the world of thermal spray

Guess what???……

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What is it, that is common in a …..

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Thermal Power PlantThermal Power Plant Jet EnginesJet Engines

Petro refineryPetro refinery Steel PlantSteel Plant

What is, that is common in a …..

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Plastic Industry Glass Industry

Oil Drilling Mining

What is, that is common in a….

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Sugar Mill Paper Mill

Dry Dock & Shipyards Cement & Chemicals

Common in the jobs from Industries???

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Plastic Extruder ScrewsTriplex pump plungers

MG Cylinder in a Paper mill Boiler Tubes in a Power Plant

Common in the jobs from Industries???

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Glass MouldsDry Dock

Steel Structures Journal Bearing halves

•

Reclamation…

All these Partsand

Many more that are being added everyday ,

undergo Life

Enhancement or

Why Just on Industrial Parts? Watch this movie clip on next slide!

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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]

Titanium on Orthopedic Implants

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Reclamation & Life Enhancement

of Critical Industrial parts?

Reclamation…

RECLAMATION: The Part in a Assembly/Sub-Assembly, Due To WEAR is unable to PERFORM its Function, ready to take up

Journey to a Scrap yard, are repaired and used.

EXAMPLE: Cracked Housings

Life Enhancement…LIFE ENHANCEMENT: The Part in a Assembly/Sub-Assembly, Either, WEAR is Detected & Preventive Action is Initiated. EXAMPLE: Bearing Area of Armature Rotor OrBased On Past Experience, PreventiveAction is Initiated, on a new part. EXAMPLE: OD of these Core Barrel Heads

The Key Word in Reclamation / Life Enhancement Is ‘WEAR’

The Phenomenon by which there is change in SHAPE/ SIZE/ TEXTURE of a Part, resulting in improper Functioning of the Sub-Assembly / Assembly.

IMPACT. ABRASION. FRICTION. COROSION. EROSION. HEAT. PRESSURE.

What is WEAR??

Thus a Thorough ‘WEAR ANALYSIS’ of A Worn-out part is a MUST. It is done with the help of ‘WEAR FACTORS’, which are:

Some of the Factors for WEAR….

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‘Alloy Selection’ KEY To COMBATING WEAR.

Alloys Like :S.S, Zinc, Aluminium, Titanium….Manganese, 13% chrome steels….Cobalt based alloys… Nickel based alloys like Ilium's, Hestalloy’s,Carbides of Iron/Chromium/Tungsten,Ceramics (Oxides) of Aluminum, Chromium,

Zirconium many more are being developed every day….

SELECTION Of THE METHOD OF DEPOSITION::

Depends on :

Base-Metal; Job Size, Cross Sectional Thickness, Alloy Thickness To Be Deposited Deposition Characteristics Cost of Deposition Thus We Have :• MANUAL METAL ARC WELDING (MMAW)• Metal Inert Gas (MIG/MAG), FCAW• Gas Tungsten Arc Welding(GTAW), Or, TIG• Thermal Spray: Including Fusible, Flame Spray, Arc-

Spray, Plasma (NTA & PTA), HVOF, Cold Spray, LASER

Welcome to

The World of

Thermal Spray

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THERMAL: Involving HEAT… SPRAY: Particles MOVING at high speed in a

medium, in our context a Gas…

What is a Thermal Spray?

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A coating produced by a process in which molten or semi-molten particles are applied by impact onto a substrate.

The impacting molten particles on the substrate rapidly solidify to form SPLATS.

What is Thermal Spray?

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1. Melting

2. Atomization and speed up

3. Temperature and speed control

4. Coating building


What are Splats?

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Splats


A Thermally Sprayed Layer…

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Bonding of Thermally Sprayed Layer…

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Range of Alloys to counter Wear that can be Range of Alloys to counter Wear that can be deposited.deposited.

The Alloys can be from Machinable to The Alloys can be from Machinable to Ultra-Hard.Ultra-Hard.

From few Microns to Couple of mm.From few Microns to Couple of mm. From Bond strengths of 10K psi to Diffusion From Bond strengths of 10K psi to Diffusion

bonded with 75K psi (depending on Process bonded with 75K psi (depending on Process of deposition)of deposition)

The next to none dilutionThe next to none dilution No undercut No undercut

Why Thermal Spray?

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Thermal Spray…Classification based on heat imparted to the Alloy Based on Gas for Heating: Self Fluxing or Fusible Coatings (Oxy-Acetylene) As-Sprayed or Flame Spray (Oxy-Acetylene) Wire Flame Spray (Oxy-Fuel / Acetylene) HVOF (Oxy-Fuel, variants have Kerosene as Fuel too) Cold Spray (Heated Nitrogen-Helium Mixture, no

combustion)Based on Electric Power: The Twin Wire Electric Arc The PLASMA Spray NTA The PLASMA PTA LASER

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Thermal Spray…

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A Torch / Gun. Alloy and Alloy feeder. Means to Heat the Alloy (Oxy-Fuel/Gases or Electricity). Carrier Gas. Controls for controlling the above 3.And.. A Prepared / Activated Substrate.

