SURFACE COATING-HARD FACING-THERMAL SPRAYING

By R.Venkatakrishnan M.Tech - I - PDM

CONTENTS
1. Introduction Of Surface Coatings 1.1 Advantages of surface coating. 2.Introductions of Hard facing 2.1Process 2.1.1Shielded Metal Arc Welding 2.1.2Gas Metal Arc Welding 2.1.3Ox fuel Welding 2.3 Process Parameters 2.4 Applications 2.5 Advantages

3.Introductions of Thermal Spraying 3.1 Working Principle 3.2 Process 3.1.1 Wire Flame Spray
3.2.2 Powder Flame Spray 3.2.3 Electric Arc Wire Spray 3.2.4 High Velocity Oxy-Fuel Spray (HVOF)

3.3 Applications 3.4 Example 3.5 Advantages

1.SURFACE COATINGS
Surface coatings are generally used to avoid the resistance of the product or substrate form the environmental aspects and improve their appearance. In many cases coatings are applied to improve the surface properties of the substrate.

1.1 Advantages of surface coating:

Wear

resistance Corrosion resistance. Improve the life of the material Need for lubrications decreases. Surface protection against the environment in addition to the required corrosion protection.

2.HARD FACING
Hard facing is a metalworking process where harder or tougher material is applied to a base metal. Hard facing may be applied to a new part during production to increase its wear resistance, or it may be used to restore a worn-down surface. It is an surface operation to increasing the service life of the industrial components and pre-emptively on new component.

2.1Hard facing can be deposited by various welding methods

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW) Ox fuel Welding (OFW)

2.1.1Shielded Metal Arc Welding (SMAW)

2.1.2Gas Metal Arc Welding (GMAW)

2.1.3Oxy fuel Welding (OFW)

Oxy fuel welding process

2.3PROCESS PARAMETERS
TRIMAY TWP 56E Operating Parameters Diameter 3.25mm,1/8 4.0 mm.5/32" 5.0mm.3/16" Amps 120-150 130-180 180-220 Volts 26-30 26-30 26-30

TRIMAY TWP 57E Operating Parameters

Diameter
3.25mm,1/8 4.0 mm.5/32" 5.0mm.3/16"

Amps
110-140 120-160 160-180

Volts
26-30 26-30 26-30

TRIMAY TWP 61E Operating Parameters

Diameter 3.25mm,1/8 4.0 mm.5/32" 5.0mm.3/16" Amps 110-140 120-160 160-180 Volts 26-30 26-30 26-30

2.4Applications
Screw conveyer Bucket teeth Bulldozer corner bits Fan blades Concrete mixer blades Hammer mill impellers Crusher jaws and roll shells

2.5 Advantages
Wear resistance Corrosion Resistance Wear prevention Improve the life of the material Flexible Low cost Low dilution Very wide range of hard-facing materials

3.THERMAL SPRAYING
Thermal spraying techniques are coating processes in which melted (or heated) materials are sprayed onto a surface of base materials. Thermal sprayed coatings are extremely effective at increasing the component life and value, decreasing machinery down-time, and improving performance in a wide variety of applications.

Line Diagram of Thermal Spraying

3.1 Working principle

The coating material for thermal spraying included metals, alloys, ceramics, plastics and composites. This materials are feed by the form of powder or wire in the feeder. In this feedstock materials are melted by heating source in the form of molten or semi molten state. And then the material is propelled by process gas and sprayed onto the substrates in the form of micrometer-size particles. Where it is solidifies and form a solid layers. The thickness of thermal spray coating is approximately 20 micrometer to several mm.

Schematic Diagram of therma sprayed coatings

3.2 Thermal Spray Coating Process

Wire

Flame Spray Powder Flame Spray Electric Arc Wire Spray High Velocity Oxy-Fuel Spray (HVOF)

3.2.1 Wire Flame Spray

3.2.2 Powder Flame Spray

3.2.3 Electric Arc Wire Spray

3.2.4 High Velocity Oxy-Fuel Spray

3.3 Applications
o o o o o o o o o o o

Aircraft Landing Gear Components. Medical Implants Textile Machinery Components Gas Turbine Printing Industry General Industrial Uses Consumer Goods Automotive Industry Steel Industry Paper Industry Aerospace

3.4 ADVANTAGES
Flame spraying with subsequent fusing Advantages: Metallurgical bonding Can use induction or vacuum furnaces Liquid- and gas-tight High Velocity Oxygen Fuel Flame Spraying (HVOF) Advantages: Very dense coatings Excellent bonding Minimal metallurgical changes Minimal temperature effects

Case study: Shoe Component for Rotary Valve

Reason to Consider Surfacing Wear on shoe component of rotary valve results in leakage in the closed position. Issues Reduce wear to eliminate material wastage and reduce maintenance costs.

Thermal sprayed rotary-valve shoe component.

Conti..

Benefits Extends the service life of the shoe by 8 to 10 times that of the uncoated part.

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