“World Class Products’’

Why Superon

…Enhancing Components Life

…Cost reduction of 10-15 %

ILL effects of Welding

Heat input, while welding leads to Creation of HAZ besides the Welded Zone

HAZ is the vulnerable area- for the welded joints

to fail

HAZ is hard and brittle – hence Cracks

Sudden/ Dynamic loads make the welded area

crack from the HAZ

Superon’s Technology basis for component life enhancement

- Lowest in class HAZ

How Superon Achieves lowest in Class HAZ

• Lowest in class input amperes

• Lowest in class arc gap

We can Demonstrate our technologies via comparitive

Demonstrations

• Lowest Input Amps

• Lowest Arc Gap

• Bead Finish

Superon’s Applications in Process Industries

• Cement

• Power

• Sugar

• Steel

• Paper

• Forging…

Our Solutions- Cement Industry

Superon in Cement Stanvac in Cement

Features Applications Demo Free trials Outcome - FADFO

• Total application – Payment after successful completion of the trial

period– Pro-Rata payments for longer trial periods.– Full job on FOC basis to prove the superiority

One of the above depending on the application and your requirements

Where would you like us to

start – JOINING or

HARDFACING.?

Thank YouEnhancing Components

Life through Lowest Heat Input

Superon in Cement

…Enhancing Components Life

…Cost reduction of 10-15 %

Blow bar of Impactor Crusher

• Application Requirements– Abrasion Resistance– Impact Resistance– Slight Erosion Resistance

• Base Material– 14% Manganese Steel

• Superon Recommendation– Base Layer with Super Stanhard FW 74 ( to

be used for building up worn out ones)– Hardfacing with Super Stanhard CC 78

(only this for new blow bars)

• Product USP’s– FW 74 is rapid work hardening nickel fortified –

Hence better impact and bond strength – Does not chunk out – 50 HRc (WH)

– CC 78 – High hardness best suited for Abrasion resistance- High wear Factor – 63-67 HRc• Very Fine stress relief checks• No chunking• Good erosion resistance

Impactor Arm• Application Requirements

– Impact Resistance– Abrasion Resistance– Slight Erosion Resistance

• Base Material– 14% Manganese Steel Casting

• Superon Recommendation– Base Layer with Super Stanhard NA 75

(max 2 layers)– Hardfacing with Super Stanhard CC 84

(Build up totally)

• Product USP’s– NA 75 has good Bonding to Mn Steels with

high Bond strength of 1 L Psi– CC 84 – High Hardness coupled with high

Impact resistance- 55- 57 HRc• No stress relief Checks• Can take very high Impact• Good Abrasion & erosion resistance

Clinker Crushers – Rotors & Hammers• Application Requirements

– Heat Resistance– Impact Resistance– Erosion Resistance

• Base Material– High Chrome

• Superon Recommendation– Base Layer with Super Stanhard NA

75 ( max 2 layers)– Hardfacing with Super Stanhard CC

84 (Build up totally)

• Product USP’s– NA 75 has good Bonding to Mn Steels

with high Bond strength of 1 L Psi– CC 84 – High Hardness coupled with

high Impact resistance. 55- 57 HRc• No stress relief Checks• Can take very high Impact• Good Abrasion & erosion resistance• Heat resistance – Doesn’t loose hardness at

high temperatures

VRM Table Liners & Rollers ( Sintered)

• Application Requirements– Good Bond Strength in CI– High Abrasion Resistance– Impact Resistance

• Base Material– Special Cast Iron with Sinter Suspended

• Superon Recommendation– Buttoning done with a special process

using Super Stanhard UL 81

• Product USP’s– UL 81 has high bond strength with

Cast Irons– Can Take good impact – Roller impact

on tyres– Very Fine stress relief checks– High Hardness of 68-70 HRc– High temperature hardness retention

Fans

• Application Requirements– High Erosion Resistance– Low build ups

• Base Material– Structural Steel – Depends on the

application• Superon Recommendation

– Super Stanhard AC 76

• Product USP’s– AC 76 Gives a single layer hardness of

over 60 HRc– Erosion resistance beads- Minimal

Ripple content in the bead– Very fine stress relief checks –

Enhanced erosion resistance– A chromium carbide rich deposits,

resists Abrasion, Fine particle Erosion and heat

• Application Requirements– Joining of Mn steel to Mn steel or dissimilar– High Tensile strength with Ductility

• Base Material– Manganese steel & Cast steels

• Superon Recommendation– Super alloy EM 35

• Product USP’s– EM 35 gives a good bonding with

Manganese steel castings and Steels– High Tensile strength of 1,00,000 Psi– Deposits have high elongation -40 %– Uniform Chemistry through the

length of the Alloy– No red Hotness during welding

through the length– Full Length Welding.

