1st quarter – vol. 16, no. 1

SPRAYTIME First Quarter 2009

Volume 16, Number 1 First Quarter 2009Publ ished by The Internat ional Thermal Spray Assoc iat ion

continued on page 6

First Announcement and Call for PapersNew Developments in Thermal Spray Coatings,

Processes and Applications ConferenceConference dates: November 16, 2009, Chicago, IL USA

Abstract Deadline: May 1, 2009PowerPoint files Due: October 1, 2009

Topic: Thermal Spray Applications and DevelopmentsThe American Welding Society and The International

Thermal Spray Association are organizing the first ThermalSpray and Coatings Conference at FABTECH 2009. This one-day event will be held in conjunction with the FABTECHInternational and AWS Welding Show. The program isintended to introduce the process and its uses to newpotential users with morning and afternoon sessions focus-ing on actual applications and new developments inthermal spray technology. It will include a half-day tutorialSunday, November 15th sponsored by the InternationalThermal Spray Association on thermal spray fundamentalstitled “What is Thermal Spray?”.

The International Thermal Spray Association is aprofessional trade organization dedicated to expanding theuse of thermal spray technologies for the benefit ofindustry and society.AWS and ITSA 2009 Program Organizers invite you to

submit your work for consideration of inclusion in thetechnical program. They are accepting 150-200-wordabstracts describing original, previously unpublished work.Presenter PowerPoint files will be due October 1, 2009.Topical areas suggested for presentation include thefollowing New Developments in Thermal Spray:

• Applications • Processes• Coatings • Spray equipment• Automation • Ancillary equipment• Safety • Sensors and controls.

The Vortex-Stabilized HVOF Spray Systemby James Browning

IntroductionBy now, most of us know about HVOF–that it is a way to

produce particle velocities so extreme that metal powderneed not be melted. Impact heating raises them to thefusion point. Superb coatings result. It is not unreason-able to believe that similar strides may occur for thespraying of wire. (The low oxide coatings of powder in the“impact-fusion” mode would not be challenged. Liquiddroplets attract oxygen.) But, what benefits might beexpected? The answer, finer wire atomization andincreased particle velocities than found in both flame andarc spray. Also, lower coating porosity and reduction ofmetal vaporization as often caused by arc intensity.Recent work has resulted in a new flame-stabilization

technique which eliminates the need for water cooling andinternal ignition. By far the simplest possible guns are nowavailable. And, many of these advances may apply equallywell to powder spraying. Thermal spray and its equipmentcosts could drop dramatically.

continued on page 2

2 SPRAYTIME First Quarter 2009

800-479-6801

No matter which dust collector you have, theHemiPleat®

continued on page 4

DiscussionVortex gas flow is an extreme case of rotary flow. From a

circular zone near the axis of rotation the gas velocity is amaximum, falling exponentially lower with radial distancefrom the axis. Within this whirling flow is a core, or eye, ofthe vortex. The gas has lost nearly all its motion, with itsgas pressure falling to vacuum levels–a tornado.Current HVOF guns premix the oxygen and fuel prior to

combustion. Premixed combustion is rapid, efficient, andgreat for lifting a rocket. But, we are not in the rocketbusiness.A rocket engine is “on” for only short periods. It depends

on adequate cooling from the flowing propellants.Additional cooling is not an option. Present HVOF gunsdepend on water cooling and suffer the loss of about one-quarter of the heat produced. Water cooling is not onlycostly and complex but, due to heat loss, significantlylowers heating of the spray material.Figures 1 and 2 help explain why vortex flow eliminates

this undue heat loss. Fig. 1 illustrates the cold-state mode.Oxygen is forced tangentially into a tubular flow path.Tangential velocities nearing the central axis approach anunsustainable level. A low-pressure eye forms. It remainscentralized through the entire tube length. The outer mainflow of cold oxygen is forced against the inner tube wall.Next, the gaseous fuel is injected axially into the eye. Thelow pressure eye is the easiest way to reach the exit. Little

mixing into surrounding oxygen is evident. In turn, theoxygen flow picks up speed along its path. Beyond the exitoxygen’s whirling motion is no longer restricted. It expandsinto the atmosphere with a strong radially outward path. Aportion of combustible fuel and oxygen reverses directionpassing back into and down the eye by forces imposed bythe vacuum. The vortex flow emits a high-pitchsqueal–which indicates everything is ready for hand-heldsparker ignition. Instantly after ignition a supersonic jetflow rushes from the nozzle. Adjusting the flows producesthe desired conditions for spraying.

Fig.2 shows the conical flame region within the tube. Ithappens that the rate of inter-diffusion of fuel gas andwhirling oxygen is lower than the radial speed ofcombustion into the oxygen. Thus, the oxygen remainscold–even next to the advancing flame front of nearly5,000°F. The flame-jet grows larger in its downstream flow.If it reaches the inner wall it may melt it. So, reduce tubelength to the point where you can keep your hand on themetal. At this “safe point” a thin cold oxygen layer ispresent. No water cooling is needed.If the vortex is strong enough a 1/2 in. diameter nozzle

bore, 8-in. long, provides a supersonic jet whichsuccessfully sprays both wire and powder when introducedto the jet beyond the exit–a super flame spray! Obviouslyspray material injected beyond the gun exit leads to zeroplugging of the nozzle. For wire, a simple hose loop directsthe wire into and along the hot jet. The extended pathwithin the jet provides a preheating level unobtainable inflame spray and arc processes. Increased spray rates result.For the 1/2 in. nozzle bore, 1/8 in. aluminum wire spraysat rates up to 30 lb/hr–3/16 in. wire to over 40. Stainlesswire has comparable rates. Compared to the twin wire-arc,a single wire of the vortex HVOF gun replaces both wires ofthe arc process. Excellent coatings of molybdenum areeasily obtained.

Fig.1 Conditions prior to combustion.

Fig.2 Conical flame condition during combustion.

continued from page 1

INDUSTRY

NEEWS

SPRAYTIME First Quarter 2009 3

Published byInternational Thermal Spray Association

Mission: To be the flagship thermalspray industry newsletter providingcompany, event, people, product, research,and membership news of interest toindustrial leaders, engineers, researchers,scholars, policy-makers, and the publicthermal spray community.

Kathy M. Dusa Managing Editor

Paul Kammer Technical Editor

Marc Froning Editor

SPRAYTIME (ISSN 1532-9585) is a quarterlypublication of the International ThermalSpray Association.

Printed on Recycled Paper

Copyright© 2009 by the InternationalThermal Spray Association.

The International Thermal SprayAssociation is not responsible for theaccuracy of information in the editorial,articles, and advertising sections of thispublication. Readers should independentlyevaluate the accuracy of any statement inthe editorial, articles, and advertisingsections of this publication which areimportant to him/her and rely on his/herindependent evaluation.

Article submissions (subject to acceptanceand edit), advertising insertions, addresscorrespondence, subscription request, backissue copies, and changes of addressshould be sent to:

Editorial and Production OfficeKathy M. Dusa, Managing Editor208 Third StreetFairport Harbor, Ohio 44077United States of Americavoice: 440.357.5400fax: 440.357.5430email: [email protected]

[email protected]

Subscription to SPRAYTIME® is free forqualified individuals interested in thethermal spray industry. Visitwww.spraytime.org to subscribe.

®

I N D E XADVERTISERS LISTING ..........................................................41

CALENDAR OF EVENTS ....................................................................40

INDUSTRY NEWSAPMI Celebrates 50 Years ........................................................................8Arkansas Thermal Spray Announces Hittmax Equipment Line ......................38ASB High Pressure KINETIKS® CGT 2000 Cold Spray Gun ............................30AWS - ITSA Call for Papers - First Thermal Spray Conference ........................1Call for Papers Thermal Spray Coatings, Processes and Applications Conference 1CO2 Cooling for Thermal Spray Advances ..................................................14Centerline SST Receives NRC-IRAP Support for New Solid State Process ........14Cold Gas Spraying Increasingly Accepted in Industry ................................13Ecka Granules joins the International Thermal Spray Association ................25F.J. Brodmann Celebrates 25 Year Anniversary ..........................................39Fabtech International and AWS Welding Show With Thermal Spray Pavilion ..29Farr Hemipleat® New Brochure Describes Retrofit Dust Collector Cartridges ..18Hard Chrome Alternatives in Today’s Economy ..........................................34MEC New High-Tech Two-Axis Manipulator................................................31NanoSteel Announces Brian Merkle for ASTM International Standards ..........42NanoSteel Hires Mike Place as Sales Director............................................42PAS Technologies Received Best Emerging Business Improvement Award ......20Praxair Introduces Closed-Loop Controller Powder Feeders ..........................19Praxair Unveils 8830MHU Arc Spray System..............................................21Progressive Technologies Next Generation 100HE Plasma Spray Torch ..........39Society of Vacuum Coaters 2009 Conference ............................................17Sulzer Celebrates 175th Anniversary........................................................20Upcoming Low Worker Safety Numbers and Your Thermal Spray Process ........26Vortex Stabilized HVOF System Introduction ..............................................1Wall Colmonoy Announces Johnson as Alloy Products VP............................42Weldmex - Fabtech - Metalform 2009, Monterrey, Mexico............................23

INTERNATIONAL THERMAL SPRAY ASSOCIATIONCompany Member Listing and Membership Information ........................22-25

TECHNICAL NOTESJournal of Thermal Spray (ASM TSS) Technology Abstract ..........................41Sprayed Particle Diagnostics Series ..........................................................9The Manipulator Series - “The Programmable Manipulator” ........................31



INDUSTRY

NEEWS

Too little work (to date) has been done in the powderspray area. Exterior injection appears to produce coatingsof zinc, aluminum, and copper equal to, or superior to,HVOF conventional straight-through gas flow. Oxide levelsare lower than their wire counterparts. Densities areequivalent. Although higher melting point powders producegood coatings, deposit efficiencies may be low. Among thelatter, stainless steel and chromium carbide/nickel chromespray easily. [With preheating more difficult using powders,longer nozzles than possible in the un-cooled dry vortexgun will probably need water cooling which at the presenttime has not been studied sufficiently. Suffice-to-say,

quench water injection into the flame has produced superbresults using impact-fusion. In some cases, grit-blastingand other surface treatments were not needed.]

Figures 3 and 4 are photographs of the 1/2 in. bore unitin operation. Fig. 3 was decided upon to show plumenarrowness compared to twin wire-arc. 1/16 in. 308stainless wire at a spray rate of 20 lb/hr is shown.Apparently nearly all the molten particles reach highvelocity. Few “satellites” are seen. Fig. 4 shows the 308wire sprayed against a 2 in. diameter steel coupon hand-held at a stand-off distance of about 2 ft. Velocities ofimpact of the very small droplets eliminate most of theFig.3 The droplet plume.

Fig.4 Coating in progress.


“splash” and bounce-off of lower velocity arc spraying. Thephotos, in places, are overexposed. The test coupon is thecircular image appearing about halfway along the plumepath. The increase of brightness of the coupon may resultfrom the release of impact energy raising each particle tohigher temperature.

The ResultsAs aluminum is, perhaps, the most popular metal wire

sprayed, vortex-sprayed coatings of it have been studiedthe most. Samples were sent to Prof. Heinrich Kreye inHamburg, Germany. His resulting photomicrographs arequite revealing. Fig. 5 shows a coating produced usingTAFA’s 1/16 in. diameter O1T aluminum. The sample diskwas positioned 8 in. downstream of the wire’s atomizationpoint. The coating is quite good, even compared toplasma spray. Porosity levels appear acceptable for mostcorrosion-protection applications.

Work is currently being carried forward to study theeffect of jet temperature reduction. By adding a quenchflow of water to the combustion oxygen using a 16 in.long composite nozzle–the first 6 in. dry vortex flow–theremaining nozzle length water cooled. This “hybrid”arrangement led to startling improvements over the drycase of Fig.5. Fig. 6 shows these improvements. TAFA 1/8

in. 01T was used. 2.4 lb/min of quench water was added tothe oxygen. The exit flame changed in color from a blue-white to orange. The spray rate had to be reduced to 13lb/hr. Stand-off distance was 16 in. Note the oxidereduction and the surprising 0.1% porosity reported fromHamburg. (That is one-tenth of one percent!)

Oxides are reduced as quenching lowers the flametemperature to below dissociation levels. As discussed byProf. Horst Richter, Dartmouth College, at an HVOFmeeting, Erding, Germany, such cooling essentiallyeliminates the main culprits–OH, CO and O. Added impactvelocities result from a doubling, or more, of mass flowwith jet momentum increases of about 30%. To speed up aslow moving particle, gas density outweighs the gasvelocity.ConclusionsNo product is successful if not used. A comparison of sub-

stituting V-Gun wire spraying for other methods follows.Some biases could be expected, but no one can fault thelow equipment and operating costs of these new devices.

V-Gun/Flame SprayWire–The V-Gun, using much higher flows of oxygen and

fuel gas, more than makes up for this by increased sprayrates, as well as reducing both coating porosity andoxidation. Compressed air acceleration is not used. Initialcosts are about the same.

INDUSTRY

NEEWS

Fig.5 Dry coating.(1/16 in. diam Al wire) 1% Porosity

Fig.6 Quench water coating.(1/8 in. diam Al wire) 0.1% Porosity

continued on page 6

PRODUCT LINE INCLUDES:• Aluminum foil tapes• Fiberglass tapes• Plasma spray tapes (Silicone rubber)• Special combination tapes

Canada/International905-564-6712

U.S.800-668-1114

Green Belting IndustriesTHERMAL SPRAY TAPES

High performance masking tapes for the Thermal SprayHigh performance masking tapes for the Thermal SprayIndustryIndustry, capable of withstanding many of the most, capable of withstanding many of the mostaggraggressive applications aressive applications are manufacture manufactured by GBI in aed by GBI in acomplete line, all available in various widths.complete line, all available in various widths.

www.greenbelting.com

Green Belting Industries

G


INDUSTRY

NEWS

6

A Poem by Jim BrowningIt’s HVOF and weighs but a pound

That doesn’t mean it makes no sound!No threads, no gaskets, no O-rings;Costs so low you’ll want to sing.No water, no air, no electricity,

The V-Gun’s proud of its simplicity.

V-Gun/Plasma SprayWire–Plasma, except for the transferred-arc case is not an

effective wire gun except above 200kw! Plasma is hot–sohot that jet momentum is low. And, who sells 200kw units?Case does not apply.

