the world of thermal spray
TRANSCRIPT
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Guess what???……
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What is it, that is common in a …..
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Thermal Power PlantThermal Power Plant Jet EnginesJet Engines
Petro refineryPetro refinery Steel PlantSteel Plant
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What is, that is common in a …..
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Plastic Industry Glass Industry
Oil Drilling Mining
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What is, that is common in a….
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Sugar Mill Paper Mill
Dry Dock & Shipyards Cement & Chemicals
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Common in the jobs from Industries???
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Plastic Extruder ScrewsTriplex pump plungers
MG Cylinder in a Paper mill Boiler Tubes in a Power Plant
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Common in the jobs from Industries???
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Glass MouldsDry Dock
Steel Structures Journal Bearing halves
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•
Reclamation…
All these Partsand
Many more that are being added everyday ,
undergo Life
Enhancement or
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Why Just on Industrial Parts? Watch this movie clip on next slide!
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
Titanium on Orthopedic Implants
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Reclamation & Life Enhancement
of Critical Industrial parts?
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Reclamation…
RECLAMATION: The Part in a Assembly/Sub-Assembly, Due To WEAR is unable to PERFORM its Function, ready to take up
Journey to a Scrap yard, are repaired and used.
EXAMPLE: Cracked Housings
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Life Enhancement…LIFE ENHANCEMENT: The Part in a Assembly/Sub-Assembly, Either, WEAR is Detected & Preventive Action is Initiated. EXAMPLE: Bearing Area of Armature Rotor OrBased On Past Experience, PreventiveAction is Initiated, on a new part. EXAMPLE: OD of these Core Barrel Heads
The Key Word in Reclamation / Life Enhancement Is ‘WEAR’
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The Phenomenon by which there is change in SHAPE/ SIZE/ TEXTURE of a Part, resulting in improper Functioning of the Sub-Assembly / Assembly.
IMPACT. ABRASION. FRICTION. COROSION. EROSION. HEAT. PRESSURE.
What is WEAR??
Thus a Thorough ‘WEAR ANALYSIS’ of A Worn-out part is a MUST. It is done with the help of ‘WEAR FACTORS’, which are:
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Some of the Factors for WEAR….
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‘Alloy Selection’ KEY To COMBATING WEAR.
Alloys Like :S.S, Zinc, Aluminium, Titanium….Manganese, 13% chrome steels….Cobalt based alloys… Nickel based alloys like Ilium's, Hestalloy’s,Carbides of Iron/Chromium/Tungsten,Ceramics (Oxides) of Aluminum, Chromium,
Zirconium many more are being developed every day….
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SELECTION Of THE METHOD OF DEPOSITION::
Depends on :
Base-Metal; Job Size, Cross Sectional Thickness, Alloy Thickness To Be Deposited Deposition Characteristics Cost of Deposition Thus We Have :• MANUAL METAL ARC WELDING (MMAW)• Metal Inert Gas (MIG/MAG), FCAW• Gas Tungsten Arc Welding(GTAW), Or, TIG• Thermal Spray: Including Fusible, Flame Spray, Arc-
Spray, Plasma (NTA & PTA), HVOF, Cold Spray, LASER
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Welcome to
The World of
Thermal Spray
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
THERMAL: Involving HEAT… SPRAY: Particles MOVING at high speed in a
medium, in our context a Gas…
What is a Thermal Spray?
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
A coating produced by a process in which molten or semi-molten particles are applied by impact onto a substrate.
The impacting molten particles on the substrate rapidly solidify to form SPLATS.
What is Thermal Spray?
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1. Melting
2. Atomization and speed up
3. Temperature and speed control
4. Coating building
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What are Splats?
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Splats
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
A Thermally Sprayed Layer…
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
Bonding of Thermally Sprayed Layer…
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
Range of Alloys to counter Wear that can be Range of Alloys to counter Wear that can be deposited.deposited.
The Alloys can be from Machinable to The Alloys can be from Machinable to Ultra-Hard.Ultra-Hard.
From few Microns to Couple of mm.From few Microns to Couple of mm. From Bond strengths of 10K psi to Diffusion From Bond strengths of 10K psi to Diffusion
bonded with 75K psi (depending on Process bonded with 75K psi (depending on Process of deposition)of deposition)
The next to none dilutionThe next to none dilution No undercut No undercut
Why Thermal Spray?
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
Thermal Spray…Classification based on heat imparted to the Alloy Based on Gas for Heating: Self Fluxing or Fusible Coatings (Oxy-Acetylene) As-Sprayed or Flame Spray (Oxy-Acetylene) Wire Flame Spray (Oxy-Fuel / Acetylene) HVOF (Oxy-Fuel, variants have Kerosene as Fuel too) Cold Spray (Heated Nitrogen-Helium Mixture, no
combustion)Based on Electric Power: The Twin Wire Electric Arc The PLASMA Spray NTA The PLASMA PTA LASER
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
Thermal Spray…
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
A Torch / Gun. Alloy and Alloy feeder. Means to Heat the Alloy (Oxy-Fuel/Gases or Electricity). Carrier Gas. Controls for controlling the above 3.And.. A Prepared / Activated Substrate.
Components of Thermal Spray System..
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Materials that can be Sprayed
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The Self Fluxing or
The Fusible Powder Welding Process..
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The First Process…
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
Process similar to Process similar to Brazing.Brazing.
The difference is in The difference is in place of filler wire, a place of filler wire, a Pre-AlloyedPre-Alloyed powder. powder.
