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OIL & GAS INDUSTRY WALL COLMONOY

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Page 1: WALL COLMONOY OIL GAS INDUSTRY - … · used extensively throughout the Oil & Gas Industry. From exploration and drilling to pumping and refining, ... machined from air or vacuum

OIL & GAS INDUSTRYWALL COLMONOY

Page 2: WALL COLMONOY OIL GAS INDUSTRY - … · used extensively throughout the Oil & Gas Industry. From exploration and drilling to pumping and refining, ... machined from air or vacuum

Wall Colmonoy is a global materials engineering group of companies

engaged in the manufacturing of surfacing and brazing products,

castings, and engineered components across aerospace, automotive,

oil & gas, mining, energy and other industrial sectors.

Known for our unique proven way of creating superior performing alloys that

enhance engineered components, we pride ourselves on long-term strategic

customer collaboration that produces value-added ideas and

creative solutions.

Combining over 75 years of engineering technology with a progressive,

visionary outlook, Wall Colmonoy offers customers trusted, customised

expertise that results in smart innovation and shared growth.

PROGRESSIVE COLLABORATION FOR SUPERIOR PERFORMANCE. WORLDWIDE.

Page 3: WALL COLMONOY OIL GAS INDUSTRY - … · used extensively throughout the Oil & Gas Industry. From exploration and drilling to pumping and refining, ... machined from air or vacuum

Wall Colmonoy’s hard-surfacing

products and engineered components are

used extensively throughout the Oil & Gas

Industry.

From exploration and drilling to pumping

and refining, our range of Surfacing Alloys

have successfully extended the useful life

of the industry’s equipment and machinery

from harmful corrosion and wear.

Our specially formulated alloys,

COLMONOY® (nickel-based) and

WALLEX® (cobalt-based), have outstanding

metallurgical and physical properties making

them ideally suited to solving wear problems

in the Oil & Gas Industry.

The alloys are applied in a wide range of

proven surfacing and thermal spraying

techniques, including Laser Cladding, PTA,

HVOF, and Spray & Powder Welding.

Wall Colmonoy also manufactures precisely

cast and machined components. Made

from our superior performing Colmonoy®

or Wallex® Surfacing Alloys or customer-

specific alloys using Investment, Centrifugal,

Sand Cast or Vacuum Cast Processes.

Engineered components are designed to

optimise wear, corrosion, abrasion and heat

resistant properties.

For more than 75 years Wall Colmonoy has

served the Oil & Gas Industry with high-

quality, hard-surfacing alloys, precisely

engineered components, expert application

consultation and field assistance.

Our Manufacturing facilities in North

America and Europe are equipped with

modern laboratory and testing facilities.

Our products are manufactured to quality

standards set by international and national

industrial associations. We maintain quality

assurance to ISO 9001.

WALL COLMONOY OIL & GAS INDUSTRY

2

Page 4: WALL COLMONOY OIL GAS INDUSTRY - … · used extensively throughout the Oil & Gas Industry. From exploration and drilling to pumping and refining, ... machined from air or vacuum

What makes our products different?

Our range of Colmonoy® and Wallex®

Surfacing Alloys are an excellent defense

against wear mechanisms such as abrasion,

erosion, corrosion and high-temperatures

encountered in service. As the world’s

leading manufacturer of nickel-based hard-

surfacing alloys, Wall Colmonoy coatings

have been extending the service life of

industrial parts for over 75 years.

What is hard-surfacing?

Hard-surfacing is the application of a layer

of wear-resistant alloy to a part for the

purpose of extending the machine’s service

life. This can be performed on worn parts to

replace metal lost through wear and on new

parts when wear is anticipated.

What is the benefit?

Parts protected with our Surfacing

Alloys – Colmonoy® or Wallex® - last

significantly longer than unprotected parts.

This means:

• fewer replacement parts needed

• less labor required to install them

• minimise down-time

In fabricating new parts, inexpensive base

metals may be used because our Surfacing

Alloy coatings withstand wear. Our

Surfacing Alloys are available as powder,

rods, wires and castings to suit different

application methods.

MAXIMISING PERFORMANCE & EXTENDING THE USEFUL LIFE OF ENGINEERED COMPONENTS

TYPES OF SURFACING POWDER PRODUCTS:

Atomised – nickel and cobalt alloys containing combinations of tungsten, chromium, chromium carbide or tungsten carbide for specific applications. Crushed – premium alloy form with high surface area and dense coatings for superior wear-resistance.