V-Gun/Conventional HVOFWire–Conversion of existing HVOF equipment for the

spraying of wire is simple. But, none of the manufactures(except for the early J-Guns) provide even simple front-endadaptors. With the development of the V-Gun, changes toexisting units could cost more and would not be aseffective.ClosureIf not practiced, the best inventions are not worth the

paper they’re written on. I believe keeping the equipmentsimple may reduce costs so significantly that a much larger-than-present market could be developed. Times aretough–“nothing new for us”-may be nearly universal. Tome, let’s get going and make and use new stuff that willsell more wire and powder. (Razor blades are where theprofits lie.) Bridge construction and maintenance, withoutadequate corrosion protection is next to criminal. Europeis 50 years ahead of us. Check the history of the “new”Firth of Forth suspension bridge where Bill Ballard madehis mark.For more information, contact author Jim Browning,

DRACO, tel: 603.632.7900, Post Office Box 6, Hanover, NH03755

In order to maintain the high level of technical qualityand integrity of the AWS ITSA joint conference, no papermay commercially promote specific products or serviceproviders.To submit your work for consideration, visit our website

at www.thermalspray.org, and then follow the instructionsat the right hand corner “Call for Papers Click Here”. Allabstract submissions must be completed by close-of-business on Friday, May 1, 2009. Before submitting yourabstract, we ask that you carefully consider your ability topresent your work at the conference. Speakers are requiredto pay a (reduced) conference registration fee, and aretotally responsible for their travel, housing and any relatedexpenses.This premier event is truly one that anyone involved in

the thermal spray and coatings community should plan toattend.Mark your calendar now, and if you are interested in

presenting your work at the conference, submit yourabstract no later than May 1, 2009.

Call For Papers continued from page 1 continued from page 5

New Thermal Spray

Cooling Technology

Using -320oF Nitrogen

©2007 Air Products and Chemicals, Inc.

Introducing a new approach to thermal spray cooling.

Nothing gets thermal spray operators

fired up quite like overheated parts.

That’s why Air Products has created a way

to put your overheating issues on ice.

Introducing Air Products’ thermal

spray cooling technology. It’s the

industry’s only cryogenic nitrogen

cooling process, and it allows temperature

control within a range of +/- 20o F. Our

cryogenic spray nozzle installs easily

on any thermal spray gun to cool parts

twice as fast as air alone. Allowing you

to work faster and more efficiently,

with less wasted powder, process gas

and booth time.

To learn more about how you can

freeze your overheating issues, call

800-654-4567, code 543, or visit

airproducts.com/spray.

tell me morewww.airproducts.com/spray

1


INDUSTRY

NEWS

8

everyone who is anyone in this business.To help celebrate the 50th anniversary of APMI, founding

Executive Director Kempton H. Roll has put into words whyand how APMI was created. You are invited to discover thetribulations and triumphs behind its creation. Thishistorical article appeared in the January/February issue ofthe International Journal of Powder Metallurgy.For more information, visit www.mpif.org

APMI Celebrates 50 Years!In the late 1950s, restlessness within the

ranks of the PM industry began to develop.Though MPIF was effectively servingcompanies in the industry, there was not anorganization devoted to individuals, many ofwhom were not employed by MPIF-member companies orwhich were otherwise not eligible for corporatemembership; and many were located outside NorthAmerica. An opportunity arose to give such individuals aforum to exchange views and discuss technology as PMindustry technologists and PM professionals.So, in 1959 APMI International (formerly the American

Powder Metallurgy Institute) was established with thesupport and collaboration of MPIF, sharing a commonheadquarters operation and governing body that was vitalto the future of powder metallurgy. Whereas MPIFrepresented parts and raw material producers, industrysuppliers and consultants; APMI represented individualspursuing a career path in the PM technology.

After 50 years, APMI continues to be a globalorganization, an example of what happens when peoplewith common interests band together. APMI remains theonly global professional society representing individuals ofthe entire PM industry: parts fabricators, powder suppliers,equipment manufacturers, end users, and academia—

ITSA Announces “SupportingSocieties” Membership Category

The International Thermal Spray Association is pleasedto announce a new “Supporting Societies” membershipcategory. The purpose of this category is to establishcommunication with other associations/societiesinvolved in thermal spray and surface engineeringactivities.This is an ideal method for membership exchange

between organizations. If your organization isinterested in a membership exchange to belong to theInternational Thermal Spray Association, please contactKathy Dusa at the headquarters office via email [email protected]

SPRAYTIME advertising rates at www.spraytime.org

9

INDUSTRY

NEWS


Sprayed Particle Diagnostics – Part 5By Mo VandenBergh – VandenBergh & Associates

This series of articles focuses on the return of investment of particlediagnostic equipment. The first three articles focused on the “easy”applications – applications that proposed payback through comparison ofresults, recognizing questionable results compared to ones of a “knownpreferred or specified result”. A thorough understanding of each measurementor the measurement process and the precision of the measurements to someextent could be overlooked. Subsequent to the first three articles, articles 4 and5 require more precise measurements and will require a better understanding ofthe measuring processes.Part 4 of this series started the discussions of the more complex use of particlediagnostics in R&D Applications in examining payback by first presenting basicsof the most common measuring devices. This was approached by posing a seriesof seven questions followed with a brief presentation for each of the first fivequestions. This article will attempt to provide answers to the last twoquestions. All seven questions are provided below:

1. What diagnostic equipment is available?2. What are the physical setup capabilities and limitations?3. What characteristics are measured?4. How are the measurements collected?5. How are the measurements treated?6. What measurements can be collected and stored?7. How can the information be used?

In answering the last two questions this article will focus around only onemeasurement system; the one most familiar to the author and perhaps the onewith the most detailed information. With the discussion for each of the lasttwo questions, an early experience will be used to demonstrate the collectionand use of stored data.What measurements can be collected and stored?The diagnostic system used for this discussion (Oseir SprayWatch™) records

information at the command of the operator in addition to an automatic logsystem that will record a limited amount of data any time the system is inoperation and taking measurements or when there is a change in the system(on, off, change in profile, etc.) This automatic recording is made on selectableintervals, recorded in a folder named “log” and consists of entries similar to:

21:32:42Spray detected

21:32:52SprayTemp (deg C) 1810.84Velocity (m/s) 649.93Flux (a.u.) 37.46Position (mm) 5.70Heading (deg) 0.79Width (mm) 7.75Divergence (deg) 1.38.

As other measurements are only recorded when prompted, this is a valuabletool in looking back to see when a process may have undergone a significantevent or change.While required to start the diagnostic system for recording or playback, the

“profile” of the camera and display settings will be chosen. Some of theinformation can be changed for ease of viewing; some is for information onlywhile some of the settings will dictate how the system will perform. The ProfilePages chart on page 10 illustrates examples of some of the pages of the profile.

continued on page 10

SPRAYTIME advertising rates at www.spraytime.org


INDUSTRY

NEWS

The profile information is recorded along with the imageand will be present when in playback mode. If care is takenin correctly interring system information for a specificevent, subsequent events under the same situation, barringany process change, will show the same results.Beyond the recordings indicated above, the operator

chooses when and what to record and has basically twochoices:1. An html report - information similar to that shownbelow. This information can be collected and printedany time during monitoring of the thermal spray process

or during the playback of recordedimages. The report can be named andis stored in a reports folder with adate and time stamp. Time and dateas well as a description of the reportcan be added but are not shownhere.

2. A recording of one or more of thefollowing can be collected any timeduring the spray process for anynumber of images. Recordings can bemade on either individual particledata or the compound rollingaverage of the data.• Images• Running averages, from a selectednumber of images and or particles,

for:- Particle Temperature- Particle Velocity- Particle Flux/Count- Plume Position (vertical distance off center line ofgun axis at target)

- Plume Heading- Plume Width- Plume Divergence- Particle Temperature Standard Deviation- Particle Velocity Standard Deviation


11SPRAYTIME First Quarter 2009

- Particle Flux/Count Standard Deviation- Plume Position Standard Deviation- Plume Heading Standard Deviation- Plume Width Standard Deviation- Plume Divergence.

•Data from each particle highlighted in each imagecollected.Below is a typical image with measured particles high-

lighted. The vertical strips are wave length filters by whichthe temperature of the particles is measured using twocolor pyrometry. The curve on the right indicates therelative brightness distribution of the plume.

The following are examples of several lines of data thatare recorded in text files for “Average Data” and “ParticleData”.

How can the information be used?Once images are saved they can be replayed. During

replay, Images, Running Averages and Particle recordingscan again be recorded with some changes in the profilesuch as the number of images to include in the averagingcalculations or filters may be added in analyzing theimages. The obvious restriction in the replay is one cannotchange the image itself or the area or volume for which theimage was taken was captured.An early experience!During an exercise, in 2006, of comparing process cells of

an early model plasma gun (Torch 1), usingnitrogen/hydrogen and a fluidized feeder; according to themanufacturers’ recommended parameters; two interesting

trends were observed:1. A relatively high particle temperature for thematerial being sprayed

2. A highly variable range in the particle temperaturemeasured.

Both cells exhibited the same trend along with variationsbetween the cells.In an attempt to understand the process further the

plasma gun and powder feeder were swapped with aninternal feed, plasma gun (Torch 2), and a volumetricfeeder using suggested parameters and hardware whichcalled for argon/hydrogen gas. Also a much lower feed rateof material was used (approximately ½). This combinationproduced a much lower and stable average particletemperature (one only a couple of hundred degrees abovethe melting point of the material) as well as a highervelocity. The desired coating property measured 150% ofthe product being produced, while doing so at greaterenergy efficiencies, deposition efficiencies, and longerhardware life. No real effort was made to optimize theparameters.In order to compare data obtained from the two systems,

recording of images, running averages and particles werecollected and the average data was graphed for particletemperature, velocity and flux. The running average at thetime was 10 images. On page 12 you will find the graphs ofparticle temperature, velocity and flux/count shown afteranalyzing the images at a running average of 1 and 60images. Following the graphs is a table showing the results

of all the measurements under those conditions.One will notice from the graphs how long running

averages of the data can hide the variability of the processas was suggested in the discussion in article 4 under thequestion of how is the data treated.This experience is just a hint of the kind of information

that can be obtained through particle diagnostics. Onlytemperature and perhaps variability to some extent were ofmajor consideration in this example and while there weremany other reference points, many seem to place emphasison only two reference points:1. Particle Temperature2. Particle Velocity .

INDUSTRY

NEWS



INDUSTRY

NEWS

The other reference points are mostlybeing ignored and that may in some casesbe sufficient for monitoring results. It wasconfirming recently to see a supplierincorporate particle flight characteristics intheir product data sheet. For roughly thesame material chemistry as examined in theexperience shared in this article, thesupplier, using AccuraSpray, reported thefollowing with their equipment andsuggested parameters.Particle Velocity (m/sec) 150 to 155Particle Temperature (°C) 2150 to 2200This might suggest that the two available

measurement processes, SprayWatch(described in this article) and Accuraspray,may be able to produce similar results if allthat is needed to define or check a processis particle temperature and velocity? Withlack of extensive data for the manymaterials available, the added informationof plume dimensions, particle count, andparticle distributions could prove valuable.In keeping with the theme of payback,

changes made through this experienceprovided significant savings in material,energy, labor and hardware while adding tothe quality of the product. Unfortunately atthe time, little effort was placed onoptimizing the process or developing aquantitative return on investment.Articles to follow will share more field

experiences as well as new developments.For more information or if you have any

questions or suggestions, please contact MoVandenBergh at VandenBergh & Associates,Inc., 5641 Station Hill Dr., Avon, IN 46123,e-mail [email protected], tel:317.718.8403, www.MoVandenBergh.com

WHERE IS YOUR ARTICLE?The SPRAYTIME Editorial Staff encourages and

welcomes your contribution.

Do you need more than one copy ofSPRAYTIME at your facility?

Send an email request [email protected]



Cold Gas SprayingIncreasingly Accepted in Industry

New cold gas sprayingtechnology utilizing rarematerials has opened upmany new industrialapplications.After years of research

efforts in the field of coldgas spray techniques, thefirst fruits can now beharvested. As an additionto tried and testedprocesses, this newtechnique provides accessto markets which hadhitherto been excluded.Today's state-of-the-art

technology has generateda wealth of opportunitiesto discover new andinnovative applications ona scale never seen before.Those coating contractorswho have realized this andhave come on board arealready pioneering applications in industrial sectors and inprocesses that would have been impossible withconventional thermal spraying.Focus on process costIn the context of their research and development on hard-ware and substances, Linde has built up many new contactswith companies and so is constantly dealing with excitingand challenging questions. Process cost has always been atthe center of our research. Our ultimate ambition inadvancing cold gas spray technology has been to usenitrogen as a process gas. Applications requiring heliumwill continue to be employed, but only where the high costof the gas and its expensive recycling method justify this.Currently there are 50 such systems in operation world-

wide, installed in job shops and at research facilities;coating job shops account for about 30 percent of these.Within the last two years however, 80 percent of theequipment sold has been acquired by industry – evidencethat the benefits of potential new applications have beenreconsidered.New materials and applicationsCopper is nowadays of minor importance in cold gas

spraying. Meanwhile, expensive rare metals such asniobium, zirconium, tantalum or titanium have beenincreasingly in demand. Also, iron- or nickel-basedmaterials as well as copper-based alloys allow for newapplications.The tasks are of a wide variety. Only some of the new

possibilities will be mentioned here as examples: forinstance, the fabrication of geometrically complex sputtertargets, and their maintenance and repair; or bearing

carriers made of bronze alloys, which have far bettergliding properties due to their low oxide content; or ironalloys for cooking pots designed for inductive ceramic

cookpots; or contact surfaces on toggleswitches.Latest developments

Tantalum and zirconium have greatpotential as anticorrosive protective layersfor special appliances due to their extremelylow oxygen content. Many more novelapplications will be added in future. Some ofthe most recent areas of research attempt toproduce cold gas sprayed zinc coatingswhich can be etched by laser beams. Thesewould substitute for the thick copper layerswhich require machining by diamond-tippedtools.A technology with a future is the coating

of heat sinks for heavy-duty electroniccomponents.For more information, contact Werner

Kroemmer, Research and DevelopmentDepartment, Thermal Spray laboratory, LindeLtd., email: [email protected], web: www.linde-gas.com

• Powders/Wires • Spray Systems • Acoustial Rooms• Robotics• Dust Collectors• Chillers & Turntables

For nearly 30 years, industries have looked to HAI Advanced Material Solutions for

quality coating solutions. We offer the highest quality and the most complete line of thermal spay products for all your most demanding coating needs.