Earthmoving Buckets

• Application Requirements– Joining of Structural Steel– High Resistance to Contaminations

• Base Material– Structural Steel

• Superon Recommendation– Super Stan Alloy ST 22

• Product USP’s– ST 22 Gives a tensile strength of

88,000 Psi.– High resistance to contaminations– Self Lifting slag– Non hygroscopic in Nature- NO HIC or

Delayed Cracking– High arc force leading to purging of

the impurities

HEMM Structures

• Application Requirements– High Strength Joints– NO PWHT possible

• Base Material– Forged Steel- High Alloys

• Superon Recommendation– Super Stan Alloy TC 41

• Product USP’s– TC 41 has a tensile strength of 88,000

Psi– Deposits can be thermally Cycled– Deposits has high elongation – 40 %– Deposits doesn’t undergoes any Heat

treatments- makes it an ideal alloy for High strength joining

– All positional welding alloy – Ideal for all Heavy machinery

High Alloy Joining – Kiln Tyre and Girth Gears

• Application Requirements– High Strength joints– Dissimilar steel composition

• Base Material– High Alloy Steels

• Superon Recommendation– Super Stan Alloy DS 34

• Product USP’s– DS 34 has a highest tensile strength of

1,35,000 Psi– High tensile strength coupled with

highest elongation due to a ideal ferrite balance

– Low temperature arcing – even at 40 Ampheres

– Contact or touch type welding– Good arc force, resists contaminations

on the components to be welded

High Strength Dissimilar Steel Joining

• Application Requirements– Thermal Cycling – Joining Dissimilar steels

• Base Material– High Alloy Steels

• Superon Recommendation– Super Stan Alloy CN 54

• Product USP’s– CN 54 has a Tensile strength of 84,000 Psi– Full length burning and no red hotness

during welding in the alloy– Uniform Chemical composition through

the deposit– No moisture pickup.– High Alloyed core wire.

Anchor Joining

• Application Requirements– Harness At High temperatures– Abrasion/ Erosion/ Impact Resistance

• Base Material– High Alloy Steels

• Superon Recommendation– Super Stanhard (T) 93

• Product USP’s– Can work at high temperatures– Hardness of 64-67 HRc– No red Hotness till the end of the

electrode– No flux dropping– Seamless Steel tube construction– Easy Strike & Re strike– Low work at lower ampherages

Tip Casting Plate /Clinker Breaker Hammer /Inlet Sectors

Thank You…Enhancing Components Life …Cost reduction of 10-15 %

Stanvac in Cement

Cement Applications

Machine Stacker Reclaimer

ComponentAlkyde Enamel Structures

Base MetalFabricated structure

Stanvac Solution

Polyhyb 2050 (1040+725)

Customer Benefits

• Self Priming , Fast curing & Easy Recoatability• Cross linked polymers• Provides cathodic Protection• Barrier Permeability• Higher Salt Spray resistance & UV – Both Indoor/ Outdoor• 5 % ( Mild)Acid/ Alkali Resistance• Self extinguising

Cement Applications

Machine Stacker Reclaimer

Component Conveyor Belts

Base MetalRubber with Cotton/ Nylon Ply

Stanvac Solution

717 Polyurethane Kote- Black

Customer Benefits

• Better than Hot/ Cold Vulcanising• Fast curing- Lower down time• Excellent elongation > 600 %• Good adheshion on rubber- Brushable & Putty grades

Cement Applications

Machine Grate Cooler

Component Structures

Base Metal St.Steel

Stanvac Solution

HHC 300 with ST3

Customer Benefits

• Temperature resistance up to 3000C• Fast drying – Dry to handle on application• Bright colors to dissipate heat as required by the

application.• Silicone Based – Hence suited for High Temp.• Better Corrosion protection combined with Temp.

Cement Applications

Machine VRM

Component Pipe Bends

Base Metal St. Steel

Stanvac Solution

731Stangard ER Xtreme/1180*

Customer Benefits

• Zirconium Carbide based- High abrasion/ erosion resistant.

• Lower down time.• Insitu application.• Enhanced life > 7 times MS

Machine VRM

Component Roller Hub

Base Metal Cast/ Forged

Stanvac Solution

731Stangard ER Xtreme/1180 For better Bonding

Customer Benefits

• Zirconium Ceramic based- High abrasion/ erosion resistant.

• Lower down time.• Insitu application.• Enhanced life > 7 times MS

Cement Applications

Cement Applications

Machine LRS Tanks

Component Tank

Base Metal Struc Steel

Stanvac Solution

712 CRS

Customer Benefits• Excellent Chemical Resistance at Elevated temp.• With Stands up to 2400C Max• Resistance to Mild Acids. Alakalies• Di electric Insualtion coating combined with Temp.