Composite – alloy particles of tungsten carbide in nickel or cobalt matrix; designed to resist sliding abrasion and abrasive wear.

SURFACING ALLOYS FOR OIL & GAS

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Page 5: WALL COLMONOY OIL GAS INDUSTRY - … · used extensively throughout the Oil & Gas Industry. From exploration and drilling to pumping and refining, ... machined from air or vacuum

An Integrated Approach - Casting, Heat Treating and Machining all from One Source

Wall Colmonoy’s precisely engineered

components are used throughout Oil & Gas

industry. The components are made from

wear, heat, and corrosion resistant Colmonoy®,

Wallex®, or customer-specific alloys designed

to optimise wear, corrosion and heat resistant

properties.

Components are either as cast or fully

machined from air or vacuum melted castings

made by investment, sand, or centrifugal

techniques.

l

All components can be offered in the as cast,

Machining facilities include EDM, wire cutting,

CNC grinding, honing, milling, lapping and

turning.

Our technical team has amassed a

wealth of skill, knowledge and know-how

turning designers’ and engineers’ rigorous

requirements into economically viable

solutions. Our expert engineers select the

optimum alloy and process to suit specific

needs.

Components for Oil & Gas Industry

are produced using Wallex® alloy and

manufactured according to API standards

include:

• Ball Valves

• Clamp Plates and Pads

• Plugs and Flow Control Cages

• Rotors

• Stem Guides

• Valve Seats

Wall Colmonoy’s on-site laboratory and test

facilities are fully approved and can certify

goods to customers specific requirements.

Wall Colmonoy has an ongoing

commitment to high quality

manufacture and offer

certification to nationally

and internationally

recognised standards.

Each engineered

component goes

through a reassuringly

stringent inspection

process before final

delivery.

DESIGNED TO OPTIMISE WEAR, CORROSION, ABRASION, AND HEAT RESISTANT PROPERTIES

CASTING METHODS:

Investment – offers design flexibility, close dimensional control, consistency & repeatability, cost savings.

Centrifugal Spun – is used to produce high integrity densely structured, cylindrical components like bushes and sleeves.

Sand – is typically used to produce larger components in smaller batches. It is capable of making mostly complex shapes using relatively inexpensive wood or resin patterns.

Vacuum Casting – is used for alloys where tight compositional control and low inclusion counts are required - difficult to achieve when using conventional air melting and casting.

PRECISION COMPONENTS FOR OIL & GAS

4

Page 6: WALL COLMONOY OIL GAS INDUSTRY - … · used extensively throughout the Oil & Gas Industry. From exploration and drilling to pumping and refining, ... machined from air or vacuum

Extending the useful life of the industry’s equipment, gears, and machinery from harmful corrosion and wear

DRILLING

Blowout Preventors, Operating Pistons - Colmonoy 52, 5

Cable Drill Bits - Colmonoy 88

Centrifugal Pump Parts and Wear Rings - Colmonoy 52, 5, 62, 6, 72

Choke and Kill Pins - Colmonoy 52, 5

Clamp Plates and Pads -Wallex 6

Compressor Rod Sleeves - Colmonoy 62

Compressor Rods - Colmonoy 62, 6

Downhole Pump Plungers – Colmonoy 42, 4, 52, 5, 62, 6

Drilling Rigs (Idler Shaft) - Colmonoy 75

Drill Bits, Stabilisers, Steering Pads - Colmonoy 25, 7331-60, 7251-60, 7541-55F

Oil Drilling Rig Wash Pipes - Colmonoy 62, 6, 69, 88

Radial Bearings, Drill Motors - Colmonoy 68, WallCarb

Riser Pins - Colmonoy 52, 5, 62, 6, 45

Steel Body Bits - Colmonoy 750

Down Hole Pump Plunger sprayed and induction-fused with Colmonoy 62

APPLICATIONS FOR OIL & GAS INDUSTRY

Clamp Plate and Kickers used for Downhole Drilling - Cast in 17/4 PH Steel

Colmonoy 25F cementing tungsten carbide inserts onto an Integral Stabiliser for Oil & Gas Exploration Industry