Call Today! 877-411-8971

Advanced Material Specialists, Inc.1688 Sierra Madre Circle, Placentia, CA 92870

• Quality Products • Large Inventory • Competitive Pricing • In House Tech Support • Worlwide & Next Day

Delivery

Quality Products & Service since 1979

Come visit us at the ITSC show in Las Vegas booth 135/137 or visitwww.haiams.com

dA van1688 S1688 Sierr

Quality Products & Service since 1979alQ lity Products & Service since 1979Quality Products & Service since 1979ity Products & Service since 1979uality Products & Service since 1979ty Products & Service since 1979ality Products & Service since 1979ty Products & Service since 1979lity Products & Service since 1979Prity Products & Service since 1979rooducts & Service since 1979Pr ducts & Service since 1979Pr ucts & Service since 1979ro cts & Service since 1979oducts & Service since 1979ts & Service since 1979ducts & Service since 1979ts & Service since 1979c &ts & Service since 1979Service since 1979ervice since 1979rvice since 1979Service since 1979vice since 1979Service since 1979ice since 1979r ce since 1979rvice since 1979evice since 1979since 1979ice since 1979ince 1979nce 1979since 1979ce 1979since 1979eince 19791ce 19799797979Q l ty Products & Service since 1979979

877-411-8971877-411-8971

pced Material Specialists,, Inc.Sie aar Mr adre Circle, Placentia, CA 92870re Circle, Placentia, CA 92870Circle, Placentia, CA 92870cle, Placcenc tia, CA 92870A 92870a Madre Circle, Placentia, CA 92870rS err

13

INDUSTRY

NEWS


CenterLine-SST Receives NRC-IRAP Supportfor New Advanced SolidState Spraying ProcessCenterLine (Windsor) Ltd. is

pleased to announce that it has received a contributionfrom the National Research Council Canada IndustrialResearch Assistance Program (NRC-IRAP). Subject to theterms of the agreement, CenterLine (Windsor) Ltd. willreceive approximately $400,000 over one and a half yearsin support of CenterLine’s efforts to develop a novel solidstate spraying process.Dr. Julio Villafuerte, head of research and development at

CenterLine, says that “the NRC¬IRAP support represents yetanother milestone for the company whose strategy is todiversify its customer base by creating innovative productsand services”. For over 50 years, CenterLine has been aleader in welding and joining for the automotive and masstransportation industries.In 2003, Centerline made a decision to develop and com-

mercialize low-pressure cold spray equipment. Cold spraytechnology, invented in Russia in the 1980s, allows theuser to spray metals on virtually any surface at lowtemperatures thus avoiding oxidation, material degradationand residual stresses, typical of traditional metal sprayingprocesses. The NRC-IRAP program was paramount to pushthe initial implementation of low-pressure cold spraytechnology by Centerline for field applications. Centerlinerecently adopted the commercialization of a novel methodinvented at the University of Ottawa. This new projectrepresents yet another milestone for solid-state spraying.This novel method also allows the spraying of hardermaterials such as titanium, steel, nickel, and cermets atincredible deposition efficiencies and rates while beingmore cost effective than current high pressure cold spraytechnology. The benefits of this method are similar toCenterline’s portable technology but for a wider range ofmaterials at higher deposition efficiencies and rates.Working directly with CenterLine, NRC-IRAP will provide arange of both technical and business oriented advisoryservices, along with financial support to help the enterpriseachieve its financial goals.For further information, please contact Julio Villafuerte,

Director of R&D, CenterLine (Windsor) Ltd., 595 MortonDrive, Windsor, Ontario, N9J 3T8, Canada, email:[email protected]

CO2 Cooling for Thermal Spray AdvancesBy David Jackson, Cool Clean Technologies and

Maurice (Mo) VandenBergh, VandenBergh & AssociatesSomething old is new again (only better)Conventional carbon dioxide (CO2) cooling and snow sprayor pellet blast cleaning technology has been available tothermal spray coating engineers for many years. Today,newer, much more capable and versatile CO2 technology isbeing introduced as new thermal spray process tools.Industries worldwide have investigated and implementedadvanced CO2-based clean manufacturing technology as analternative to energy-intensive, resource-wasting and pol-luting industrial processes. Western Digital, Pentel,Gillette-PaperMate, Raytheon, Seagate, Hughes, and TRWare examples of businesses that have implementedadvanced CO2 manufacturing technology in one form oranother and have improved the productivity, environmentalquality, and profitability of their operations (1-4).Although new to most thermal coating engineers, advancedCO2 technology promises several benefits. Advanced CO2composite sprays provide a unique combination of thermalspray process tools including surface preparation (i.e., bothetching and precision surface cleaning), temperaturecontrol during coating to increase target efficiency(increased percentage of time on the part) and cooling-lubrication during post-finishing (i.e., machining)processes.Advanced “CO2 composite spray” technologyCO2 sprays have been used commercially for cleaning and

cooling applications for many years. Properly designedconventional systems can be effective for a limited numberof cleaning or cooling applications. However, operatingcost is always a prime concern, along with a need foreffective process control, both of which have proven to bea challenge for conventional CO2 processes. This isparticularly true in high capacity applications. Moreover,adaptability to process tools has been very difficult.Advanced CO2 composite spray technology addresses the

drawbacks and limitations of conventional CO2 spraycleaning and cooling processes. CO2 composite spraytechnology provides several process control andperformance advantages. These include CO2 conservation,impact stress control, precise temperature control, additivetechnology, and easier adaptability to automation andprocess equipment. Moreover, CO2 composite spraytechnology has been adapted to address the needs ofmodern machining, providing near-dry to dry cooling-lubri-cation functions during processes such as turning, milling,stamping, and drilling. Figure 1 on page 16 illustrates thepatented, Coanda nozzle and composite spray technologyused in combining the components of the cooling spray.While Figure 2 presents a graph of the cooling spraytemperatures as the system is adjusted.

14

Would You Prefer to ReceiveSPRAYTIME Electronically?

If you would prefer to read the SPRAYTIME newsletteronline, please send an email [email protected] and let us know yourpreference.You can request an online version only (no print copy

will be sent to you) or both an online and a print copyWe will then send you an email message when the

next SPRAYTIME issue is ready to be viewed online.continued on page 16

INDUSTRY

NEWS


Referring to Figure 1, a CO2 composite spray has threeingredients; 1. CO2 particles having a certain size andconcentration, 2. clean compressed air (CA) having anadjustable pressure (P), temperature (T) and flow, and 3.optional additive component comprising an adjustablemicroscopic flow of liquids (i.e., lubricants) or solids (i.e.,micro-abrasives). The patented, Coanda nozzle technologyis used to combine the ingredients and deliver the spraycomposition to a surface. The ternary diagram abovesuggests a 70% air-30% CO2 composition.

Figure 2 shows an exemplary temperature profile for a CO2composite spray given the setup indicated in the top leftcorner (air at 80 psi and 67°F). As the percentage of CO2is increased, the temperature of the cooling streamdecreases. Spray temperatures as high as +300°F to lessthan -70°F can be produced depending upon a particularcomposition employed.Unlike high pressure liquids and gases, a CO2 composite

spray can generate impact stresses as high as 60 MPa, andmuch higher if micro-abrasive, solid additives are incorpo-rated within the spray composition. It is this physicalproperty, as well as the unique chemistry of CO2, that

provides the basis for its excellent cleaning, cooling andlubricating performance. For example, Figure 3 is a SEMphotomicrograph showing the ability of a CO2 compositespray to remove sub-micron aluminum oxide particles froma complex surface.

CO2 technology is a clean manufacturing solution forthermal spray engineersClean manufacturing practices are continuous preventive

measures that concentrate on optimizing manufacturingresources and processes to minimize or eliminate wastes ofvarious forms. Advanced CO2 technology reduces wastegeneration at the production operation level (source) bymodifying the manufacturing processes themselves. Forthermal spray processes, advanced CO2 composite spraytechnology provides a combination process modificationcapabilities, as follows:1. Surface preparation: micro-roughening, etching and

precision cleaning,2. Temperature control: maintenance of substrate surface

temperature during coating within an upper and lowercontrol boundary, and

3. Post-operations: precision cleaning and machiningoperations for following manufacturing procedures ordimensional requirements.

Replacing conventional surface cleaning agents with CO2’sgreen chemistry eliminates process inputs such as liquidcleaning solvents, aqueous clean agents, detergents,dionized rinse water, and heated air dryers, among otherwaste-producing inputs. For temperature control, theremarkable cooling efficiency of solid carbon dioxideparticles due to three-phase heat extraction involvingsublimation, boiling liquid and gas provide superior heatcapacity for maintaining surface temperatures duringthermal spray coating as compared to cold air or nitrogen.Another benefit is that the cooling spray is also a very

energetic cleaning spray, which simultaneously dislodgesloosely adhering coating particles during the coatingprocess. In post-coating operations, CO2-based advancedminimum quantity cooling lubrication (AMQCL) replacesflooded cutting fluids and associated waste-producingoperations such as metalworking fluids management, wastehauling and air pollution control. In particular CO2machining fluid technology enables the economic use ofadvanced cutting tools employing diamond or CBN formachining hard or abrasive substrates, while deliveringimproved surface finish and cleanliness.

16

Fig.1 CO2 composite spray technologyfor cleaning, cooling and machining.

Fig.2 Precise spray temperature control.

Fig.3 Precision sub-micron particle and film removal.


INDUSTRY

NEWS




INDUSTRY

NEWS

DeWAL Industries, Inc.

15 Ray Trainor Drive, P.O. Box 372 Saunderstown, RI 02874

www.dewal.com [email protected] (International: 001-401-789-9736)

DeWAL Industries offers the highest quality, most complete line of thermal spray tapes — aluminum foil, fiberglass fabric, silicone-impregnated fiberglass, and combinations of these materials.

For wire arc and HVOF, DeWAL double-ply tapes reduce set-uptime and withstand the harshest environments. DeWAL tapes canbe single-ply or multi-layer.

DeWAL tapes adhere aggressively, ensuring sharp edges, resist-ing temperatures to 1000°F, and removing cleanly after spraying.

Call DeWAL today, then thermal spray away.

Quality Approvals: GE, Pratt & Whitney, Rolls Royce, etc.

STICK WITH THE BESTDeWAL Thermal Spray TapesSTICK WITH THE BESTDeWAL Thermal Spray Tapes

Since there are a number of potential applications for theCO2 beyond just cooling parts during thermal spray andbecause there are a number cooling processes andassociated costs, the next article will discuss the benefitsof using CO2 vs. other gases and cleaning processes from anenvironmental and cost basis.Summary

Benefits of Using CO2 CoolingWith the Thermal Spray Process

Thermal Spray Coating Benefits•Decreased cleaning and handling cost

Time, materials and disposal•Increased target efficiencies

Powder savingsEnergy savingsFaster coating timesIncreased productionGreater capital utilizationDecreased labor per part

•Improved coating characteristicsCleaner interfaceControlled coating stress

Improved Post-Coating Benefits•Longer machining tool life•Higher machining speeds/feeds

•Precise thermal control of machining•Elimination of cooling liquid contamination

Cooling System Features•Transportable•Most efficient cooling and cleaning process•Low capital expenditure•Low operating costsFor more information please contact: David Jackson,

Chief Technology Officer for Cool Clean Technologies by e-mail: [email protected] or telephone:661-775-5964 or Mo VandenBergh by phone: 317-718-8403, e-mail, [email protected] or by web:www.MoVandenBergh.com

New Brochure Describes Hemipleat® RetrofitDust Collector Cartridges

A new brochure from Farr Air Pollution Control (APC)makes it easy to retrofit existing dust collection equipmentwith Farr HemiPleat®filters for upgradedperformance. The four-page brochure describesthe full line of“HemiPleat RetrofitCartridges”, using asimple cross-referencetable and orderingchart to facilitatefilter selection forvirtually any type ofc y l i n d r i c a lc a r t r i dge - s t y l ecollector.HemiPleat filters offer the proven

ability to enhance performance or solve problems ofexisting dust collection systems. The filters use an award-winning “open pleat” media technology that results inmore effective cleaning and better airflow, leading to longelement life and excellent energy performance. Theadvanced high efficiency “PolyTech™” media is available infive standard types to meet different performancerequirements. Media choices and other product features andbenefits are detailed in the new brochure.For further information, contact Farr APC at (800) 479-

6801; fax (800) 222-6891; or write to Farr APC, 3505 S.Airport Road, Jonesboro, AR 72401; e-mail [email protected]; web www.farrapc.com. For adownloadable copy of the brochure, go to:http://www.farrapc.com/literature/data-sheets/retrofit-cartridge.pdf.

C a l l F o r Pa p e r sNew Developments in Thermal Spray Coatings,

Processes and Applications ConferenceStory on page one.


INDUSTRY

NEWS

Praxair Surface Technologies IntroducesClosed-Loop Controlled Powder Feeders ThatBoost Productivity and Improve ConsistencyPraxair Surface Technologies Inc., a wholly-

owned subsidiary of Praxair Inc. (NYSE: PX),today introduced TAFA models 1264i and1264WL closed-loop controlled powder feeders.The 1264i powder feeder is a major redesign ofthe world renowned model 1264 feeder thatincludes latest generation electronics, improvedergonomics, and enhanced features current 1264feeder users desired to help boost productivity,reduce costs, and improve consistency. The1264i feeder includes a sophisticated touch-screen operator interface terminal (OIT)pendant that can be remotely located, a pro-grammable logic controller (PLC) for powderfeeder control, state-of-the-art electronics,and a removable, expanded-capacity powderhopper .

Based on the proven, volumetric-feedtechnology of the model 1264 feeder, the1264i feeder increases powder feed accuracy by close-loop-ing rpm control of the feed wheel. For even more improvedpowder feed accuracy and reliability, the model 1264WLfeeder offers weight-loss control capability.Increased spray timeThe 1264i feeder incorporates a quick-change hopper that

holds 30 % more powder than previous generation hoppers.The new hopper has a capacity

of 300 in.3 (4916 cc) and israted for pressures ofup to 125 psi (862kPa). The designallows for rapidhopper replacementreducing downtimewhen switchingbetween powdersand preventing

cross-contaminationby dedicating a hopper for

each type of powder. Spare hop-pers can be used for storage of

excess powder. An optional hopper storage rack allowssafe storage of spare hoppers and includes receptaclesfor heater blanket plug-in.Control powder feed rate by weightThe model 1264WL powder feeder includes all the

features of the model 1264i feeder as well as load celltechnology that delivers an enhanced level ofreliability in weight-loss control of the powder feedrate. Through rapid weight-loss over timecalculations, the 1264WL feeder automatically cali-brates the powder feeder to the pre-programmedpowder feed rate and maintains that feed rate for theduration of the spray run.

About Praxair Surface TechnologiesPraxair produces and markets high-performance coatings

that reduce the harmful effects of abrasion, oxidation,corrosion, erosion, wear and extreme temperatures on

metal parts for the aviation, power generation, oilfield,transportation, and printing industries as well as

thermal spray equipment and powder.Praxair Inc. is the largest industrial gasescompany in North and South America,and one of the largest worldwide, with2008 sales of $10.8 billion. Thecompany produces, sells and distributesatmospheric, process and specialtygases, and high-performance surfacecoatings. Praxair is a recognized leaderin the commercialization of newtechnologies that bring productivity and

environmental benefits to a diverse group ofindustries, including aerospace, chemicals,

electronics, energy, food and beverage, healthcare,manufacturing, metals and others.For more information on Praxair, visit www.praxair.com

or www.praxair.com/thermalspray.

Optionalspare hopperstorage rack.

Model 1264WLpowder feeder.

