SURFACE TECHNOLOGIES Bangalore and Pune
Surface Modification Technologies
Bangalore Plant : A 413, 9th ain, 2nd stage,Peenya Indl area
Bangalore 5600058 , [email protected] Tel : 080-28364565 , mobile : 9916903701
Pune Plant :T 180, T Block, MIDC , Bhosari, Pune
Tel 020- 27110020 Mobile ; 8149046272
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SPRAYMET
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Various surface Modification processes
SPRAYMET
Core Surface Modification Technologies operated by Spraymet
Flame Spray : Powder / Wire Robotic Plasma Spray Robotic High Velocity Spray (HVOF) Cold Spray ( future Planning )
Cladding : PTA / TIG HWTIG /Laser ( future Planning )
Plating : Electroless ( ENP)
Nitriding ( liquid-QPQ and Gas)
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15Schematic o f
thermal spray coating
Heat source, spray gun
Acceleration Impacting Spreadening and cooling
Feedstock materials
Stick
Wire
Powder
Thermal Spray : Process Flow
Gun- Flsme/Plasma/HV
OFFlame Temp 3000-15000*C
Semi molten particle temp t
Particle velocity V ~ 400-1200m/sec
Spray dist 6-15 inches – No heat transfer to base
Grit blasted surface
Hot particle quenches @surface to give Hardness Splat ~ D= 3X
d Adhesion : Micro welding +
mechanical bonding
Practical size ~d 15-106 microns Spherical in shape
D-- = 3.5
d
SURFACE COATING
Heated particles propelled
Impact force = 1/2mv2
Concept and Schematic of
THERMAL SPRAY
Layer by layer coating builds up
Plasma spraying
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• Most versatile process in terms of range of coatings •plasma temperature: up to 15000 ºC.
• virtually all existing materials including ceramics. Flame spray 350-
500m/sec
High-velocity oxy fuel spraying (HVOF)
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Cold spraying
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• gas temperature: under the phase transition temperature ~ 800,1000C• sprayed materials: pure Al, Zn, Cu, Ni Alloys : NiCr, Cr- Carbide/NiCr
Process and prosperities comparison
Adhesion Strength (Mpa)
Processes Particle speed m/s (km/h)
Spray rate kg/h
Porosity Levels
%
Thickness capablity
mm
Flame Temp °C
Powder Flame 70 (144) 1...8 10...15 0,2...5 3000 10...30
Wire Flame 70 (144) 5...8 0,2...0,4 0,2...5 3000+1100 n. 300
Arc Spray 220 (790) 6...40 10...20 0,2...10 3000 10...30
Plasma 600 (2160) 1...6 2...8 0,2...2 16500 20...70
HVOF 800 (2880) 2...9 0,5...2 0,2...2 2800 60...120*
HVAF 800 (2880) 10...30 0,1...1,5 0,1...1.5 1800 60...120*
Detonation 900 (3240) 2...6 0,1...1,5 0,1...0.50 4500 75...120*
Characteristics of thermally sprayed coating structures(Typical Expected values)
As sprayed (3-5Ra)
Oxide-(max 3%) Cracks-(Not allowed) Pores (1-2%)
t
Grit blasted surface3-6 Ra
Unmolten particle 3 % maxEmbedded grit blasting
pieces-10% or area max
“over-blasted”area
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Plasma transfered arc spraying (PTA)
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• Fe, Ni, Co, Cr based alloys, stainless steels, cermets•Dilution ~ 2 %
HW/TIG bore cladding
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Common Base Material Grades API 5L X52 to X70, A106 Gr. B, ASTM A333 Gr.6, A182, A350, A694, AISI 4130, 8630
Common Weld Overlay Grades STAINLESS Steel 316L, 410, 904L, Duplex/Super Duplex, MONEL Alloy 200, 400; INCOLOY 825, INCONEL 625,C22; C276, Copper Nickel Alloy and others on customer requirement.
CRA Clad Pipe, Tubular Components Weld overlay of pipe in up to 6m lengths, extended to 12m by “double jointing”
Flanges and Connectors Flanges / Swivel Ring Flange :1-1/2”NB (min)
Bends (3D-5D) or on customer requirement, SR/LR Elbows, Tees, Reducers, Hubs /Caps
Weld overlay can be carried out on elbows priorto forming or after induction bending depending onthe dimensions.
Pressure Vessel Components CRA clad nozzles, vessel strakes, tube sheets
Valves & Valve Components Blocks, Manifolds, Gates, Seats, Bonnets, Ball Plug,Xmas Trees
Working Capabilities - Pipe cladding start from 4” diameter
Laser cladding
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• virtually all metal alloys, cermets and ceramics. Dilution < 1 %
Laser cladding process – Dilution/distortion negligible
Laser cladded stabilizer
Rotor repair Hyd. Ram and piston guides
Pump and valve applications Pump and valve applications
Cage carbide coated Knife Gate valve body carbide coated
Sleeve ceramic coated& Impeller ceramic coated Ground
Ceramic coated sleeves Hardfaced pump sleeve For Food industry 19
24” Ball valve coating
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Measurement After blasting HVOF coating
20” Ball tungsten carbide coated – Metal Seated Severe service application .
Ball HVOF coated and Lapped
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Plug valve, feed screw and Other applications
Plug valve carbide coating plug carbide or stellite possible
Control vale cage Ball valve carbide coating
Extrusion screw coating Valve disc stellite 6 PTA
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Oil and gas applications
BOP Double Ram piston BOP single ram piston
7” gate
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Metal seated gate vlave Pune plant facility
Metal seated - Seat rings
Other coponents oil and gas
Plug carbide coating Control valve plug -stellited
Ball and seat TC coated and match lapped Mud Rotor : Repaired and Tc coated
+ super polished
BOP Piston rod carbide coated and Ground
Pump plungers
Super finish 0.05 Ra
PROGRESSIVE PUMP ROTORCARBIDE COATED and super polised ( Earlier this application was Hard chrome)
Carbide coated and Ground Gate Valve( Replacement for Nitriding )
Plunger Ceramic coated
SPRAYMETThank You
SPRAYMET SURFACE TECHNOLOGIES PVT LTD.A413, 9th Main, 2nd Stage, Peenya Industrial area,
Bangalore . Email [email protected]
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