5

Mud Motor Radial Thrust Bearing with WallCarb coating on inside

Page 7: WALL COLMONOY OIL GAS INDUSTRY - … · used extensively throughout the Oil & Gas Industry. From exploration and drilling to pumping and refining, ... machined from air or vacuum

Colmonoy 52 fused onto a plunger with propaneFracturing Pump Plunger using Colmonoy 88

APPLICATIONS FOR OIL & GAS INDUSTRY

Machining of a Thermowell Thermowell Tip - Wallex 6

FRACTURING

Fracturing Pumps Plungers

Colmonoy 62, 88, 6, 62H, 88H, 72

Hydrocyclone Casting - Wallex 6

REFINING

Baffle Grids (Catalyst) - Colmonoy 62, 6

Catalytic Cracker Throats - Colmonoy 62, 6

Thermowell Protecting Plates - Colmonoy 62, 6, 88

Thermowells - Wallex 42, 50, Colmonoy 62, 6, 88

Hydrocyclone Castings - Wallex 6

6

Page 8: WALL COLMONOY OIL GAS INDUSTRY - … · used extensively throughout the Oil & Gas Industry. From exploration and drilling to pumping and refining, ... machined from air or vacuum

PUMPING

Ball Check Cages - Colmonoy 52, 5, Wallex 6

Blowout Preventors, Operating Pistons - Colmonoy 52, 5

Centrifugal Pump Parts and Wear Rings - Colmonoy 52, 5, 62, 6, 72

Choke and Kill Pins - Colmonoy 52, 5

Oil Pump Sleeves - Wallex 55

Oil Rod Couplings - Colmonoy 62, 6

Oil Well Pump Wear Rings - Colmonoy 52, 5

Oil Well Pump Plungers - Colmonoy 62, 6, 88

Oil Well Rod Guides - Colmonoy 62, 6

Polish Rods and Liners - Colmonoy 52, 5, 62

Pump Plungers (Triplex) - Colmonoy 62, 6, 635, 88, 730

Pump Rods, Sleeves and Seal Faces - Colmonoy 62, 6

Pump Shafts (Caustic) - Colmonoy 62, 6

Pump Sleeves (Hot Oil) - Wallex 50

Pump Sleeves and Bushings - Colmonoy 69, 88, 705

Spiral Rod Guides - Colmonoy 62, 6

Sucker Rod Couplings – Colmonoy 62, 6

Vertical Gas Pumps (Propane and Butane) - Colmonoy 52, 5

Pump Sleeves - Wallex 50

APPLICATIONS FOR OIL & GAS INDUSTRY

Rotor Cast and Machined - Wallex 6Pump plunger sprayed with Colmonoy 52Sucker rod coupling spray and induction fused on a Carousel with Colmonoy 62SA

Inducer Casting - Wallex 6

7

Page 9: WALL COLMONOY OIL GAS INDUSTRY - … · used extensively throughout the Oil & Gas Industry. From exploration and drilling to pumping and refining, ... machined from air or vacuum

Ball Valve HVOF sprayed, PTA or TIG welded - Wallex 6

APPLICATIONS FOR OIL & GAS INDUSTRY

Ball Valve TIG repaired - Wallex 6

Plug valve spray and fused with Spraywelder- Colmonoy 52

Slide Valve Carrier - Wallex 6

Rotating gates HVOF coated with Colmonoy 88H

Valve repair Laser Cladding - Wallex 6

Plug Casting - Alloy Grade C

VALVES

Catalytic Slide Valve Gates (Seats) - Colmonoy 88

Flow Control Valve parts - Colmonoy 62, 6

Gate Valve Seats - Colmonoy 42, 4, 84

Oil Well Safety Valves - Colmonoy 62, 6

Plug Valves - Colmonoy 42, 4, 52, 5, Wallex 50

Plugs and Flow Control Cages - Wallex 6

Ball Valves - Colmonoy 52, 5, 69SC, 88, Wallex 50

Stem Guides - Wallex 6

Valve Gates - Colmonoy 52, 5, 84, 730

Valve Stem Seats (Ammonia) - Colmonoy 62, 6

Valves (Stationary Engines) - Colmonoy 52, 5

Wedge Valves (Steam) - Colmonoy 52, 5

8

Page 10: WALL COLMONOY OIL GAS INDUSTRY - … · used extensively throughout the Oil & Gas Industry. From exploration and drilling to pumping and refining, ... machined from air or vacuum

Adhesive, or galling, occurs from

metal-to-metal contact between

processing equipment such as screws and

barrels. Contacting metal surfaces subject to

extreme temperatures

often momentarily weld together and then

crack upon separation,

depositing metal particles in the

material being processed.