Nation Coating Systems501 Shotwell Dr. Franklin, OH 45005

www.NationCoatingSystems.com

Creative Thermal Spray Coating Solutions

p:(888) 665-5525f: (937) 746-7658

• Met Lab for Testing, R&D, Material Applications• Spray Booth devoted to R&D• Coating Technology includes HVOF, Plasma, Arc Spray

Aerospace, Military, Power Generation, Automotive, Petrochemical, Pulp & Paper, Printing, General Industrial

Call us to discuss your coating challenges - We can help!

International Thermal SprayLaunches New Website

The ITSA website now includes an “employment” and“for sale” area.

SPRAYTIME issues are included in this website withcontent search capability.

Visit www.thermalspray.org to see our new look andvaluable industry information.

Would You Prefer to ReceiveSPRAYTIME Electronically?

If you would prefer to read the SPRAYTIME newsletteronline, please send an email [email protected] and let us know yourpreference.You can request an online version only (no print copy

will be sent to you) or both an online and a print copyWe will then send you an email message when the

next SPRAYTIME issue is ready to be viewed online.


Sulzer Celebrates 175th Anniversary(Following is the introduction to new Sulzer publications.)“Dear readers,Experience Sulzer: This is the motto with which our

company celebrates its 175th anniversary in 2009. We wantto show what the Sulzer name stands for. Our vision is tobe a recognized leader in innovative, sustainable,engineered, and customer-focused solutions forperformance-critical applications in six main markets: theoil and gas, hydrocarbon processing, power generation,pulp and paper, aviation, automotive and other selectedindustries. The focus of this anniversary publication is howSulzer products and services provide solutions to make ourcustomers more competitive.Since its founding in 1834, Sulzer has been a reliable

partner, satisfying high expectations and delivering what itpromises. From the beginning, Sulzer has transformed thelatest engineering know-how into innovative solutions toserve customers’ needs. From very early on, Sulzer hastaken a global approach, building a worldwide client basewhile establishing a multi-local presence. This is howSulzer has become what it is today: a technology companythat continually renews itself, resulting in leadingpositions in important global markets.From the industrialization of the 19th century to the high-technology society of the 21st century, priorities andchallenges have changed dramatically. In the past, Sulzer’ssteam and diesel engines contributed significantly to thesechanges—replacing the need for heavy human labor withmachinery. Today, the challenge is to satisfy an increasingdemand for oil and gas, electricity, mobility and paperwhile ensuring that natural rescources are used efficientlyin order to minimize the enviromental impact.Reliability, innovation and global thinking remain essen-

tial for Sulzer to master the chalIanges of the future. Indoing so, we thank our 12,500 employees for their sus-tained dedication and our clients around the world for theircontinued trust.Enjoy the reading.”

Ton Büchner, CEOFor more information on these publications, visit

www.sulzer.com

PAS Technologies Received Best EmergingBusiness Improvement Deployment AwardPAS Technologies announced today that it has been

selected as the winner for the Global Six Sigma andBusiness Improvement Awards in the category of “BestEmerging Business Improvement Deployment.” The awardwas accepted on behalf ofall PAS Technologies’employees by RobertWeiner (right), Presidentand CEO at the WCBF 2008Gala Awards Dinner andCeremony on Wednesday,October 15th at TheGaylord Palms Resort andConvention Center inOrlando, Florida.Robert Weiner, President

and CEO said. “This awardis a testament to the hardwork and dedication ofour employees. The greatthing is that when PASTechnologies wins awardsfor process improvements,it is an indication thatour customers are winning, too – through the best deliverytimes, quality and customer satisfaction. ”The Global Six Sigma and Business Improvement Awards

are given to companies and individuals who demonstratethe most outstanding organizational achievements throughthe deployment of business improvement programs. Thefocus of the awards program is to demonstrate to the glob-al business community the real results and excellence thatorganizations achieve through the successful deploymentof Six Sigma and other business excellence programs.

A privately held corporation headquartered in NorthKansas City, Missouri, PAS Technologies Inc., specializes inproviding cost-effective repair and overhaul solutions forthe aerospace, oilfield and industrial markets. By usinginnovative and proprietary high-technology repairprocesses, along with repair solutions licensed from OEMs,the company saves its customers from having to purchasecostly replacement parts. It services a broad range ofcomponents, including gas turbine engines, critical air-frame parts, gates and seats used in oil fields, specializedprovider of services to the power generation industry, andcomponents used in other industrial high-wear, high-heatand highly corrosive environments.For more information, visit www.pas-technologies.com

20

INDUSTRY

NEWS

Search back issues of SPRAYTIME atwww.spraytime.org




Praxair Surface Technologies Unveils 8830MHU Arc SpraySystem with Enhanced Features and Improved Controls

Praxair Surface Technologies Inc., a wholly-owned subsidiary of Praxair Inc.(NYSE: PX), today unveiled the TAFA 8830MHU arc spray system featuring state-of-the-art features and controls.

The 8830MHU arc spray system, the latestgeneration design of the world renownedmodel 8830 system, uses advances in arcspray technology to enhance quality,repeatability, and versatility of arcspraying. The 8830MHU system controlconsole can now be unbundled formaximum application versatility.Enclosed wire covers and console-mounted voltage control andamperage readout allow for easieruse, and safe, precise operation.Enhanced Power Supply

An optional, enhanced powersupply developed exclusivelyfor arc spray operation resultsin smoother operation, higherdeposit efficiencies of mostmaterials, and improvedcoatings. The TAFA 353ECVpower supply utilizes sophisti-cated control technology thatminimizes operating arc volt-

age to reduce coating oxidelevels and, depending upon material

being sprayed, significantly increasedeposit efficiency.

25-Years Later: TAFA 8830 Arc Spray Gun Remains the Industry StandardThe extra heavy-duty, 350-amp TAFA 8830 arc spray gun, featuring precision

spray rate, has been the industry standard for reliable arc spraying for over 25years. Design features include reliable air turbine driven wire drive motor,integrated high velocity, focused spray pattern alignment housing, quickdisconnect wire conduits, and a proven, robust drive design. Options includeArcJet® spray attachment for aircraft quality coatings as well as fan-spray andantiskid attachments.

For more information on Praxair, visit www.praxair.com orwww.praxair.com/thermalspray.ArcJet® is a trademark of Praxair Technology, Inc. in the United States and/or

other countries.

21

INDUSTRY

NEWS

Prefer to Receive SPRAYTIME Electronically?If you would prefer to read the SPRAYTIME newsletter online, please

send an email request to [email protected] can request an online version only (no print copy will be sent to

you) or both an online and a print copyWe will then send you an email message when the next SPRAYTIMEissue is ready to be viewed online.

WHERE IS YOUR ARTICLE? The SPRAYTIME EditorialStaff encourages and welcomes your contribution.

Ardleigh can ship all of yourrecyclable materials on one truck, at one time.

Ardleigh Minerals’ Thermacycle™

process enables complete recycling of dust collector filters, tape and other mask materials. Ardleigh accepts a broad range of materials for recycling including:

silicon carbide, glass, plastic and shot)

and turnings

from thermal spray, plasma spray and HVOF—includingpowders and dusts, solids, sludges and cakes containing chromium, cobalt, copper, indium, molybdenum, nickel and tungsten, as well as

Corporate offices are located in Shaker Heights, OH. Facilities are located in Cleveland, OH; Augusta, GA; and Houston, TX.

T: 216-921-6500 F: 216-921-3840

www.ardleigh.net

ONE-STOP RECYCLING FOR THE THERMAL SPRAY INDUSTRY

TheMinerals’Ardleigh

one time.oonmaterialsrecyclableashipcanArdleigh

Y INDUSTRSPRAAY INDUSTRFOR THE THERMAL

ONE-STOP RECYCLING

™ermacycle

attruck, oneyour ofall

YSTRRMALYCLING

and shot)silicon carbide, glass

for recycling including:orangebroadaaccepts

materialsmaskotherfilterscollectordustof

completenablesprocessTheMineralsArdleigh

s, plastic

materials ofArdleigh s.

andtapes,recycling te

ermacycle

and tungsten as well as indium, molybdenum, nickel chromium, cobalt, cosludges and cakes copowders and dusts, sspray and HVOF—in

, pfrom thermal sprayy, plasma

and turnings

l asm, nickel

,opperontaining solids, ncluding plasma

GA; and Houston, TX.OHCleveland,inlocatedFaOH.Heights,Shaker

areofficesCorporate

and tungsten, as well as

Augusta, H;areacilities

inlocated

l as

.ardleighwwwF: 216-921-38: 216-921-65T

h.net840500

J O B SHO P M EMB E R COMPAN I E SAccuwright Industries, Inc. - Gilbert, AZ, USA

www.accuwright.com 480.892.9595Mr. David Wright, [email protected]

BASF Catalysts LLC - East Windsor, CT USAwww.basf.com 860.623.9901Mr. Marc Froning,[email protected]

Bender USVernon, CA USA www.benderus.com 323.232.2371Mr. Doug Martin, [email protected]

Cascadura Industrial S.A. - Sorocaba SP Brazilwww.cascadura.com.br 55.15.3332.9622Mr. Ricardo Leoni, [email protected]

Cincinnati Thermal Spray, Inc. - Cincinnati, OH USAwww.cts-inc.net 513.793.0670Mr. Bill Menth, [email protected]

Ellison Surface Technologies, Inc. - Cincinnati, OH USAwww.ellisonsurfacetech.com 513.770.4924Mr. Tim Perkins, [email protected]

Exline, Inc. - Salina, KS USAwww.exline-inc.com 785.825.4683Mr. Doug Porter, [email protected]

F.W. Gartner Thermal Spraying - Houston, TX USAwww.fwgts.com 713.225.0010Mr. Jimmy Walker, [email protected]

Ferrothermal Spray Coating - Monterrey N.L. Mexicowww.drexel.com.mx 52.818.331.0816Mr. Renato Drexel, [email protected]

Harper Corporation of America - DePere, WI USAwww.harperimage.com 704.588.3371Mr. Lee Kluttz, [email protected]

Hayden Corporation - West Springfield, MA USAwww.haydencorp.com 413.734.4981Mr. John O. Hayden, [email protected]

Nation Coating Systems - Franklin, OH USAwww.nationcoatingsystems.com 937.746.7632Mr. Larry Grimenstein, [email protected]

National Coating Technologies Inc. - Winnipeg, MB Canadawww.nationalcoating.com 204.632.5585Mr. John Read, [email protected]

Nooter Construction Company - Trevose, PA USAwww.nooterconstruction.com 215.244.3526Mr. Mike Murphy, [email protected]

Plasma Coatings - Union Grove, WI USAwww.plasmacoatings.com 262.878.2445Mr. Daniel Cahalane, [email protected]

Plasma Technology, Inc. - Torrance, CA USAwww.ptise.com 310.320.3373Mr. Robert D. Dowell, [email protected]

St. Louis Metallizing Company - St. Louis, MO USAwww.stlmetallizing.com 314.531.5253Mr. Joseph P. Stricker, [email protected]

Soleras LTD - Biddeford, ME USAwww.soleras.com 207.282.5699Mr. Guy Laverriere, [email protected]

Spraymetal, Inc. - Houston, TX USA713.921.0012Mr. Jim Hollingsworth, [email protected]

Superior Shot Peening, Inc. - Houston, TX USAwww.superiorshotpeening.com 281.449.6559Mr. Albert Johnson, [email protected]

Thermal Spray Technologies, Inc. - Sun Prairie, WI USAwww.tstcoatings.com 608.825.2772Mr. Bill Lenling, [email protected]

United Surface Technologies - Altona, Melbourne Australia61.393.98.5925Mr. Keith Moore, [email protected]

S U P P L I E R M EMB E R COMPAN I E S3M Abrasive Systems Division - St. Paul, MN USA

www.mmm.com 800.362.3550 or 651.736.5459Mr. Troy Heuermann, [email protected]

Air Products and Chemicals - Allentown, PA USAwww.airproducts.com/metals 800.654.4567Mr. Stewart Stringer, [email protected]

Alloy Sales - Delta, BC Canadawww.alloysales.com 604.940.9930Mr. Randy Eckert, [email protected]

AMETEK, Inc. - Eighty-Four, PA USAwww.ametekmetals.com 724.250.5182Mr. Richard Mason, [email protected]

Ardleigh Minerals, Inc. - Shaker Heights, OH 44122 USAwww.ardleigh.net 216.921.6500Mr. Ernie Petrey, [email protected]

Bay State Surface Technologies, Inc. - Auburn, MA USAwww.baystatesurfacetech.com 508.832.5035Mr. Jay Kapur, [email protected]

Carpenter Powder Products - Pittsburgh, PA USAwww.carpenterpowder.com 412.257.5102Mr. Chip Arata, [email protected]

Centerline Windsor Limited - Windsor, ON Canadawww.supersonicspray.com 519.734.8464Mr. Julio Villafuerte, [email protected]

Deloro Stellite Company, Inc. - Goshen, IN USAwww.stellite.com 574.534.8631Mr. David A. Lee, [email protected]

Donaldson Company, Inc. - Minneapolis, MN USAwww.donaldson.com/en/industrialair 800.365.1331Ms. Lori Lehner, [email protected]

Ecka Granules of America - Orangeburg, SC USAwww.ecka-granules.com 803.536.0215Mr. Nic Veloff, [email protected]


Farr APC - Jonesboro, AR USAwww.farrapc.com 800.479.6801Mr. Lee Morgan, [email protected]

Flame Spray Technologies, Inc. - Grand Rapids, MI USAwww.fst.nl 616.988.2622Mr. Terry Wilmert, [email protected]

Fujimi Inc. - Arlington Heights, IL USAwww.fujimico.com 847.398.6544Mr. Michael Akiyoshi, [email protected]

Genie Products, Inc. - Rosman, NC USAwww.genieproducts.com 828.862.4772Mr. Richard Grey, [email protected]

Green Belting Industries LTD - Mississauga, ON, Canadawww.greenbelting.com 905.564.6712Mr. Tim Connelly, [email protected]

Global Tungsten and Powders Corp - Towanda, PA USAwww.globaltungsten.com 570.268.5398Mr. Paul Sedor, [email protected]

H. C. Starck, Inc. - Newton, MA USAwww.hcstarck.com 513.942.28155Mr. Jim Ryan, [email protected]

HAI Advanced Material Specialists - Placentia, CA USAwww.hardfacealloys.com 877.411.8971Mr. Daren Gansert, [email protected]

Haynes Wire Company - Mountain Home, NC USAwww.haynesintl.com 828.692.5791Mr. Jeff Smucker, [email protected]

Kennametal - Houston, TX USAwww.kennametal.com 281.387.4287Mr. Eric Hanson, [email protected]

Lineage Aloys - Baytown, TX USAwww.lineagealloysllc.com 281.426.5535Mr. Gordon Jones, [email protected]

Linde Gas USA LLC - Murray Hill, NJ USAwww.us.linde-gas.com 908.771.1353Dr. Joe Berkmanns, [email protected]

Metallisation LimitedDudley West Midlands, United Kingdomwww.metallisation.com +44.1384.2524646Dr. Terry Lester, [email protected]

North American Höganäs - Hollsopple, PA USAwww.hoganas.com 814.361.6857Mr. Jim Morris, [email protected]

Northwest Mettech CorporationNorth Vancouver, BC Canadawww.mettech.com 604.987.1668Mr. Alan Burgess, [email protected]

PM Recovery, Inc. - Harrison, NY USAwww.pmrecovery.com 860.536.5396Mr. Paul Sartor, [email protected]

Parker Hannifin, domnick hunter DivisionCharlotte, NC USAwww.domnickhunter.com 800.345.8462Mr. Jim Tomczyk, [email protected]

Polymet Corporation - Cincinnati, OH USAwww.polymet.us 513.874.3586Mr. Bob Unger, [email protected]

Praxair Surface Technologies - Concord, NH USAwww.praxair.com/thermalspray 603.224.9585Mr. Richard Thorpe, [email protected]

Progressive Technologies, Inc. - Grand Rapids, MI USAwww.ptihome.com 800.968.0871Mr. Bill Barker, [email protected]

Saint-Gobain Ceramic Materials - Worcester, MA USAwww.coatingsolutions.saint-gobain.com 508.795.2351Mr. Howard Wallar, [email protected]

Sulzer Metco (US) Inc. - Westbury, NY USAwww.sulzermetco.com 516.334.1300Ms. Mae Wang, [email protected]

Thermach, Inc. - Appleton, WI USAwww.thermach.com 920.779.4299Mr. David Lewisen, [email protected]

Thermion, Inc. - Silverdale, WA USAwww.thermioninc.com 360.692.6469Mr. Dean Hooks, [email protected]

A S S O C I AT E M EMB E R ORGAN I Z AT I ON SAdvanced Materials and Technology Services, Inc.