Components of Thermal Spray System..

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Materials that can be Sprayed

Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected] 27

The Self Fluxing or

The Fusible Powder Welding Process..


The First Process…


Process similar to Process similar to Brazing.Brazing.

The difference is in The difference is in place of filler wire, a place of filler wire, a Pre-AlloyedPre-Alloyed powder. powder.

This is sprayed with This is sprayed with help of a specially help of a specially designed torch, using designed torch, using oxy-acetylene gases.oxy-acetylene gases.

The Self Fluxing or FUSIBLE-COATINGSFUSIBLE-COATINGS

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1. Oxygen & Acetylene Controls2. Powder & Powder feeder

Lever.3. Nozzle4. Oxygen & Acetylene gas

Connections

The Self Fluxing Torch

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1

2

3

4


Movie clip Fusible Process..

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Diffusion bonded (Metallurgical Bonds) with 55K. psi Bond Strengths.Diffusion bonded (Metallurgical Bonds) with 55K. psi Bond Strengths. The Minimum dilution (the deposited alloy is fused with Base Metal, The Minimum dilution (the deposited alloy is fused with Base Metal,

which remains un-melted).which remains un-melted). No undercut (The demarcation observed between a Base layer & a No undercut (The demarcation observed between a Base layer & a

deposited layer (in Arc welding). deposited layer (in Arc welding). Range of Self Fluxing Alloys to counter Wear.Range of Self Fluxing Alloys to counter Wear. The Alloys can be from Machinable to Ultra-Hard.The Alloys can be from Machinable to Ultra-Hard. High Re-Melting Temperatures.High Re-Melting Temperatures. From few Microns to Couple of mm. From few Microns to Couple of mm. All Non-Heat treated / Toughened Iron based Alloys can be sprayed All Non-Heat treated / Toughened Iron based Alloys can be sprayed

upon.upon.

The Characteristics of FUSIBLE-COATINGS..FUSIBLE-COATINGS..

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In the Indian context is still a Work HorseIn the Indian context is still a Work Horse

Some of the Key Applications are..Some of the Key Applications are..

The Self Fluxing or FUSIBLE-COATINGS..FUSIBLE-COATINGS..

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The Plastic Industry Single Extruder

ScrewsClick here to read a

write up

Key Applications of Fusible Coatings..Key Applications of Fusible Coatings..

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Coated

Coated and Ground


The Plastic Industry

The Twin Extruder Screws frontal zones


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The Glass industry.. Glass moulds. The Mould

Plungers. The Neck Ring The Glass cutters. Conveyer Track

Pads.


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Key Applications of Fusible Key Applications of Fusible Coatings..Coatings..

In Oil Drilling Mud Pump

Plungers


Key Applications of Fusible Key Applications of Fusible Coatings..Coatings..

In Sugar Industry

Scrapper Plate



Some Applications which are also being done..

The Engine Valves The Mechanical Seals

(the refrigeration compressor / Pumps)


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Some Applications which are also being done in various industries..

The screw type of Centrifuge / Conveyers in Paper/ Textiles / Cements


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The Road Transport The Stub Axle bearing areas The Main Shaft bearing areas


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Some Applications which are also being done in Geotechnical Drilling

The Couplings


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The Head of Core Barrel


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The Outer Tubes


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Pyramid wrenches


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Boiler tube CoatingClick Here for Presentation


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Please call us for the Please call us for the Part2 of ‘The World of Part2 of ‘The World of Thermal Spray’Thermal Spray’ which covers:which covers:

A Recap of the A Recap of the ‘Basic of Thermal Spray’‘Basic of Thermal Spray’ ‘‘Powder Spray Process’ Powder Spray Process’ with Movie Clip & with Movie Clip &

Applications.Applications. ‘‘Wire Flame Spray ProcessWire Flame Spray Process’ ’ with Movie Clip & with Movie Clip &

Applications.Applications. ‘‘The Twin Arc Spray Process’ The Twin Arc Spray Process’ with Movie Clip with Movie Clip

& Applications.& Applications.

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You can go through (please click You can go through (please click on): on): ‘Glossary on Thermal Spray‘Glossary on Thermal Spray’ ’ & & ‘Surface Preparation’‘Surface Preparation’

You can also click: ‘Jobs that You can also click: ‘Jobs that challenged us & the processes’challenged us & the processes’

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Your feed back means a lot to us,Your feed back means a lot to us,

Please provide it on: Please provide it on:

[email protected] [email protected]

http://www.facebook.com/http://www.facebook.com/innovativeengrsinnovativeengrs

Phone: +91 98255 30436Phone: +91 98255 30436

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Thank You for your Time..Thank You for your Time..

We are planning next in the series..We are planning next in the series..

‘‘Thin Film Coatings’Thin Film Coatings’

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the world of thermal spray

Documents

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heat spray

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plasma spray nta

counter wear

berange of alloys

electric power

core barrel headsthe