Abrasive wear is caused by hard

particles gouging or chipping the

surfaces of machine parts. These

abrasive particles are usually sands,

mud, rock or metal pieces dislodged

by adhesive wear.

Corrosion results from chemical

reactions between processing

equipment and the material being

processed. Corrosive agents such as acid at-

tack at the surface of machine or equipment

parts and components.

Erosive wear, is similar to abrasive

wear except the particulate is

suspended in a fluid that impinges

on the part.

Combinations of wear are common. Often

corrosive fluids cause corrosion products (ie.

Rust) to be formed. This corrosion product

is then able to act as an abrasive or erosive

media.

There are various types of wear prevalent in the Oil & Gas Industry. Our alloys

are industry standards for wear-resistant performance. We have developed new

alloys and enhanced others to meet your wear surfacing demands.

WEAR DEMANDS ADDRESSING THE INDUSTRY’S DEMANDS

TYPES OF WEAR

Galling

Abrasive

Corrosion

Erosive

9

Page 11: WALL COLMONOY OIL GAS INDUSTRY - … · used extensively throughout the Oil & Gas Industry. From exploration and drilling to pumping and refining, ... machined from air or vacuum

OUR SURFACING ALLOYS COMBATTING WEAR PREVALENT IN OIL & GAS INDUSTRY

Colmonoy®

(nickel-based)

1.8 2.7

1.8 0.5 10.0 2.5 3.2

2.5 0.5 11.0 4.5 3.3

3.0 0.6 14.0 4.0 4.2

3.0 0.6 14.0 4.0 4.2

3.5 0.5 16.5 3.0 3.0 5.0 Cu: 2.0

3.2 0.5 12.0 4.0 3.0 13.0

1.4 1.1 29.0 2.2 7.5

3.0 0.6 15.0 3.5 4.0 15.5

2.2 0.4 10.0 2.5 2.3

2.3 0.5 13.8 4.0 3.4

3.0 0.6 14.0 4.0 4.2

15.0 3.5 16.0 4.5 Mn: 1.2

<0.075 22 <5.0 9.0 <0.5 Nb: 3.75

1.9 2.3 8.0 2.5 3.0 30.8 Co: 2.1

1.4 2.9 7.5 2.5 2.4 41.4 Co: 6.0

1.5 2.0 5.4 2.5 2.3 48.0 Co: 0.1

1.8 2.4 8.4 2.5 2.4 39.2 Co: 2.1

0.7 2.5 2.4 0.7 1.8 57.4

0.7 2.5 1.1 57.4

0.75 3.0 3.4 1.5 1.5 46 Co: 5.5

B C Cr Fe Mo Si W Ni Others HRC

NOMINAL COMPOSITION (%) HARDNESS COMMENTSALLOY

25 42 52 62 63 69 72 84 88 4 5 6 276 625 635 75 705 730 7331-60 7251-60

7541-55F

Wallex® (cobalt-based)

1.2 28.0 <3.00 <1.00 1.3 4.5 <3.00 Co:Bal 40-44

2.0 0.6 16.2 2.0 1.9 7.6 13.5 Co:Bal 41-46

3.4 0.8 19.0 2.0 2.8 10.0 18.0 Co:Bal 56-61

2.0 2.3 12.0 1.2 1.7 34.8 12.6 Co:Bal >58 35% WC

642 5055

10

25-31

35-40

45-50

56-63

57-63

58-63

57-62

40-45

59-64

35-40

40-45

56-63

25

97 HRB**

57-63

57-63

58-63

57-63

30-40*

25-31*

Dressing and re-dressing steel and nonmagnetic parts

50% WC

50% WC Use as a buffer layer with 7331-60 / 7251-60 on non-magnetic parts

35% WC

50% WC

50% WC

35% WC

Atomised, crushed or composite powders to be used with most laser cladding and PTA cladding equipment. Reamers; hole openers, steering pads, stabilisers, drill bits etc.

