3%) Cracks-(Not allowed) Pores (1-2%)

t

Grit blasted surface3-6 Ra

Unmolten particle 3 % maxEmbedded grit blasting

pieces-10% or area max

“over-blasted”area

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Plasma transfered arc spraying (PTA)

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• Fe, Ni, Co, Cr based alloys, stainless steels, cermets•Dilution ~ 2 %

HW/TIG bore cladding

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Common Base Material Grades API 5L X52 to X70, A106 Gr. B, ASTM A333 Gr.6, A182, A350, A694, AISI 4130, 8630

Common Weld Overlay Grades STAINLESS Steel 316L, 410, 904L, Duplex/Super Duplex, MONEL Alloy 200, 400; INCOLOY 825, INCONEL 625,C22; C276, Copper Nickel Alloy and others on customer requirement.

CRA Clad Pipe, Tubular Components Weld overlay of pipe in up to 6m lengths, extended to 12m by “double jointing”

Flanges and Connectors Flanges / Swivel Ring Flange :1-1/2”NB (min)

Bends (3D-5D) or on customer requirement, SR/LR Elbows, Tees, Reducers, Hubs /Caps

Weld overlay can be carried out on elbows priorto forming or after induction bending depending onthe dimensions.

Pressure Vessel Components CRA clad nozzles, vessel strakes, tube sheets

Valves & Valve Components Blocks, Manifolds, Gates, Seats, Bonnets, Ball Plug,Xmas Trees

Working Capabilities - Pipe cladding start from 4” diameter

Laser cladding

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• virtually all metal alloys, cermets and ceramics. Dilution < 1 %

Laser cladding process – Dilution/distortion negligible

Laser cladded stabilizer

Rotor repair Hyd. Ram and piston guides

Pump and valve applications Pump and valve applications

Cage carbide coated Knife Gate valve body carbide coated

Sleeve ceramic coated& Impeller ceramic coated Ground

Ceramic coated sleeves Hardfaced pump sleeve For Food industry 19

24” Ball valve coating

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Measurement After blasting HVOF coating

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

Ball HVOF coated and Lapped

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Plug valve, feed screw and Other applications

Plug valve carbide coating plug carbide or stellite possible

Control vale cage Ball valve carbide coating

Extrusion screw coating Valve disc stellite 6 PTA

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Oil and gas applications

BOP Double Ram piston BOP single ram piston

7” gate

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Metal seated gate vlave Pune plant facility

Metal seated - Seat rings

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 and Ground

Pump plungers

Super finish 0.05 Ra

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

Carbide coated and Ground Gate Valve( Replacement for Nitriding )

Plunger Ceramic coated

SPRAYMETThank You

SPRAYMET SURFACE TECHNOLOGIES PVT LTD.A413, 9th Main, 2nd Stage, Peenya Industrial area,

Bangalore . Email spraymet@gmail.comwww.spraymet.com

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