Simi Valley, CA USAwww.adv-mts.com - 805.433.5251Dr. Robert Gansert, [email protected]

ASM Thermal Spray Society - Materials Park, OH USAwww.asminternational.org 440.338.5151Mr. Thom Passek, [email protected]

State University of New York at Stony BrookStony Brook, NY USAwww.matscieng.sunysb.edu/tsl/ctsr 631.632.8480Prof. Sanjay Sampath, [email protected]

The Zanchuk Group, LLC - Concord, NH USAwww.zanchuk.com 603.226.3712Mr. Val Zanchuk, [email protected]

S U P POR T I N G S O C I E T I E SGTS e.V., the Association of Thermal Sprayers

Höllriegelskreuth, Germanywww.gts-ev.de +49.89.31001.5203Mr. Werner Kroemmer, [email protected],

23

International Thermal Spray AssociationHeadquarters Office

208 Third Street • Fairport Harbor, Ohio 44077voice: 440.357.5400 • fax: 440.357.5430

email: [email protected]: www.thermalspray.org



The International Thermal SprayAssociation is closely interwoven with

the history of thermalspray developmentin this hemisphere.Founded in 1948,and once known as

Metallizing ServiceContractors, theassociation has beenclosely tied to most majoradvances in thermal spraytechnology, equipment andmaterials, industry events,education, standards andmarket development.A company-member tradeassociation, ITSA invites allinterested companies totalk with our officers,committee chairs, and

company representatives to better understand memberbenefits. A complete list of ITSA member companies andtheir representatives are at www.thermalspray.org

ITSA Mission StatementT h e I n t e r n a t i o n a l T h e rm a l S p r a y

A s s o c i a t i o n i s a p r o f e s s i o n a l t r a d eo r g a n i z a t i o n d e d i c a t e d t o e x p a n d i n g t h eu s e o f t h e rm a l s p r a y t e c h n o l o g i e s f o rt h e b e n e f i t o f i n d u s t r y a n d s o c i e t y.

OfficersChairman: Marc Froning, BASF Catalysts LLCVice-Chairman: Dan Hayden, Hayden CorporationTreasurer: Bill Mosier, Polymet CorporationExecutive Committee (above officers plus)Corporate Secretary: Kathy DusaJohn Read, National Coating TechnologiesScott R. Goodspeed, H. C. Starck, Inc.John Hayden, Hayden CorporationJoseph Stricker, St. Louis Metallizing Company

ITSA Scholarship OpportunitiesThe International Thermal Spray Association offers annual

Graduate Scholarships. Since 1992, the ITSA scholarshipprogram has contributed to the growth of the thermal spraycommunity, especially in the development of newtechnologists and engineers. ITSA is very proud of thiseducation partnership and encourages all eligibleparticipants to apply. Please visit www.thermalspray.org forcriteria information and a printable application form.

ITSA Thermal Spray Histor ica l Col lect ionIn April 2000, the International Thermal Spray

Association announced the establishment of a ThermalSpray Historical Collection which is now on display at theirheadquarters office in Fairport Harbor, Ohio USA.Growing in size and value, there are now over 30 differentspray guns and miscellaneous equipment, a variety of spraygun manuals, hundreds of photographs, and severalthermal spray publications and reference books.Future plans include a virtual tour of the collection on theITSA website for the entire global community to visit.This is a worldwide industry collection and we welcome

donations from the entire thermal spray community.

ITSA SPRAYTIME NewsletterSince 1992, the International Thermal Spray Association

has been publishing the SPRAYTIME newsletter for thethermal spray industry. The mission is to be the flagshipthermal spray industry newsletter providing company,event, people, product, research, and membership news ofinterest to industrial leaders, engineers, researchers,scholars, policy-makers, and the public thermal spraycommunity.

For a free SPRAYTIME subscription, visitwww.spraytime.org and complete the short questionairre.

ITSA Headquarters208 Third Street, Fairport Harbor, Ohio 44077 USA

tel: 440.357.5400 fax: [email protected] www.thermalspray.org

Chairman Froning

INTERNATIONAL

THERMAL

SPRAY

ASSOCIATION

SCHOLARSHIP OPPORTUNITIESUp to three(3) Graduate scholarships worth$2,000.00 each to be awarded each calendar

year.Since 1991, the ITSA Scholarship Program has

contributed to the growth of the Thermal SprayCommunity, especially the development of newtechnologists and engineers. The International ThermalSpray Association is very proud of this educationpartnership and encourages all eligible participants toapply.

New Application Dates:Scholarship applications are now acceptedannually April 15 through June 30 ONLY.

Please visit WWW.THERMALSPRAY.ORG Scholarship areafor details and a printable application form.


Become a Member of TheInternational Thermal Spray

AssociationYour company

should join theI n t e r n a t i o n a lThermal Spray

Association now! As a company-member, professionaltrade association, our mission is dedicated to expandingthe use of thermal spray technologies for the benefit ofindustry and society.ITSA members invite and welcome your company to join

us in this endeavor.Whether you are a job shop, a captive in-house facility,

an equipment or materials supplier, an educational campus,or a surface engineering consultant, ITSA membership willbe of value to your organization.

The most valuable member asset is our annualmembership meetings where the networking is priceless!Our meetings provide a mutually rewarding experience forall attendees - both business and personal. Our one dayTechnical Program and half day business meeting balancedby social activities provide numerous opportunities todiscuss the needs and practices of thermal spray equipmentand processes with one another.

As an ITSA member, your company has excellentmarketing exposure by being listed on our website, in everyissue of SPRAYTIME, as well as in our free edition of “WhatIs Thermal Spray?”. ITSA members also receive anadditional 10% advertising discount in the SPRAYTIMEnewsletter. ITSA member companies are also highlightedin the ITSA booth at several trade shows throughout theyear (International Thermal Spray Conference ITSC, FabtechInternational and AWS Welding Show Thermal SprayPavilion, Weldmex Mexico, and TurboExpo in 2008).If you would like to discuss the benefits of your

company becoming a member of the International ThermalSpray Association, we suggest you contact Kathy Dusa atour headquarters office or our membership chairman JimRyan at [email protected] or visit the membershipsection of our www.thermalspray.org website.

International Thermal SprayLaunches New Website

The ITSA website now includes an “employment” and“for sale” area.

SPRAYTIME issues are included in this website withcontent search capability.

Visit www.thermalspray.org to see our new look andvaluable industry information.

ITSA Announces “SupportingSocieties” Membership Category

The International Thermal Spray Association is pleasedto announce a new “Supporting Societies” membershipcategory. The purpose of this category is to establishcommunication with other associations/societiesinvolved in thermal spray and surface engineeringactivities.This is an ideal method for membership exchange

between organizations. If your organization isinterested in a membership exchange to belong to theInternational Thermal Spray Association, please contactKathy Dusa at the headquarters office via email [email protected]

International Thermal Spray AssociationWelcomes New Member

Ecka Granules of America LLC has joined theInternational Therml Spray Association.

ECKA Granules is one of theworld's leading manufacturer ofnon-ferrous metal powders,with 18 production units around

the globe. ECKA's performance is based in the areas ofMetal Powder- Technology, Alloying-Technology andApplication-Technology. Our direct proximity to customerscan be seen in our global network with over 38 salesoffices.

The productionprogram comprisesthe manufacture ofnon-ferrous metalpowders from thepure metals ofcopper, aluminiumand magnesium andtheir alloys; Ecka®Powders such asgas/air and water-atomized copper andcoper-alloyed powders, powders of nickel and cobalt basedalloys for thermal spraying applications (including HVOF,

Plasma, PTA and Coldprayapplications). ECKA® Standardpowders gives a wide choice ofalloy compositions and hadnessvalues to satisfy customer needs.The products are supplied aspowders, granules and finishedmixed products.

For more information, contact ITSA companyrepresentative Nic Veloff, General Manager of Sales andTechnical Support, Ecka Granules of America L.L.C., 500Prosperity Drive, Orangeburg, SC 29116, tel: 803.536.0215,fax: 803.536.0516, email: [email protected], web:www.ecka-granules.com


Upcoming, Low Worker Safety Numbers andYour Thermal Spray Process

California OSHA UpdateBarbara Kanegsberg, BFK Solutions LLC

As is evident from the impact of the decreased allowableexposure levels for Cr(VI), worker inhalation numbers thatare set for airborne chemicals can have a major impact onthermal spray operations. While companies and professionalorganizations may recommend worker exposure levels,OSHA (Federal OSHA) can set legally-enforceable inhalationlevels such as a PEL (Permissible Exposure Limit); so cansome state agencies such as Cal/OSHA (California OSHA,please see “A Brief Guide through the Alphabet Soup”). Ihave been attending Cal/OSHA PEL process meetings forseveral years now. Now that a new PEL process that wasadopted in March, 2007 is underway, I am starting a seriesof articles to keep ITSA and the thermal spray industryinformed about pertinent events in the Cal/OSHA PELprocess and about specific chemicals of interest.Low California PEL’sThe new Cal/OSHA PEL process may impact your thermal

spray operation. Cal/OSHA uses a risk assessment paradigmthat increases the likelihood of much lower PEL’s andrelated worker safety numbers. Because the lower numberswill be legally-enforceable throughout California, in myestimation, there is almost certain to be a “ripple effect”,

an impact on industry throughout the United States,whether or not the levels are adopted nationwide by OSHA.The lower the PEL, the lower the amount of chemical that

employees can be exposed to. Low PEL’s tend to translateto increased controls and more reporting requirements, aswell as higher capital and process costs. If the number islow enough, companies may be impelled to chemicalsubstitution. Especially for components and products thatare critical to health, public safety, and/or to mission-readiness; research and validation are required to minimizerisks related to such substitution.Risk Asessment

In the California process, a Health Experts AdvisoryCommittee (HEAC) first evaluates the chemical underconsideration and recommends a PEL or some other workerexposure level. Table 1 shows the worker exposure levelsthat are currently under discussion by the HEAC; exposurelevels set or recommended by other groups are shown forcomparison. Please note that “under discussion” is not thesame as “done deal.” Table 2 on page 26 shows selectedchemicals that would be expected to be of particularinterest to ITSA members and to those involved in thermalspray and/or engineered coatings. These chemicals havebeen prioritized as “1” or “2” by Cal/OSHA staff, so theyare likely to be discussed sooner rather than later. The pri-oritization list seems to be rather fluid; and because somepriority 2 compounds have already been assigned to HEAC

26

INDUSTRY

NEWS


members, they are likely to be discussed in the near future.The HEAC evaluation is based on risk assessment, typicallyusing animal studies. Generally, studies on worker popula-tions have not been accepted because of the presence of“confounding factors.” That is, despite what you may think,industry does not keep workers caged up like lab rats.Further, people at work are typically exposed to a largervariety of chemicals than are animals in a controlled study,so it tends to be more difficult to pin down cause andeffect. However, employing a rigorous risk assessmentapproach means that even where a chemical has been usedindustrially for decades and decades without apparent illeffect, the absence of observable problems in the workerpopulation is not considered in the risk assessment. If apublished animal study indicates an effect, even at a highconcentration of chemical, this impact is considered in rec-ommending a PEL.

OEHHA InfluenceThe HEAC process is heavily assisted by an agency that is

separate from Cal/OSHA, OEHHA (Office of EnvironmentalHealth Hazard Assessment). OEHHA is a California agencyinvolved with environmental and community, risk assess-ment. Among other things, OEHHA sets the risk assessmentnumbers that are used to establish the Proposition 65 list.Proposition 65 requires businesses to post warnings if alisted chemical might be present; the signs are ubiquitousand are found at such establishments as the local super-market. OEHHA uses an academic, risk assessment approachto setting community standards based on published animalstudies. Extrapolating from the OEHHA risk assessmentnumbers for communities and adjusting to an 8 hour workday would result in very, very low allowable worker inhala-tion numbers. This represents a more purely academicapproach than may be taken by other agencies.

In fact, proposed California legislation, AB515, would have mandated the use of theOEHHA numbers to set worker safetynumbers. I considered the legislation to beill-advised; and I provided technicalinformation in opposition. The legislationdid not pass. However, the general expecta-tion is that it will be reintroduced. Even inthe absence of legislation, OEHHAcontinues to have a very strong and a veryinfluential presence at HEAC meetings.OEHHA does have extensive resources; andI have utilized some of their reports.However, in my opinion, a strong,independent Cal/OSHA, would be desirablefor workers and for industry.Feasible?After the HEAC has recommended a work-

er exposure level, the compound underconsideration goes to the FAC, theFeasibility Advisory Committee. Thus far,there have been no appointees to a FAC.The HEAC recommendation appears to bethe dominant one. One might note that inthe course of planning the new PEL process,the FAC was originally called the FRAC; butthe “R” for “Reasonable” was removed.

Many factors traditionally consideredimportant by Industrial Hygienists and oth-ers involved in setting worker safety arebeing consigned to consideration by theFAC, in a manner that is secondary to therisk assessment.In Table 1, I have attempted to summarizethe status of various compounds underconsideration. Levels are presented as theyappear in the “5155 Substance Status List1-09.” The documents are available on theCal/OSHA website.

