THERMAL SPRAYING
- THERMAL SPRAYING
Thermal spraying uses combustion flames and electrical energy to heat metals and ceramics to a molten or semi-melted state. It is one of the surface modification technologies that attaches them to the surface of the base material to form a film. This makes it possible to add excellent functions and quality to the surface of various equipment and devices such as aircraft, power generation equipment, automobiles, and all other industrial machines.
Introduce our “optimal thermal spraying” on this homesite.
WATER PLASMA SPRAYING
The high-pressure water flow supplied to the torch creates a cylindrical vortex water flow inside. In such a state, when a voltage is applied between the carbon cathode and the metal rotating anode to forcibly generate a DC arc, the water on the inner surface of the vortex water flow evaporates and decomposes into a plasma state, which is continuous. A plasma arc is generated at. The plasma arc is narrowed down by a swirling cylindrical water flow, and while increasing the energy density, a stable high-temperature, high-speed plasma jet flame is ejected from the nozzle by the rapid thermal expansion of the plasma. Since the maximum temperature of the plasma jet flame reaches about 30,000 ° C, it is possible to easily spray even high melting point ceramics, and it is possible to form a thermal spray coating up to about 20 mm. This thermal spraying process is our unique technology that cannot be achieved by other companies.
- GAS PLASMA SPRAYING
When a voltage is applied between the tungsten cathode and the copper nozzle anode in a working gas such as argon or helium to generate a DC arc, the working gas dissociates and ionizes, and a plasma arc is continuously generated. This causes a heat source: a plasma jet of 15,000 ° C or higher to be ejected. Gas plasma spraying is a method of spraying a thermal spray material into the heat source and accelerating the coating while melting it. Thermal spraying of refractory materials such as ceramics is also possible. In addition, the plasma jet sprays the molten particles onto the material at high speed, enabling the formation of a high-quality sprayed coating.
- HIGH-VELOCITY OXYGEN FUEL SPRAYING
High-speed flame spraying is a thermal spraying method in which the velocity of flying particles is significantly increased and a thermal spray coating is formed with a strong impact force. From this, a sprayed coating that is extremely dense and has excellent adhesion strength is formed. The sprayed powder materials that are mainly applied are metals and cermets. Especially for cermets, high hardness film formation can be achieved by using materials with WC-based and CrC-based carbides.
Since the combustion gas ejected in high-speed flame spraying has a velocity exceeding the speed of sound, a shock wave is generated, and a white shining rhombus called a shock diamond may be formed. Expansion waves and compression waves are continuously generated in the high-speed gas ejected from the gun, and the gas pressure and gas temperature in the compression part are higher than in the expansion part, so it is brighter than other parts, which is the occurrence of shock diamond. Is the cause of.
- ARC SPRAYING
Arc spraying is a thermal spraying method in which a DC arc discharge is generated at the tips of two continuous spraying materials (metal wires) and the molten metal is blown off with compressed air.
For the power supply, a constant voltage that converts three-phase alternating current to direct current, or a direct current power supply with somewhat rising characteristics is used. The thermal spray material uses a wire with a wire diameter of 0.8 to 5.0 mm (usually 1.6 mm). It is mainly used for shape restoration, rust prevention and corrosion prevention.
- FLAME SPRAYING
Frame spraying can be divided into powder type frame spraying and molten wire type frame spraying, but we own a molten wire type frame spraying device.
Thermal spraying is a thermal spraying method in which a linear thermal spray material is mechanically sent into the combustion frame of oxygen and fuel, and the material melted in the frame is blown off by compressed air to form a thermal spray coating. Since wire is used as the thermal spraying material, it is also called wire spraying along with arc spraying. It is mainly used for rust prevention applications such as aluminum, but most metal materials that can be used as wire rods can be installed.
ABOUT PLATING
- PLATING
Plating is extremely thin compared to thermal spraying, and it cannot be applied on-site, so it may be difficult to apply it to repair products, but it can be applied if you order a new product. Of course, depending on the wear condition of the repaired product, we can propose the optimum combination of construction methods from plating, overlay welding, and thermal spraying. The merit of plating is that it is inexpensive and has high adhesion. When ordering to our company, we will carry out the construction at a partner company that has been affiliated for many years, but we will finish all processes such as inspections other than plating construction under our management standards.
THERMAL MATERIAL
- METALS, ALLOYS
Metals and alloys are used for various purposes such as rust prevention, shape restoration, overlay repair, oxidation corrosion resistance, and imparting electrical characteristics. Almost any metal or alloy that can be processed into powder or linear can be sprayed.
- AUTOLYTIC ALLOY
We are spraying Ni- and Co-based autolyzed alloys. We use thermal spraying materials equivalent to Meteco 16C, Meteco 18C, Meteco 31, Meteco 16E, and Stellite SF20. Compared to other thermal spray materials, autolyzed alloys can form a denser film, and are excellent in adhesion, wear resistance, erosion resistance, corrosion resistance, and high temperature oxidation resistance.
- CERMET
Cermet is a composite material obtained by sintering ceramic powder and metal powder. It has hardness, abrasion resistance, heat resistance, oxidation resistance, chemical resistance, and rigidity, plasticity, and plasticity of ceramics. It has elasticity. Thermal spraying can give these features to the surface. We perform thermal spraying of tungsten carbide type and chrome carbide type.
- CERAMIC
There are various types of ceramics such as oxide-based and carbide-based. We use oxide-based alumina and zirconia as thermal spray materials.
The characteristics of ceramics are that they have low thermal and electrical conductivity and have high strength even at high temperatures. Among them, single oxide ceramics can withstand ultra-high temperatures.
- ABRASION RESISTANCE
There are various causes of wear, but by spraying a high-hardness material such as ceramics or cermet material by thermal spraying, the base material such as metal and alloy can be protected from wear.
- CORROSION RESISTANCE, ANTI-RUST
There are various types of corrosion, such as sulfurization corrosion, chloride corrosion, acid corrosion, and electrical corrosion. If there is a corrosive atmosphere that cannot be completely prevented by the properties of the substrate alone, or if the material is too expensive to be used as a substrate even if it has tolerable properties, the surface can be modified by thermal spraying.
- HEAT RESISTANT
In recent years, heat-resistant parts are required to have higher heat-resistant performance than ever before in order to improve the efficiency and life of equipment. In order to reduce maintenance costs and improve performance, thermal spray coatings with excellent heat resistance and high temperature oxidation resistance have become indispensable in various fields such as gas turbines, jet engines, boiler parts, and steel. increase. With many years of experience as a partner of a major blast furnace manufacturer, we have a wealth of know-how and achievements in heat resistance and high temperature oxidation resistance.
- SHAPE RESTORATION, THICKENING
When operating equipment such as industrial machine parts, wall thinning and defects are inherent due to friction between metal parts and defects due to impact. One of the effective means in such a case is the overlay repair by thermal spraying. Machine parts are often repaired with mild steel or 13Cr-based materials, but it is also possible to improve durability by spraying ceramics or cermet materials after repairing.
- ELECTRICAL CHARACTERISTICS
Excellent electrical characteristics can be imparted by spraying an alloy of Cu or Al. On the other hand, it is also possible to add insulation by spraying high-purity alumina.