*Depending on method of deposition **Depending on application type and parameter settings

52 Composite blend matric for stabilisers, drill bits, and steering pads for oil & gas extrusion

Bal

Bal

Bal

Bal

Bal

Bal

Bal

Bal

Bal

Bal

Bal

Bal

Bal

Bal

Bal

Bal

Bal

Bal

Bal

Bal

Bal

Page 12: WALL COLMONOY OIL GAS INDUSTRY - … · used extensively throughout the Oil & Gas Industry. From exploration and drilling to pumping and refining, ... machined from air or vacuum

APPLICABLE SPECIFICATIONSThere are several specifications that are applicable to Colmonoy hard-surfacing

products. The most common of which are outlined below.

ERNiCr-A Colmonoy 4 Colmonoy 4

ERNiCr-B Colmonoy 5 & 56 Colmonoy 52, 53, 56

ERNiCr-C Colmonoy 6 Colmonoy 62, 63

CLASSIFICATION ROD PRODUCTS EQUIVALENT POWDER PRODUCTS

MIL-RNiCr-B-1 Colmonoy 5 & 56 Rod

MIL-RNiCr-C-1 Colmonoy 6 Rod

DESIGNATION PRODUCTS

N99644 Colmonoy 4

N99645 Colmonoy 5

N99646 Colmonoy 6

UNS DESIGNATION PRODUCTS

GE P50YP164 Colmonoy 6

NACE MR-01-75 Colmonoy 4, 5 & 6

GENERAL ELECTRIC

NATIONAL ASSOCIATION OF CORROSION ENGINEERS

11

Page 13: WALL COLMONOY OIL GAS INDUSTRY - … · used extensively throughout the Oil & Gas Industry. From exploration and drilling to pumping and refining, ... machined from air or vacuum

PLASMA TRANSFERRED ARCPTA Machine applying coating to a downhole toolPhoto courtesy of Lion Engineering Ltd (Great Yarmouth)

APPLICATION PROCESSES

We also provide hard-surfacing products for wire or rod application.

HVOFColmonoy 88 HVOF sprayed to Pump Sleeve

SPRAYWELDERColmonoy 52 sprayed by a Spraywelder™ System to Down Hole Pump Plunger

LASER CLADDINGColmonoy 88 Laser Cladded to Pump Sleeve

12

Spraywelder™ J-3 System 106 - 38

Fusewelder™ Torch 106 - 20

M-cut 125 - 45

PTA P1: 180 - 75 P2: 150 - 63 P3: 125 - 53

HVOF H1: 63 - 20 H2: 53 - 20 H3: 45 - 15

Laser 150 - 63

EQUIPMENT NOMINAL PARTICLE SIZE RANGE (μm) MESH SIZE

140 / 400

140 / 625

120 / 325

P1: 80 / 210 P2: 100 / 230 P3: 120 / 270

H1: 230 / 625 H2: 270 / 625 H3: 325 / 800

100 / 230

Page 14: WALL COLMONOY OIL GAS INDUSTRY - … · used extensively throughout the Oil & Gas Industry. From exploration and drilling to pumping and refining, ... machined from air or vacuum

Colmonoy® 52 Colmonoy 52 is a premium nickel-based alloy

powder produced by inert gas atomisation.

The particle size distribution is closely controlled

and optimised for application with the Model

J-3 SpraywelderTM System.

Colmonoy® 7331-60P2 Colmonoy 7331-60P2 PTA is a composite blend of

a gas atomised nickel-based alloy powder and 60%

by weight monolithic tungsten carbide. The combi-

nation of an extremely tough matrix and very hard

carbide produces an exceptional impact and wear

resistance combination. A dense carbide distribution

with small inter-carbide spacing allows for a large

surface area of tungsten carbide to be exposed to

wear environment to provide maximum service life.

Colmonoy® 730Colmonoy 730 is composite blend consisting

of a highly corrosion resistant nickel-chromium-

tungsten matrix and fine, extremely abrasion

resistant tungsten carbide particles. This unique

combination provides excellent protection against

both corrosion and abrasion. This makes it an ideal

coating for pump plungers operating at

temperatures up to 1200°F (650°C).

HIGHLIGHTED PRODUCTS HARD-SURFACING ALLOYS FOR OIL & GAS

Photomicrograph of Colmonoy 52 applied by the Sprayweld process and fused (original at 50x).