Cement Applications

MachineElectrical panel Areas

ComponentDie Electric Flooring

Base MetalConcrete/ Tiles/ marbles

Stanvac Solution

1311 Insulkote A / B

Customer Benefits

• Meets requirement of 15652-2006• BDV of more than 34/ 45 KV in air medium• Abrasion resistant & No tracking due to non

accumulation of dust.• Non Inflammable• Repairable

Cement Applications

Machine Pumps- utilities

ComponentCasing & Impellors

Base Metal Grey Cast Iron

Stanvac Solution

1170/1180 or731/1180

Customer Benefits• Improves the efficiency- lower energy consumption• Higher Abrasion/ Erosion resistance- Higher life.• Zirconium Ceramic based Putty

Cement Applications

Machine Work Shop

ComponentShafts/Emergency Leak Reapairs

Base MetalForged Steel / bar stock

Stanvac Solution

815 StangardSteel Putty

Customer Benefits

• Ultra High Compressive strength• Fast curing• Repeated no of applications• Machinability. Good Shore hardness• Temperature range -100C to +2000C

Cement Applications

Machine Cement Silo

Component Silo

Base Metal Concrete

Stanvac Solution

754 ( Inner)754+ 725 ( Outer)

Customer Benefits

• Non sticking of Cement – Easy Flow• Protects moisture and Vapour Migration- Rebar Protection• Stops carbonation of the concrete• Improved Aesthetics- Prevents lichen, moss and fungus growth

Cement Applications

Machine Cooling Towers

Component Cooling Tower

Base Metal Concrete

Stanvac Solution

1311 MVT System

Customer Benefits

• Stops carbonation of the concrete• Improved Aesthetics• Enhances Life.• High Tolerance to Salt & Chloride• Wet Tolerance capability – best suited for Cooling towers

Cement Applications

Machine Machine Beds

Component Machine Beds

Base Metal Concrete

Stanvac Solution

751 Stanfloor

Customer Benefits

• Quick Setting• No Shrinkage- 100 % Solids• Chemical Resistant• Can be made self levelling• Longer Life

Cement Applications

Machine VRM

ComponentReject Cone - Outer

Base Metal ST 55

Stanvac Solution

731Stangard ER Xtreme/1190

Customer Benefits

• Zirconium Ceramics based- High abrasion/ erosion resistant.

• Lower down time.• In-situ application.• Enhanced life > 7 times MS

Cement Applications

Machine VRM

Component Cage Mill stator

Base Metal Structural Steel

Stanvac Solution

1180/731Stangard ER Xtreme

Customer Benefits• Abrasion Resistant• Erosion Resistant• Ease of Dynamic Balancing• Insitu applications- No down time

Cement Applications

Machine VRM

Component Water sprinkler

Base Metal Pipe Steel

Stanvac Solution

731 xtreme

Customer Benefits• Abrasion Resistant• Erosion Resistant• Insitu applications- No down time

Cement Applications

Machine VRM

Component Outlet Elbow

Base MetalSt Steel+ Ceramic Tiling

Stanvac Solution

731Stangard ER Xtreme

Customer Benefits• Abrasion Resistant• Erosion Resistant• Insitu applications- No down time

Machine VRM

Component Nozzle Ring

Base Metal Fabricated/ Cast

Stanvac Solution

731Stangard ER Xtreme

Customer Benefits

• Abrasion Resistant• Erosion Resistant• Insitu applications- No down

time

Cement Applications

Machine Kiln

ComponentCoal Burner nozzle Pipe

Base Metal St. Steel- y Piece

Stanvac Solution

731Stangard ER Xtreme

Customer Benefits• Abrasion Resistant• Erosion Resistant• Insitu applications- No down time• High cost benefit

Cement Applications

Machine Rotary Packer

Component Packing Spout

Base Metal St. Steel

Stanvac Solution

731Stangard ER Xtreme

Customer Benefits• Abrasion Resistant• Erosion Resistant• Insitu applications- No down time• High cost benefit

Cement Applications

Machine Battery room

Component Flooring

Base Metal Concrete Floor

Stanvac Solution

4029 System

Customer Benefits• 98% H2SO4 33% HCL resistance• 100 % Volume Solids• High Build

Cement Applications

Machine GCT

ComponentScrubber Structure/ Flooring

Base Metal Steel/ Concrete

Stanvac Solution

1040/756+ 718EGF-NV+ 727*- System

Customer Benefits

• 98% H2SO4 33% HCL resistance• 100 % Volume Solids• High Build• Resists thermal Shocks and temp up to

1000C & 1400C intermittent

Cement Applications

Machine Kiln

ComponentKiln Shell Corrosion

Base Metal St Steel

Stanvac Solution

HHC 600

Customer Benefits• Heat Resistance• Stops Corrosion due to sweating• No reduction of shell thickness

Cement Applications

Machine GCT

Component Flue Gas Ducts

Base MetalSt Steel With Insulation

Stanvac Solution

Aluclad 710/ 706 Stangard

Customer Benefits• Heat Resistance- upto1600C• Stops Corrosion due to sweating• No reduction of shell thickness• 710- Stop Moisture Entry into the Ducts

Cement Applications

MachineReverse Air Bag House & LRS Tanks

Component Structures

Base MetalSt Steel With Insulation

Stanvac Solution

Z712 Quicksteel CRS

Customer Benefits

• Heat Resistance- upto2800C• Stops Corrosion due to S02,So3

Condensation• No reduction of shell thickness• Resists Acid/ Alkali Attacks

Cement Applications

Thank you