This is sprayed with This is sprayed with help of a specially help of a specially designed torch, using designed torch, using oxy-acetylene gases.oxy-acetylene gases.
The Self Fluxing or FUSIBLE-COATINGSFUSIBLE-COATINGS
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
1. Oxygen & Acetylene Controls2. Powder & Powder feeder
Lever.3. Nozzle4. Oxygen & Acetylene gas
Connections
The Self Fluxing Torch
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1
2
3
4
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
Movie clip Fusible Process..
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
Diffusion bonded (Metallurgical Bonds) with 55K. psi Bond Strengths.Diffusion bonded (Metallurgical Bonds) with 55K. psi Bond Strengths. The Minimum dilution (the deposited alloy is fused with Base Metal, The Minimum dilution (the deposited alloy is fused with Base Metal,
which remains un-melted).which remains un-melted). No undercut (The demarcation observed between a Base layer & a No undercut (The demarcation observed between a Base layer & a
deposited layer (in Arc welding). deposited layer (in Arc welding). Range of Self Fluxing Alloys to counter Wear.Range of Self Fluxing Alloys to counter Wear. The Alloys can be from Machinable to Ultra-Hard.The Alloys can be from Machinable to Ultra-Hard. High Re-Melting Temperatures.High Re-Melting Temperatures. From few Microns to Couple of mm. From few Microns to Couple of mm. All Non-Heat treated / Toughened Iron based Alloys can be sprayed All Non-Heat treated / Toughened Iron based Alloys can be sprayed
upon.upon.
The Characteristics of FUSIBLE-COATINGS..FUSIBLE-COATINGS..
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
In the Indian context is still a Work HorseIn the Indian context is still a Work Horse
Some of the Key Applications are..Some of the Key Applications are..
The Self Fluxing or FUSIBLE-COATINGS..FUSIBLE-COATINGS..
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
The Plastic Industry Single Extruder
ScrewsClick here to read a
write up
Key Applications of Fusible Coatings..Key Applications of Fusible Coatings..
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Coated
Coated and Ground
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
The Plastic Industry
The Twin Extruder Screws frontal zones
Key Applications of Fusible Coatings..Key Applications of Fusible Coatings..
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
The Glass industry.. Glass moulds. The Mould
Plungers. The Neck Ring The Glass cutters. Conveyer Track
Pads.
Key Applications of Fusible Coatings..Key Applications of Fusible Coatings..
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Key Applications of Fusible Key Applications of Fusible Coatings..Coatings..
In Oil Drilling Mud Pump
Plungers
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Key Applications of Fusible Key Applications of Fusible Coatings..Coatings..
In Sugar Industry
Scrapper Plate
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Some Applications which are also being done..
The Engine Valves The Mechanical Seals
(the refrigeration compressor / Pumps)
Key Applications of Fusible Coatings..Key Applications of Fusible Coatings..
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
Some Applications which are also being done in various industries..
The screw type of Centrifuge / Conveyers in Paper/ Textiles / Cements
Key Applications of Fusible Coatings..Key Applications of Fusible Coatings..
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
The Road Transport The Stub Axle bearing areas The Main Shaft bearing areas
Key Applications of Fusible Coatings..Key Applications of Fusible Coatings..
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
Some Applications which are also being done in Geotechnical Drilling
The Couplings
Key Applications of Fusible Coatings..Key Applications of Fusible Coatings..
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
Some Applications which are also being done in Geotechnical Drilling
The Head of Core Barrel
Key Applications of Fusible Coatings..Key Applications of Fusible Coatings..
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
Some Applications which are also being done in Geotechnical Drilling
The Outer Tubes
Key Applications of Fusible Coatings..Key Applications of Fusible Coatings..
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
Some Applications which are also being done in Geotechnical Drilling
Pyramid wrenches
Key Applications of Fusible Coatings..Key Applications of Fusible Coatings..
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
Boiler tube CoatingClick Here for Presentation
Key Applications of Fusible Coatings..Key Applications of Fusible Coatings..
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
Please call us for the Please call us for the Part2 of ‘The World of Part2 of ‘The World of Thermal Spray’Thermal Spray’ which covers:which covers:
A Recap of the A Recap of the ‘Basic of Thermal Spray’‘Basic of Thermal Spray’ ‘‘Powder Spray Process’ Powder Spray Process’ with Movie Clip & with Movie Clip &
Applications.Applications. ‘‘Wire Flame Spray ProcessWire Flame Spray Process’ ’ with Movie Clip & with Movie Clip &
Applications.Applications. ‘‘The Twin Arc Spray Process’ The Twin Arc Spray Process’ with Movie Clip with Movie Clip
& Applications.& Applications.
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
You can go through (please click You can go through (please click on): on): ‘Glossary on Thermal Spray‘Glossary on Thermal Spray’ ’ & & ‘Surface Preparation’‘Surface Preparation’
You can also click: ‘Jobs that You can also click: ‘Jobs that challenged us & the processes’challenged us & the processes’
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Your feed back means a lot to us,Your feed back means a lot to us,
Please provide it on: Please provide it on:
[email protected] [email protected]
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Phone: +91 98255 30436Phone: +91 98255 30436
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Thermal Spray, A Key line in Reclamation & Life Enhancement by Innovative Engineers, Phone: +919825530436, Email: [email protected]
Thank You for your Time..Thank You for your Time..
We are planning next in the series..We are planning next in the series..
‘‘Thin Film Coatings’Thin Film Coatings’
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