27

Table 1 Cal/OSHA Health Expert Advisory Committee (HEAC)

(a) = under discussion(b) = recommendation made, closer to becoming a PEL, will move to FAC

INDUSTRY

NEWS



HEAC MembersThe HEAC is composed of volunteers, selected by

Cal/OSHA. Some HEAC members are associated withWorksafe! Worksafe! is a non-profit advocacy group, withthe stated purpose of protecting workers. They stronglysupport the low exposure limits suggested by OEHHA andwere heavily involved in the effort to pass AB515. However,at least two HEAC members are Industrial Hygienists withpractical, real-world experience in supporting workersafety. One of them, Jim Unmack, CIH,(Certified IndustrialHygienist), is a long-time advisor to Plasma Technology,Inc., a long-time and active member of ITSA.Keeping you PostedMy intent is to continue to attend the HEAC meetings and

to continue to alert the International Thermal SprayAssociation and those involved in thermal spray and otherengineered coatings to issues of concern. Worker safety isof critical importance. To achieve a safe work environment,a correct, reasonable, and practical evaluation of all dataand studies needs to occur as part of setting workerexposure limits. I am concerned that many of the levels

currently under discussion at HEAC are inappropriate andcould be detrimental to the work environment.While the HEAC discussions are complex and convoluted

for everyone involved, I am able to critically follow thediscussions and reasoning, because I have a somewhatcheckered past. In addition to being “The Cleaning Lady,”I have extensive education and experience in biology, bio-chemistry, clinical chemistry, and analysis of toxicologicalstudies. For this reason, I have been reporting events atCal/OSHA to interested groups, including an inter-agencymilitary group.Some chemical manufacturers have sent advocates or

lobbyists to the HEAC meetings. With rare exceptions, thoseindividuals attend only to observe discussion of thechemical(s) of immediate interest. I think this is a mistake;it is like attempting to provide significant input to thepolicies of a foreign land without understanding the cultureor the ground rules. Cal/OSHA tends to downplay any inputfrom industry. Better opportunities for providing productivecomment will be achieved by participating in the Cal/OSHAPEL process and by showing ongoing interest.

I will keep you posted. Continuing tohave observers physically present atHEAC meetings sends a very clearmessage that organizations like ITSAare aware of the Cal/OSHA activities,understand the approaches used byCal/OSHA, and that ITSA as well asother concerned professionalorganizations and companies reservethe option to make public and/orwritten comments where appropriate.For more about the Cal/OSHA PEL

process, see the Kanegsberg &Kanegsberg column, “ContaminationControl In and Out of the Cleanroom” inthe December, 2008 issue of ControlledEnvironments Magazine, web:http://www.cemag.us/Barbara Kanegsberg, BFK Solutions, is

an independent consultant in criticalcleaning processes and surface quality.For more information, contact her at

[email protected] Journey Through the Alphabet SoupAB 515, a now-defunct but seeming-

ly perennial California proposedlegislation that would proliferate anarray of exceedingly low Cal/OSHAPEL’sACGIH, American Conference of

Industrial Hygienists, a professionalorganizationAIHA, American Industrial Hygiene

Association, a professionalorganization of CIH’s, andprofessionals concerned with workersafety

28

Table 2. Some Cal/OSHA Prioritized Chemicals of Interest to theThermal Spray and Engineered Coatings Industries

• at the Federal level, a draft report by National Toxicology Programwas distributed in December, 2008. continued on page 30

INDUSTRY

NEWS


More than 1,100 suppliers. New technology. Problem-solving solutions.

Career-enhancing networking. Peer interaction. Hands-on demonstrations.

Cost-saving resources. Unparalleled education programs.

ALL UNDER ONE ROOF.

Make plans now to attend the one and only industry event where

you’ll find the innovations, knowledge and business connections

you need to stay competitive and thrive in the year ahead.

REGISTER ONLINE TODAY! www.fabweldform.com

NORTH AMERICA’S LARGEST METAL FORMING, FABRICATING & WELDING TRADE SHOW

November 15–18, 2009 McCormick Place | Chicago, Illinois USA

COSPONSORSINDUSTRY PARTNERS

.fabweldforwww

COSPONSORS

m.comfor

RSARY PINDUSTR

McCormick Place voNTNERSR

Illinois USAChicago,|ck Place 8,5–1ember 1v

nois USA2009


INDUSTRY

NEWS

these be listed as “reasonably anticipated to be a humancarcinogen”. Such a listing is almost certain to eventuallyresult in the adoption by OSHA of a PEL for these materialsand probably a TLV by the ACGIH. Currently there is no TLVor PEL for cobalt-tungsten carbides. Related TLVs and PELsare:-TLVs: tungsten metal - 5 mg/m3 and cobalt

- 0.02 mg/m3-PELs: cobalt - 0.1 mg/m3, tungsten is not listed.The ACGIH (2008 edition) also lists cobalt as a Class A2

carcinogen—confirmed animal carcinogen with unknownrelevance to humans. The International Agency forResearch on Cancer (IARC) lists cobalt metal withouttungsten carbide in Group 2B (possibly carcinogenic tohumans) and cobalt metal with tungsten carbide in Group2A (probably carcinogenic to humans).Adoption of an OSHA PEL is likely to require actions by

producers, sellers and users of cobalt-tungsten carbidepowders. For more information on the NTP and IARC go totheir web sites at: http://ntp.niehs.nih.gov/ andhttp://www.iarc.fr/.

Cal/OSHA, California OSHA, can set legally-enforceableworker safety standardsCAS Number, Chemical Abstract Society Number, sort of

a social security number for chemicals, useful forunambiguously identifying chemicalsCDC, Center for Disease Control, a Federal agencyCIH, Certified Industrial Hygienist, a worker safety

expertFAC, Feasibility Advisory Committee, part of the

Cal/OSHA PEL processHEAC, Health Expert Advisory Committee, part of the

Cal/OSHA PEL processHESIS, Hazard Evaluation System and Information

Service, another California agency with a mission to helpprevent workplace illness and diseaseNIOSH, National Institute of Occupational Safety and

Health, a Federal agencyOEHHA, Office of Environmental Health Hazard

Assessment, performs risk assessments related toenvironmental exposureOEL, Occupational Exposure Limits, may be set by

manufacturers, professional organizations, governmentagencies, the limits are not legally-enforceable but areoften used as guidelinesOSHA, Occupational Safety and Health Administration, a

Federal agency, conducts research and makesrecommendations, part of the CDCPEL, Permissible Exposure Limit for workers, legally-

enforceableREL, Recommended Exposure Limit or NIOSH REL,

recommended by NIOSH scientists to OHSASTEL, Short term exposure limit for workers, usually 15

minutesTWA/TLV, Threshold Limit Value/Time Weighted Average,

the amount of a substance that an “average” worker canbe exposed to without ill-effect, day after day, with anormal work schedule

Technical Editor’s NoteOn the US federal level, cobalt-tungsten carbide powders

(as well as hardmetals/cemented carbides) are the subjectof a review in the National Toxicology Program (NTP) fortheir inclusion in the “Report on Carcinogens” (RoC). In arecent action, the Expert Review Panel recommended that


High Pressure KINETIKS®CGT 2000 Cold Spray Gun

Shown is the newly engineeredKINETIKS® 2000 High Pressure Cold

Spray System from CGT Cold Gas Technology GmbH. Thehand-held gun compliments the wide range of high

pressure cold sprayequipment availablefrom CGT.

The innovative CGT2000® System is capableof reaching expansiongas temperature to500°F (300ºC) with up to300 psi (20 bar)pressures. CGT-ColdGas Technology GmbH

in Ampfing, Germanyworked closely with ASB Industries on conceptdevelopment. All CGT equipment offers advancedtechnology systems that give users production quality coldspray surfacing for a variety of new and practical

applications complimenting thermal spraysurfacing technologies. ASB Industries, Inc.is the North American distributor forequipment sales, technology developmentalong with installation and maintenancesupport. ASB Industries houses multiplesystems with the infrastructure to producehigh pressure gas required for operation andcustomer evaluation.For more information, please contact ASB

Industries at 330.753.8358 [email protected]

Lineage Alloys offer a comprehensive range of thermal spray powdersto the industry.

Please visit our website www.lineagealloysllc.com to view ourproducts, services and special order capabilities.Lineage Alloys technical staff are ready to discuss your thermal spray

powder requirements and determine how we can best meet your needs.For information, contact us at 281.426.5535, fax: 281.426.7484,

email: [email protected]

Tungsten CarbidesChromium CarbidesMetal Powders

Pure Metal PowdersSpecial Order

1901 Ellis School RoadBaytown, Texas 77521


New “MEC” High-Tech Two Axis Manipulator“MEC” has developed a new automatic two-axis manipulator with job rotation

arrangement for coating on piston rings, which is designed for high volumeproduction with uniform coating thickness to economize the coating cost interms of the consumption of powder and time. The system assures controlledtwo-axis gun manipulation for consistent and precise coating.The two-axis manipulator is fitted with two servo motors and a spray distance

adjustment slider. The tail stock has a special feature which takes care of theincrease in the mandrellength due to thermalexpansion during thecoating operation. Themachine is packed withlot of flexibility andsafety features.

The spray gun ismounted on themanipulator to cover theentire mandrel length ofthe piston rings. All thesequence of operations iscontrolled by a touch

screen PLC. The job spray length and spray angle can be varied by feeding thedata into the MMI.The programmed sequences in the system take care of all major aspects of

thermal spray which include:a) Start positioning and flame stabilizing control.b) Setting of pre heat parameters.c) Powder ON/OFF control and stabilizing delay.d) Angle of spray with respect to job axis.e) Coverage of various job diameters.f) Integration with external spray system for controlling the start/stopof gun and powder.

g) External interlocking for safety, shutting down all movements if triggered.h) Remote pendant provision for checking/setting up the movements manually.i) Operator safety switching facility to avoid any injury while working withloading/unloading of job.

For different jobs and sizes MEC can provide special manipulators that inte-grate with thermal spray systems like plasma, HVOF, flame and arc spray, etc.For further information for above system, please contact

Ankur Modi, Executive Director, tel: (0291) 2747601/60, web: www.mecpl.com,email: [email protected] See advertisement on page 6.

The Programmable ManipulatorEighth in a Series from Plasma Powders and Systems

Robots used for thermal spray operations are typically of the articulated stylewith either five or six axis, six being preferable for flexibility. The articulatedrobot employs rotary joints for motion, and functions much like a human arm.In fact, human anatomy terms, such as wrist and arm, are often used to describerobotic operations.A key to the success of the articulated robot is the advanced controller

software. Thermal spray operators are generally most comfortable with X-Y-Zmanipulators since it is difficult to visualize a position based on the angularposition of six rotary joints. The advanced robot software takes care of thistransformation and allows the programmer/ operator to think in Cartesiancoordinates.

INDUSTRY

NEWS


INDUSTRY

NEWS


Three different options are provided for the operator to manually move orjog the robot using a joy-stick or series of motion buttons:1. Joint coordinate system. The joint coordinate system is used tocontrol individual robot joints. The position and attitude of the robot aredefined by angular position of each joint. The joints are numbered (onethrough six for a six axis robot) starting with the base or main body of therobot. The programmer often selects this coordinate system for initialpositioning of the robot.2. X-Y-Z or world coordinate system. This coordinate system is fixed inthe work space and is generally set with the origin on axis 1 and at theintersection of the orthogonal plane of axis 2. This coordinate system usesthe same nomenclature that was developed for airplanes; X towards thefront (forward direction of travel), Y for motion to the left when “facing”the same direction of the robot, Z for up (altitude) and then W (yaw), P(pitch) and R (roll) for the three rotational components. Programmers oftenselect this system for manually moving the robot to selected positionsalong the part to be coated.3. A tool coordinate system is a Cartesian coordinate system that definesthe position and the attitude of the thermal spray gun. For this system, theorigin is usually the point of application on the part to be coated. Thiscoordinate system is especially useful when adjusting the position of thethermal spray gun with reference to the part being coated.Note that these coordinate systems are for manually jogging the robot.

Once the points and path are defined for a coating program, the robot willfollow the prescribed motion program regardless of the coordinate systemused for manually jogging the robot during programming.The coating program will consist of a number of housekeeping tasks (e.g.,resetting counters that keep track of the number of passes), discretecommands to sequence the various units (dust collector, etc.) and a seriesof motion commands.Motion commands are instructions to move the gun between two points

in the coating motion program. Typically there are three motion commandtypes available:1. Joint. All joints rotate at a specified speed and will arrive at the finalpoint at the same time. The path of motion is usually nonlinear and theattitude of the gun is not controlled. Therefore, this motion is usually notused during a coating pass.2. Linear. The gun path is controlled from one point to the next and alonga linear path. The attitude of the gun is also controlled. This is the motionmost used in coating operations.3. Circular. The circular motion mode controls the path of gun from a startpoint to an end point through a passing point.Next in the series, Continuous path, Singular Points and Tool Center Point

(TCP).For more information, please contact series author, Dale Moody via [email protected]

Join the ASM Thermal Spray Society OnlineCommunity Forum

ASM TSS members welcome visitors to register and access the newsearchable forum, as well as explore the new online community.To subscribe, visit http://tss.asminternational.org, choose net-

working and forum for instructions.


32


INDUSTRY

NEWS

Hard Chrome Alternatives in Today’s EconomyJ. Scott Moore, Ph.D., President, Thintri, Inc.

Hard chrome plate has long been a crucial component ofaerospace hardware, in manufacture, overhaul and repair.Chrome has long provided wear resistant coatings for suchimportant applications as landing gear, gas turbines,hydraulics and other components. Unfortunately thehexavalent form of chrome used in plating operations hasbeen found to cause serious injury to workers in platingplants.In recent years growing awareness of chrome’s significant

health and environmental dangers has led to a gradualmigration to alternative coating technologies. Increasinglystrict environmental and health regulations over the lasttwo decades have seriously disrupted the domestic hardchrome industry, driving as many as half the plating shopsout of business or out of the country to places with fewerrestrictions.Meanwhile alternatives to chrome plating have steadily

gained markets. The best known hard chrome alternative isthermal spray, which has established itself in the aerospaceindustry and also expanded markets outside aerospace ingeneral industry and heavy vehicles. Thermal spray,however, is facing competition from some of the sametechnologies that compete with chrome.The advantages offered by many chrome alternatives have

gone beyond simply avoiding the environmental and healthissues associated with chrome plating, and now includesignificant improvements in performance and/or cost. Anumber of new coating methods have reached or areapproaching commercialization, and some newtechnologies are even obtaining approvals for use inaerospace.