Photomicrograph of Colmonoy 7331-60P2 showing carbide distribution in PTA Weld Over-lay (etched with marbles reagent, original at 100x magnification).

Photomicrograph of Colmonoy 730 (original at 50x)

13

Page 15: WALL COLMONOY OIL GAS INDUSTRY - … · used extensively throughout the Oil & Gas Industry. From exploration and drilling to pumping and refining, ... machined from air or vacuum

Colmonoy® 88 US PATENT NO. 5,141,571

This patented alloy contains chromium, tungsten

borides and carbides for maximum abrasion and

corrosion resistance.

Its premium chemistry provides product versatility

and excellent wear resistance properties. In fact,

its chemistry is such that bi- and tri- metallic hard

phases are precipitated throughout the alloy during

the manufacturing process and during fusion of the

coating.

This hard-phase formation occurs due to the specific

compositional relationship between the elements

of tungsten, chromium, boron, silicon, and carbon.

Rapid quench gas atomisation is utilised to allow

nucleation of hard phases during the manufacturing

process. This distribution of hard phases produces

the exceptional wear characteristics of this alloy.

As an integral part of Colmonoy 88 alloy, these

hard phases do not sink or settle out during the

application process as would the carbides in a

blended composite powder. Thus, the first 0.001”

layer and the last 0.001” layer are virtually the same.

As a pre-alloyed homogeneous powder product,

there is no need for concern about segregation

of carbide and matrix or unexpected loss of hard

phases during the coating process.

HIGHLIGHTED PRODUCTS (CONTINUED)

Photomicrograph of Colmonoy 88 (original at 200x)

G -65 DRY SAND ABRASION TEST

This chart compares abrasive wear test results of several materials under the same conditions. The relatively low volume loss proves the superiority of Colmonoy 88 to all but the hardest of materials.

VOLU

ME

LOSS

CU

BIC

(mm

)

Hardness (Rockwell C) 61 Melting Range:

Density 9.9gm/cc Solidus 987°C (1810°F)

Apparent Density 4.8gm/cc Liquidus 1182°C (2160°F)

14

Page 16: WALL COLMONOY OIL GAS INDUSTRY - … · used extensively throughout the Oil & Gas Industry. From exploration and drilling to pumping and refining, ... machined from air or vacuum

Rockwell C Scale Hardness of Gas Welded Alloy Deposits

HOT HARDNESS Colmonoy® 62 alloy outwears hardened steel by up to twenty times

High “hot hardness” is a valuable asset for a hard-surfacing alloy, even where it doesn’t

appear that heat is a contributing factor to the wear problem. One of the most important

reasons why Colmonoy® 62 alloy outwears hardened steel by up to twenty times is that the

Colmonoy alloy maintains a higher degree of its initial hardness under high temperatures

than steel.

While some steel can be made initially harder by heat treatment, the surface will become

soft under the heat of friction to a point lower than that of Colmonoy® or Wallex® under

like conditions. It then wears more rapidly. Colmonoy® and Wallex® alloys regain most if not

all of their original hardness upon cooling.

Colmonoy®

(nickel-based)

35-40 34 33 29 26 45-50 46 45 42 3856-63 57 54 49 4550-55 50 48 44 4156-63 57 54 49 4557-62 62 62 56 4159-64 62 61 56 43

21°C (70°F) 315°C (600°F) 427°C (800°F) 538°C (1000°F) 650°C (1200°F)

TEMPERATUREALLOY

42526256697288

40-44 33 27 22 2041-46 38 36 30 2556-61 56 56 56 49

64250

Wallex® (cobalt-based)

15

Page 17: WALL COLMONOY OIL GAS INDUSTRY - … · used extensively throughout the Oil & Gas Industry. From exploration and drilling to pumping and refining, ... machined from air or vacuum

HOT HARDNESS CHART COLMONOY AND WALLEX COATING

TEMPERATURE - °F (°C)

KEY

Colmonoy®

(nickel-based)Wallex® (cobalt-based)

RO

CK

WEL

L C

SC

ALE

HA

RD

NES

S

RO

CK

WEL

L C

SC

ALE

HA

RD

NES

S

16

Page 18: WALL COLMONOY OIL GAS INDUSTRY - … · used extensively throughout the Oil & Gas Industry. From exploration and drilling to pumping and refining, ... machined from air or vacuum

SpraywelderTM System

The SpraywelderTM System offers tight spray

patterns and high spray rates to produce dense,

wear resistant overlays. The Model J-3 is the

culmination of more than 65 years of technical

innovation following the invention of our first

thermal spray gun.