However, a new market study by Thintri, Inc.(www.thintri.com) on hard chrome alternatives, an updateto an earlier study, shows that the move to hard chromealternatives has changed from the earlier steady progressto a more complicated picture. Issues relate primarily tothe cost of migrating to new methods, reflected in theexpense of procuring and setting up thermal spray cells,and uncertainty over performance, not to mention thecurrent economic climate. Ironically, some hesitation stemsfrom an overestimation of the capability of alternatives likethermal spray. Consequently, some sectors of the industryhave continued to move from chrome to thermal spray andsome are resisting. Meanwhile, new coating methods areemerging that deal with the limitations of both chrome andthermal spray, that could offer new options formanufacture, overhaul and repair.The Hard Chrome Market in Aerospace

Chrome plating is an important part of aerospacemaintenance, overhaul and repair, and is used not onlyduring parts manufacture, but in rebuilding parts that werenot originally chrome plated in order to restore dimensionaltolerance. The ease and low cost of application combinedwith the quality of chrome wear coatings has led tochrome’s long-standing dominance in wear coating

applications.Chrome plate’s properties are generally good, but hardly

ever excellent. Chrome’s limited hardness and corrosionresistance are increasingly unsatisfactory in today’s moredemanding wear environments. Chrome coatings sufferfrom pitting, spalling and other failures under stress.Chrome’s slow rates of deposition and long bakes add tocost of ownership and turnaround times. Coating non-uniformity often forces follow up machining to meetdimensional tolerances.Most importantly, hexavalent chrome, a prime component

in the process of hard chrome plating, is a known healthhazard. Worker exposure to the mist produced duringplating has resulted in not only cancers but an array ofother medical problems, including irritated, ulcerated andperforated septum, dermatitis, burns and other issues.Waste disposal of the toxic bath solutions is also difficultunder today’s pollution control legislation.Chrome Alternatives

In the 1990s thermal spray, embodying a range ofdifferent coating technologies, emerged as the leadinghard chrome plate alternative. Thermal spray occupiesimportant markets not related to chrome replacement, butin providing an alternative to hard chrome, thermal spray,has become nearly indispensible in important markets likeaerospace.Thermal spray offers important advantages over chrome

plating in some aerospace applications, including fastdeposition rates, ability to deposit on heat-sensitivesurfaces, use of portable equipment, and a wide range ofcoating materials. Most importantly, at least in some situ-ations, thermal spray is comparable to chrome in cost oreven less expensive.For aerospace applications, the most common form of

thermal spray in use is high velocity oxy-fuel, or HVOF.HVOF is suitable for processing large parts. While a platingtank for a large component could be very expensive to setup and maintain, applying a HVOF coating to a large partrequires no extra investment in terms of capacity, as longas the part fits in a standard cell. Small parts, like thosethat could be shoveled, can be processed much less expen-sively in a chrome plating tank.Another important advantage of HVOF, or any thermal

spray for that matter, is the reduced processing timecompared with plating. Process hours for a typical HVOFapplication are as little as a fifth those for electroplatedhard chrome.There are of course tradeoffs in using thermal spray.

Surface complexity points up some significant differencesbetween the two methods. Chrome plating easily reachesthe entire surface of a complex part, but that is not alwaysthe case with thermal spray, where complex geometries canpresent significant challenges. Therefore HVOF is mostcompetitive with chrome on large, relatively simple shapes.Given that thermal spray is a line-of-sight application,

non-line-of-sight (NLOS) geometries and particularly innerdiameters less than about 6-8 in. (15-20 cm) are a bigproblem for HVOF. Today about 20% of aerospace coating

35SPRAYTIME First Quarter 2009

INDUSTRY

NEWS

applications are NLOS, so the inability to use HVOF on suchsurfaces will ultimately limit the penetration of HVOF inchrome replacement to 80% in that market.Another big issue with HVOF is the significant up-front

investment required, including consumables andequipment. However, in taking into account long termeconomic benefits such as faster turnaround time, greaterperformance and longer wear lifetime, reduced hazardouswastes, etc., thermal spray is often quite economicallycompetitive with chrome, that advantage increasing withevery added regulation on chrome plating.In any case HVOF is so far the alternative of choice in

replacing hard chrome plating, given its superiorperformance, favorable economics and flexibility. Largesegments of the aerospace industry, as well as sectors likeoil and gas, heavy equipment and other industries, havebegun a large scale migration away from hard chrome andtoward thermal spray and a few other alternatives. Theeffect of this movement on the overall volume of thechrome plating industry is fairly small, but growth inmarkets for alternatives has overall been strong, albeit withsome inconsistencies.The Shift to Thermal Spray in AerospaceChief among the chrome alternatives, thermal spray has

made steady, solid gains in aerospace markets, particularlylanding gear where it has nearly become a standard.Industry consensus was that the erosion of chrome marketswould continue to the point where chrome plate was moreor less a niche application, which has happened with jetengines. However, in recent years, some segments of theindustry have stalled in their acceptance of thermal spray

in other important applications, like landing gear. Someimportant companies have given up on thermal spray forlanding gear, and others rationalize delays inimplementation. The current economic downturn has onlycomplicated the picture.Small, regional and corporate jets have largely stuck with

chrome plate for landing gear. Even some larger airlines,like Lufthansa, after early initiatives to adopt thermalspray, have settled on chrome. In Lufthansa’s case, thestrategy rests largely on the company’s decision to sell offaircraft before the type of extensive servicing that makesuse of HVOF or chrome is needed. Of the smaller aircraftusers, including regional and corporate jets, many reportthat they have no intention of moving from chrome tothermal spray for landing gear. Such companies haveactually made a gamble, based on a perceived superiorityof performance in HVOF coatings. As aircraft manufacturerslike Boeing and Airbus move to thermal spray inmanufacture of landing gear, some owners of small aircraftare betting that the HVOF coatings will last longer than theservice lifetime of the component they are on, thuseliminating the need for restoring coatings. For those fewthat need restored coatings due to trauma or some unusualevent, the repair of the landing gear will be outsourced tofirms specializing in thermal spray.While there are cases where a substrate will fail before a

coating, most thermal spray experts are quite skeptical thatHVOF coatings will outlast the components they are appliedto. In that case, companies who have put off decisions onmoving to thermal spray may find themselves forced tomake uncomfortable decisions without much time for



The strength of the wear coating sector is that even if newequipment purchases decline, coated surfaces in use muststill be repaired, keeping markets somewhat active inthermal spray for wear coatings.The portion of the wear coatings market confined to

chrome replacement benefits from the migration away fromchrome to alternatives like HVOF, and so can expect asubstantially brighter outlook than overall wear coatings,largely at the expense of chrome plating markets (Fig. 1).While many markets for chrome alternatives are suffering

from today’s economic conditions, inertia on the part ofpotential users, and a general reluctance to move to aprocess with greater up-front cost, most sectors can beexpected to begin a solid advance around 2010 or 2011,given expectations on the current downturn. Most of theindustries that can benefit from chrome alternatives, butparticularly aerospace, deal with equipment and materialsthat are specified by a relatively small number of OEMs.Once the top three or four OEMs in any industry haveconverted to alternative processes, the rest of the industrycan generally be expected to follow. In nearly all sectorsdiscussed in the Thintri report, the major OEMs are indeedmoving to replace chrome with thermal spray, although atdifferent rates.There is little likelihood at this time that HVOF will adapt

to inner diameters (although some variations on plasmaspray are still under investigation for that purpose), non-line of sight and other geometries that present difficultiesfor the method. For that reason alone, HVOF cannot beexpected to capture more than 80% of its target markets inaerospace. Lack of economic competitiveness in treatingsmall and complex parts will lead to even lower penetrationtargets in heavy equipment and general industry.

A number of experts in the thermal spray industryinterviewed for the Thintri study believe that while largemarkets remain to be captured, the “low hanging fruit” hasalready been taken. Over the past ten years, the move toalternatives in large, well-paying and easy applications likelanding gear and hydraulic cylinders began quietly butcontinued a solid advance. What remains are large but

highly segmented marketswhere potential users have tobe convinced of the costeffectiveness of thermal spray,and may have little interest inswitching. Other availableapplications are those wherethermal spray has not donewell, such as inner diameters,which are now the target ofcompeting methods likeelectroless plating. Continuedsuccess for chrome alternativesin general will depend onpenetrating a large number ofsmaller, more difficult markets.


planning. However, the issue has not been resolved, and noone knows for sure how thermal spray coatings will lastwith respect to the lifetime of the part. In any event,several firms specializing in servicing landing gear forregional and corporate aircraft report that they and theircustomers are quite happy with chrome, even given theadded regulatory burden, which has largely stabilized.Effects of the RecessionThe current economic crisis has precipitated a downturn

in consumption of resources in aerospace markets, on topof delays in the high profile Boeing 787 and Airbus A380production. Business cycles have been disrupted, andprices of goods and services have plunged. Air traffic,which had been expected to grow robustly for most of thenext ten years (largely due to market growth in Asia), willstall somewhat, depending on the duration of therecession.The recession has accelerated an anticipated “dip” in

aircraft production and materials and resource consumptionthat was predicted by many in the aerospace industry for2011 to 2012. This dip prediction was based only onhistorical cycles, rather than economic fundamentals. Manyaerospace industry analysts now believe that this dip istaking place now, a reasonable assumption, although theextent of the decline will be greater than what wasexpected for 2011 to 2012. Most analysts predict an upturnbeginning in late 2010. In the meantime, declining airtraffic revenue will only make investment in updatedmaintenance, repair and overhaul equipment more difficultto justify.Case Study: Wear Coatings MarketsOverall wear coating markets for thermal spray, not just

those in chrome replacement, are adversely affected bytroubles in the airline industry, but other factors also playan important role. With a deepening recession, companiesare reluctant to embark on new capital spending. Selectedmarkets are more depressed than others and it happensthat some of the most troubled industries are those thatcould make the most use of wear coatings.

Fig. 1 Thermal spray wear coatings market forecast confined to chrome replacement.

INDUSTRY

NEWS


www.fst.nl

Coating SolutionsYou need all the pieces to complete the picture

A Materials and Technology Partnership

3040 Charlevoix Drive S.E.Suite 203IGrand Rapids, MI 49546 USAemail: [email protected]: 616.988.2622fax: 616.988.2629


Accordingly, those marketing chrome alternatives willhave to bring resources to bear on diverse applications,where potential users may have little or no familiarity withchrome alternatives and need to be convinced of the longterm cost savings and performance advantages inapplications where there may now be little supportive data.ConclusionA number of factors have acted in concert to delay and

complicate the movement away from hard chrome coatingsin aerospace and toward alternatives like thermal spray.Some are a function of current economic conditions, whileothers indicate a surprising resilience on the part of chromein some applications. Chrome’s appeal rests primarily on itssimplicity and low cost, and most importantly itsversatility. Alternatives offer narrowly defined advantages,in that no single alternative promises the capability ofreplacing chrome across the board. Replacement of chromewill be most likely be accomplished by simultaneous use ofa number of alternatives. For example, while HVOF willreplace chrome on many exterior surfaces, inner diametersand other non-line of sight applications will make use of adifferent alternative, such as electrodepositednanocrystalline coatings.In any case most in the industry believe that chrome’s

usage in aerospace will, in the long run, continue todwindle while alternatives with fewer liabilities and betterperformance continue to capture chrome’s markets.About Thintri, Inc.Thintri, Inc., is a full-service consulting firm specializing

in market research and custom consulting, covering topicsin materials, aerospace, electronics and semiconductors,telecommunications, manufacturing, logistics, imaging andmany other markets.For more information, visit www.thintri.com

38

Low Pressure PlasmaAir Plasma

HVOFEBPVD

Pack CoatingAluminide

Vapor CoatingCVD

Plating Components

Accuracy - Consistency - ProductivityERW, Inc. --- Supplying you with metal maskingthat will consistently outperform the competition!

91 Highland Drive • Post Office Box 431Putnam, CT 06260

Phone 860-928-1199 Fax 860-928-9499E-mail [email protected]

Web www.erwinc.com


INDUSTRY

NEWS

Arkansas Thermal Spray AnnouncesHittmax Equipment Line

The thermal spray division of Hitachi Maxco (USA) hasbeen transfered to Arkansas Thermal Spray. These HitachiMaxco Max Jet II and Mini Max HVOF systems are nowcalled Hittmax I and Hittmax II.

For the past three years,Arkansas Thermal Spray hasbeen handling the sales andservice of thes units. They willstill be offering free parameterwork, free training, andinstallation to any customerpurchasing one of these units- as well as offering a full lineof replacement parts andmaintenance services for allunits.

New literature is availableupon request.These thermal spray systems

have been sold to such customers as Pratt & Whitney-Paton, Siemens, Foster Wheeler, and The Ellison Group.These customers have been very satisfied with thesesystems because of the simplicity of use, operating costand overall cost of the unit. One of the main reasons is theversatility; these units spray powder - wire or cord - all atHVOF velocity. The Hittmax II (previously Mini Max) iscompact and portable for onsite use.For more information, contact Arkansas Thermal Spray,

1216 Fulbright, Walnut Ridge, AR 72476, tel: 870.886.7060or 870.759.1775

SPRAYTIME archives are searchableVisit www.thermalspray.org and choose

SPRAYTIME to search previous issues for data.




Progressive TechnologiesLaunches Next Generation 100HE

Plasma Spray TorchProgressive Technologies is pleased to

announce a new and improved generation of the proven100HE Plasma Spray Torch. The sleek new body style is 1 lb(0.45kg) lighter and over 1 in. (25mm) shorter, enablingbetter manipulation capabilities and easier access to partswith complicated geometries. We achieved this whilemaintaining the high performance and quality coatingsproduced with the original 100HE. How did we do it? Werearranged some internal cooling water channels, shiftedsome “O” rings, and developed an even simpler design thanthe original 100HE. However, all of the patented internalhardware components and geometry remained the same.

In addition to maintaining extremely high throughput andexceptional coating qualities, reported hardware life hasbeen a very pleasant surprise for our customers. Jay Morseof Henry Pratt, a long time user of the 100HE, recentlycommented “we often see anode life in the range of 1500hr, and up to 400 hr cathode life”.The 100HE has a wide window for spraying nearly any

powder, including abradables, metallics, carbides, cermetsand pure ceramics. Recent coating development programshave proven its capability to spray TBC ceramics of verydense (< 1%) to high (20%) porosity lev-els at spray rates up to 40 lb/hr (300g/min) and deposition efficiencies in the70% to 80% range. Because of thethermally dynamic plasma created by the100HE’s patented hardware design,several companies have also discovered itis a great tool to manufacture and densi-fy thermal spray powders. High qualitypowders are now manufactured and den-sified at feed rates in excess of 66 lb/hr(500 g/min).

39

If you want to step up to the next level inPpasma spray Ccatings, take the 100HECHALLENGE; choose a material, contactProgressive and let us prove how much time

and money you can save over your current application.For more information visit us in Booth 124 at ITSC 2009

or contact Progressive Technologies at 800.968.0871; fax616.957.3484; email [email protected]; webwww.ptihome.com; or write to Progressive TechnologiesInc., 4695 Danvers SE, Grand Rapids, MI 49512.

INDUSTRY

NEWS

25 Year Anniversary forF.J. Brodmann and Company

For 25 years F.J. Brodmann and Company, located inHarvey, Louisiana has specialized in the manufacturing ofpowders, grains, and pellets from metal and metal alloys,carbides, cermets, ceramics, glass, advanced materials andpolymer based feed stock materials. Since 2005, thecompany has expanded its particle size range offerings forpowders and composite from nano-size to millimeter sizediameters. The powders are designed for coatingapplications via thermal spray, cold spray and polymerpowder coating systems. The manufacturing capacity ofthermal spray composite powders has recently beenexpanded to 100,000 lb annually. The grain particles sizedto 50-2000 microns are used for surface preparations viablasting and shot peening primarily in biomedical partsmanufacturing. The pellets measuring 1-10 mm in diameterare speridized for grinding and milling applications.Starting in 2008, many engineered compositions are not

only supplied as dry powders and composites, but also asaequeous or non-aqueous dispersions. In response tohealth and safety concerns, nano-sized powders areprocessed and supplied in a wet medium suitable forthermal spraying and other coating methods. The companyhas issued an anniversary edition of its technical brochurewhich includes a collection of property data related to itsexpanded product lines. A w4 hour Technical Service isoffered for questions and quotations by calling504.460.4365.

For more information, contact FJ. Brodmann andCompany, LLC, Oakmere Business Park, 2072 Sussex Street,Harvey, Louisiana 70058, tel: 1.504.340.9579, fax:504.340.9579, web: www.fjbco.com


Is Your Event Listed? Send yourevent not ice to

sprayt [email protected]

CALENDAR OF EVENTSAPRIL 2009

13-16 Karlsruhe, Germany Int’l. Trade Fair for IndustrialCoating Technology - contact FairFair GmBH,www.paintexpo.de16-18 Orlando, FL USA International Thermal SprayAssociation Membership Meeting and Technical Program -contact ITSA, [email protected], 440.357.540028-29 Toronto Canada - Shot Peening and Blast CleaningWorkshop - Electonics, Inc. Education Division,1.800.832.5653, www.electronics.inc.com

MAY 20093-6 Helsingør Denmark 15th Int’l Conference on theJoining of Materials - contact: JOM tel: +45.48355458,email: [email protected] Las Vegas, NV USA ITSC 2009 International ThermalSpray Conference & Expo - contact ASM Int’l tel:440.338.5151,web: www.asminternational.org, email:[email protected] Santa Clara, CA USA SVC 52nd Annual TechnicalConference - visit www.svc.org12-15 Moscow Russia Essen Welding Russia 2009, 3rd Int’lTrade Fair Joining Cutting Surfacing - Visit Messe EssenGmbH www.messe-essen.de or DVS www.dvs-ev.de20-22 Vancouver, British Columbia Canada 9th Int’lASTM-ESIS Symposium on Fatigue and Fracture Mechanics -contact NASA Glen Research Center tel: 216.521.3490,email: [email protected] Miami, FL USA Institute of Industrial EngineersAnnual Conference and Expo - contact Elaine Fuerst, IIE tel:770.449.0460 x102, email: [email protected]

JUNE 20092-4 Monterrey, Mexico AWS Weldmex, Cintemex ExhibitionCenter, Monterrey, Mexico - vist www.aws.org2-4 Aachen, Germany Tool 09 Tool Steels - email:[email protected], tel: +49.241.809.52552-5 Shanghai, China - 14th Beijing Essen Welding &Cutting - Visit DVS www.dvs-ev.de or Chinese MechanicalEngineering Society www.cmes.org7-11 Dayton, OH USA Aromat 2009 Novel & EngineeredMaterials System & Processes for the Aerospace Industry -contact ASM Int’l tel: 440.338.5151,web:www.asminternational.org, email:[email protected] Norfolk, VA USA MegaRust Navy Corrision Conference- visit www.nstcenter.com8-12 Orlando, FL USA ASME TurboExpo 2009 - Orlando World Marriott Resort - visitwww.turboexpo.org16-18 Edmonton, Alberta Canada - WesternManufracturing Technology Show - Visit www.wmts.ca28 JUN - 1 JUL Las Vegas, NV USA MPIF/APMI Conferenceon Powder Metallurgy - visit www.mpif.org

JULY 200912-17 Ottawa, Ontario Canada 12th Int’l Conference onFracture (ICF12) - visit www.icf12.com27-29 State College, PA USA Basic Powder Metallurgy

Short Course - MPIF visit www.mpif.orgAUGUST 2009

25-29 Berlin, Germany Thermec 2009 Int’l Conference onProcessing & Manufacturing of Advanced Materials - visitwww.thermec.uow.edu.au

SEPTEMBER 20097-9 Bremen, Germany 4th Int’l Conference on SprayDeposition and Melt Atomization SDMA 2009 and 7th Int’lConference on Spray Forming ICSF VII - [email protected] Essen, Germany International Trade Fair - Joining,Cutting, and Surfacing - visit web: www.messe-essen.de,contact email: [email protected]

OCTOBER 200919-22 Toronto,Ontario Canada Canadian ManufacturingTechnology Show 2009 - visit www.sme.org20-23 Munich, Germay Ceramitec, 11th Int’l Trade Fair forMachinery, Equipment, Plant, Processes and Raw Materialsfor Ceramics and Powder Metallurgy - tel:+49.89.9.49.1.1378, email: [email protected]

NOVEMBER 20095-6 Erding, Germany 8th Colloquium High Velocity Oxy-Fuel Flame Spraying - Visit GTS www.gts-ev.de,http://hvof.gts.ev.de or Linde AG www.lindegas.com15-18 Chicago, IL USA FABTECH Int’l & AWS Welding Showand Metalform- with a Thermal Spray Pavilion andConference - organized by AmericanWelding Society, www.aws.org,Fabricators and Mfgrs Assoc,www.fmafabtech.com, Soc. of Mfg.Engineers, www.sme.org/fabtech

FEBRUARY 201014-18 Seattle, WA USA TMS 2010 Linking Science andTechnology for Global Solutions - TMS Meeting Services, tel:724.776.9000 x243, email: [email protected], web:www.tms.org10-12 Mumbai, India - 4th Essen Welding India - Visitwww.messe-essen.de

OCTOBER 201010-14 Florence, Italy Powder Metallurgy World Congress& Exhibition - visit www.epma.com/pm2010

NOVEMBER 20102-4 Atlanta, GA USA FABTECH Int’l & AWS Welding Showand Metalform- with a Thermal Spray Pavilion andConference - organized by AmericanWelding Society, www.aws.org,Fabricators and Mfgrs Assoc,www.fmafabtech.com, Soc. of Mfg.Engineers, www.sme.org/fabtech30NOV - 4DEC Boston, MA USA 2009 MRS Fall Meeting -visit www.mrs.org

CALENDAR

OF

EVENTS


A D V E R T I S E R S L I S TYo u r S P RAY T IM E n ews l e t t e r i s p r o v i d e d t o yo u a t n o c h a r g e b y o u r

a d v e r t i s e r s . We e n c o u r a g e yo u t o t h a n k t h e s e a d v e r t i s e r s b yv i s i t i n g , c o n t a c t i n g , a n d r e f e r r i n g t h e i r p r o d u c t s a n d s e r v i c e s a te v e r y o p p o r t u n i t y.

Air Products......................................7Ardleigh Minerals ..............................21DeWal Industries, Inc. ........................18ERW, Inc. .........................................38Ellison Surface Technologies................8Fabtech Int’l and AWS Welding Show....29Farr Air Polution Control.....................2Flame Spray Technologies ...................37Genie Products, Inc. ..........................9Gartman Technical Services .................39Green Belting Industries.....................5HAI Advanced Material Specialists .......13H.C. Starck .......................................43IMR Test Labs ...................................42

ITSA Member Companies .....................22,23Lineage Alloys ..................................30Metallizing Equipment Company...........6Nation Coating Systems......................19Northwest Mettech ............................26Polymet Corporation ..........................3Praxair Surface Technologies ...............32Progressive Technologies, Inc. .............4Society of Vacuum Coaters ..................17Sulzer Metco.....................................44Thermach, Inc...................................35Thermion..........................................31TurboExpo ........................................15Weldmex/Fabtech/Metalform Mexico.....33

Journal of Thermal Spray Technology®A publication of the ASM Thermal Spray SocietyAbstract: Corrosion Properties of Cold-Sprayed

Tantalum CoatingsHeli Koivuluoto, Jonne Näkki, and Petri Vuoristo

Cold spraying enables the production of pure and densemetallic coatings. Denseness (impermeability) plays animportant role in the corrosion resistance of coatings, andgood corrosion resistance is based on the formation of aprotective oxide layer in case of passivating metals andmetal alloys. The aim of this study was to investigate themicrostructural details, denseness, and corrosion resistanceof two cold-sprayed tantalum coatings with a scanningelectron microscope and corrosion tests. Polarizationmeasurements were taken to gain information on thecorrosion properties of the coatings in 3.5 wt.% NaC1 and40 wt.% H2SO4 solutions at room temperature andtemperature of 80°C. Standard and improved tantalumpowders were tested with different spraying conditions.The cold-sprayed tantalum coating prepared from improvedtantalum powder with advanced cold spray system showedexcellent corrosion resistance: in microstructural analysis,it showed a uniformly dense microstructure, and inaddition, performed well in all corrosion tests.

Read the entire article in the March 2009Journal of Thermal Spray Technology.

For more information, visitwww.asminternational.org/tss

Editor: Christian MoreauEditor Emeritus: Christopher C. Berndt

Associate Editors:Kendall Hollis, Seiji Kuroda, and Armelle Vardelle

INDUSTRY

NEWS

SCHOLARSHIP OPPORTUNITIESUp to three(3) Graduate scholarships

worth $2,000.00 eachto be awarded each calendar year.

Since 1991, the ITSA Scholarship Program hascontributed to the growth of the Thermal SprayCommunity, especially the development of newtechnologists and engineers. The International ThermalSpray Association is very proud of this educationpartnership and encourages all eligible participants toapply.

New Application Dates:Scholarship applications are now acceptedannually April 15 through June 30 ONLY.

Please visit WWW.THERMALSPRAY.ORG Scholarship areafor details and a printable application form.




PEOPLE

IN

THE

NEWS

Your employee should be listed here.

Wall Colmonoy Announces Johnson as AlloyProducts Vice President

Wall Colmonoy announces theappointment of Craig Johnson to theposition of Vice President, AlloyProducts Group.

Craig has over twenty years ofservice at Wall Colmonoy, mostrecently as the Commercial Directorfor the Alloy Products Group. He

began his career at Wall Colmonoy as the Materials Managerfor the Alloy Products Group where he was responsible fornegotiating the purchase of strategic metals used tomanufacture Colmonoy® alloys and Nicrobraz® filler metals.As Vice President, Alloy Products Group, Craig will be

responsible for the sales and marketing functions.For more information, visit the Wall Colmonoy website at

www.wallcolmonoy.com/alloyproductsgroup.html.

NanoSteel® Hires Mike Place as Sales DirectorThe NanoSteel® Company, a leader in nanostructured steelalloy surface technologies, announces the addition of MikePlace as sales director for the company’s portfolio of SuperHard Steel® coating, overlay and wear plate solutions.Place has more than 23 years experience specializing in

boiler thermal spray applications for fossil powergeneration, oil and gas and pulp and paper covering a widerange of roles including management of field operations,projects and sales.“Mike’s breadth of knowledge and hands-on application

experience is an outstanding addition to the NanoSteelteam,” says Mike Quinlan, vice president of sales andmarketing. “As we continue to strengthen our solutions forboiler erosion protection, I am confident that Mike will addsignificant value to our customers.”Place arrives from Liquid Metal Coating Solutions where

he was national sales director and field operationsmanager. Prior to this, Place held positions of increasingresponsibility with other coating application companies.Earlier in his career, Place gained valuable experienceunderstanding boiler maintenance and refurbishment bycompleting institutional training, serving an apprentice-ship and earning a journeyman ticket as a boilermaker.

NanoSteel® Announces Brian Merkle toParticipate in ASTM International’s Standards

Committee on Abrasive WearThe NanoSteel® Company is pleased to announce that

Brian Merkle, director - engineering operations, willparticipate in ASTM International’s Committee G02.30 onAbrasive Wear, a subcommittee of ASTM's Committee G02on Wear and Erosion.ASTM International’s Committee G02.30 on Abrasive Wear

develops test methods, standard practices, guides andsuggested reporting procedures for tests related to theabrasion of materials caused by abrasive particles. Merklewill work on this committee’s task group for revisions toASTM’s G65-04 Standard Test Method for Measuring AbrasionUsing the Dry Sand/Rubber Wheel Apparatus, a test utilizedby the wear industry to evaluate a product’s resistance toabrasive wear.“We are very pleased with the inclusion of Brian as a wor-

thy contributor in the ongoing discussion and developmentof ASTM International wear testing standards,” says TomSantos, vice president of operations.Merkle manages operations at NanoSteel's applications

engineering and R&D facilities in Idaho Falls. Prior tojoining NanoSteel, Merkle held positions of increasingresponsibility at Superior Graphite Company in Chicago andthe U.S Department of Energy's Ames Laboratory at IowaState University. Merkle is an Iowa State Universitygraduate with BS and MS degrees in metallurgicalengineering. In addition to ASTM International, Merkle isalso a member of APMI International and the AmericanCeramic Society (ACerS).

ASTM International is one of the largest voluntaryorganizations in the world for the development of technicalstandards for materials, products, systems and services. Formore information about ASTM International and itscommittees, visit www.astm.org.

The NanoSteel Company, Inc., headquartered inProvidence, R.I., develops and markets a patented portfolioof Super Hard Steel nanostructured alloy coating, overlayand wear plate solutions that effectively solve or alleviatemany operational challenges faced in critical industriestoday, including wear, erosion and corrosion in a widerange of complex service environments.

For additional information contact Greg Nixon,marketing and communications manager, The NanoSteel

Company, 67 Cedar Street, Suite 101,Providence, Rhode Island 02903, phone(401) 270-3549, ext. 161, cell (407) 616-5167, e-mail: [email protected],web site: www.nanosteelco.com.

WHERE IS YOUR ARTICLE?The SPRAYTIME Editorial Staffencourages and welcomes your

contribution.

IMR Test Labs131 Woodsedge Drive

Lansing, NY 14882 USA

Testing Services for TS, TBC and Diffusion Coatings

For complete brochure, contact:Tel: 888.464.8422 (toll free in USA)Tel: 607.533.7000, Fax: 607.533.9210Email: [email protected] or [email protected]: www.imrtest.com

1st quarter – vol. 16, no. 1

Documents