The SpraywelderTM is easy to operate, safe and

versatile. It has built-in efficiency:

Tight spray patterns

High Spray Rates - up to 8 kg/hr with standard

model, and 14 kg/hr with high-output unit.

Dense coatings – flame energy of up to 92,000

BTUs and increased target efficiency deliver hot

metal spray particles to the base metal. The final

result is a strong, dense overlay.

Reliable – The J-3 SpraywelderTM is designed from

our vast field experience and built for years of

daily use with a proven record of success.

“Tight spray patterns and high spray rates to produce dense, wear resistant overlays”

WALL COLMONOY’S HARD-SURFACING EQUIPMENT

98% of the spray powder hits the part within a 19 mm (3/4 in) target when using the D nozzle at 4.5-5.4 kg (10-12) lbs/hr.

19mm 3/4 inch

17

Page 19: WALL COLMONOY OIL GAS INDUSTRY - … · used extensively throughout the Oil & Gas Industry. From exploration and drilling to pumping and refining, ... machined from air or vacuum

THE 5-STEP SPRAYWELD PROCESS:

1. SURFACE PREPARATION

The surface to be overlaid should be clean and free of oil or oxides. Surface preparation involves the following:• Degreasing• Undercutting• Grit Blasting

Our Nicrobraz® Green Stop-Off™ may be applied to prevent thermal spray materials from bonding to adjacent surface areas.

2. PREHEATING

Preheating time varies with the type of base metals:• Mild steels (<0.25% Carbon): <149°C

(<300°F) • Austenitic stainless steel (300 series):

316 - 371°C (600° - 700°F) • Martensitic steel (4340 and 400 series):

260° - 371°C (500° - 700°F)

3. SPRAYING

To produce a uniform, mechanically bonded overlay, the following resources are needed:

• SpraywelderTM including pistol, panel, and hoses

• Spraywelder TM grade powder• Oxy-acetylene or oxy-propylene gases• Compressed air• Variable-speed turning device (as a lathe)• Clean, dry air

4. FUSING

The objective of fusing is to transform the mechanical bond created in the spraying operation into a metallurgical, or welded bond. Most common methods include oxy-fuel torch, controlled atmosphere furnace or induction.

The Colmonoy® and Wallex® overlay and base metal surface must reach a temperature between 982 - 1138°C (1800 - 2080°F) (based on powder selection), at which point the overlay will wet and bond with the base surface without running or losing its shape.

5. FINISHING Wall Colmonoy’s Spraywelder TM powders are easily finished by grinding or machining. For finishing recommendations, request a technical data sheet.

“The culmination of more than 65 years of of technical innovation”

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Page 20: WALL COLMONOY OIL GAS INDUSTRY - … · used extensively throughout the Oil & Gas Industry. From exploration and drilling to pumping and refining, ... machined from air or vacuum

WORLD HEADQUARTERSWALL COLMONOY | 101 W. Girard | Madison Heights, MI 48071

Tel 248-585-6400 | Fax 248-585-7960 Web www.wallcolmonoy.com | Email [email protected]

EUROPEAN HEADQUARTERSWALL COLMONOY | Alloy Industrial Estate | Pontardawe Swansea Wales (U.K.) SA8 4HL

Tel +44 (0) 1792 862287 | Fax +44 (0) 1792 869474 Web www.wallcolmonoy.co.uk | Email [email protected]

WCL_Oil-&-Gas-Brochure_ENG_0817250

WALL COLMONOY. PROGRESSIVE COLLABORATION FOR SUPERIOR PERFORMANCE. WORLDWIDE.

CINCINNATI | LOS LUNAS | OKLAHOMA CITY | PUNE (INDIA) | WALES (U.K.) | WINDSOR (CANADA)

The information provided herein is given as a guideline to follow. It is the responsibility of the end user to establish the process information most suitable for their specific application(s). Wall Colmonoy Limited (UK) assumes no responsibility for failure due to misuse or improper application of this product, or for any incidental damages arising out of the use of this material.

Copyright © 2017 Wall Colmonoy Limited. All rights reserved.