Coatings for the severe service Industry :

Ball valve, Plug Valve, Gate valve,

control valve and Pumps

SPRAYMET SURFACE TECHNOLOGIES Pvt Ltd

Bangalore : A 413, 9th main, 2nd stage,Peenya Indl area ,Bangalore

5600058 spraymet@gmail.com , Tel : 080-28364565 mobile : 9886116400

Pune Unit : T 180, T Block, MIDC, Bhosari, Pune 411026

spraymetpune@gmail.com, Tel 8149046272

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SPRAYMET

SURFACE TECHNOLOGIES

SPRAYMET

SPRAYMET

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5Schematic o f thermal spray coating

Heat source, spray gun

Acceleration Impacting Spreadening and cooling

Feedstock materials

Stick

Wire

Powder

>200 alloys * Upto 15000 deg C * Upto mach 2.5 * Bond > 10000PSI

Thermal energy vs. kinetic energy

in thermal spray

3

Ther

mal

Ener

gy

Kinetic Energy >>>> BOND strength >>>

Elect ARC

Plasma

HVOF

CS

Wirearc Spray 5000 deg C

Plasma Spray 15000 dec C

High velocity oxy fuel

Cold Spray

Melt or partially melt

Solid

SPRAYMET

200m/sec1200mts/sec

High energy Hi velocity Plasma HE

Plasma

600mts/sec

HVAFHigh velocity AIR fuel

1960 1980 2005

Process Flow

SPRAYMET

How coating bonds?

Plasma spraying

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• plasma temperature: up to 30000 ºC.

• virtually all existing materials.

High-velocity oxy fuel spraying (HVOF)

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• gas temperature: 3000 ºC;

• sprayed materials: virtually all existing

materials, in practice mostly carbide/metal

and carbide / self-fluxing alloy mixtures.

HVOF – Exclusive process for carbides

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Plasma transfered arc spraying (PTA)

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• Fe, Ni, Co, Cr based alloys,

stainless steels, cermets

Laser cladding

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• virtually all metal alloys, cermets and

ceramics.

Coatings’ properties

Adhesion and porosity

Spray technology Velocity, m/s Porosity, % Adhesion, MPa

Flame spraying

• powder

• wire

30

180

6 – 15 17 – 70

15 – 20

Arc spraying 240 2 – 8 40

Plasma spraying (different

modifications)

240 – 1200 < (0,5 – 2) 20 – 70

Detonation gun spraying 910 < 1 ≥ 100

HVOF, HVAF 610 – 1500 < 0,5 65 – 90

Cold spraying 500 – 1200 1 – 3 60 – 100

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Process and prosperities

comparison

Adhesion

Strength

(Mpa)

Processes Particle speed

m/s (km/h)Spray rate

kg/hPorosity Levels

%

Thickness capablity

mm

Flame Temp °C

Powder Flame 70 (144) 1...8 10...15 0,2...5 3000 10...30

Wire Flame 70 (144) 5...8 0,2...0,4 0,2...5 3000+1100 n. 300

Arc Spray 220 (790) 6...40 10...20 0,2...10 3000 10...30

Plasma 600 (2160) 1...6 2...8 0,2...2 16500 20...70

HVOF 800 (2880) 2...9 0,5...2 0,2...2 2800 60...120*

HVAF 800 (2880) 10...30 0,1...1,5 0,1...1.5 1800 60...120*

Detonation 900 (3240) 2...6 0,1...1,5 0,1...0.50 4500 75...120*

Characteristics of thermally sprayed coating structures(Typical Expected values)

As sprayed (3-5Ra)

Oxide-(max 3%) Cracks-(Not allowed) Pores(1-2%)

t

Grit blasted surface3-6 Ra

Unmolten particle3 % maxEmbedded grit blasting

pieces-10% or area max

“over-blasted”

area

HVAF sprayed WC-10Co-4Cr Coating

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HVOF carbide hardness

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ASTM G 65 abrasion test

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Coating Capabilities and Range

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BALL COATING, GRINDING AND LAPPING CAPABILITIES :

Robotic HVOF : Fanuc Robot and Praxair JP5000HVOF with Ball holding fixtures for Lathe rotation or Turn table rotation. Ball Grinding : Upto 24 “ SPM with diamond grinding segments Ball Lapping : Upto 8” full diameter Lapping with matching eat 8”-16” : Seal area Lapping with matching seat Testing : NDT (on Ball), HV(0.3),Bond test, Bend Test (on Cuopons) Leak Test : Ball and seat will be tested for leak with ethanol in ball and seat pocket and 2 Bar air pressure from bottom SPRAYMET Coating selection guide for METAL SEATED BALL VALVE

Coating Hardness Hv 0.3 typical

Typical Wear factor

Corrosion factor

Temp resistance

Coting method

Typical finish thickness

Application area

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Tungsten carbide

1100Hv ( Rc 70)

5 2 Upto 400 deg C

HVOF 150-200 microns

most widely used in non corrosive atm.

2

Chromium carbide

850 HV (Rc 65)

4 4 Upto 850 deg C

HVOF 200-300 Used where wet corrosion is present : Steam, ammonia etc Default coating in unknown condition.

3 NiCrBSi ( colmonoy6)

58 Rc 3 4 Upto 650 deg C

HVOF 200-300 Corrosion and temp conditions . Power stations, ash handling. Low cost to carbide

4 Stellite 6 + other stellitegrades1,12,21

42 RC 3 5 Upto 650 HVOF 200-300 Widely used where corrosion and temp are present . Direct replacement for weld stellite

5 Inconel 625,718 etc

30 RC 2 5 Upto 650 HVOF 200-400 Extreme corrosion resistance, marine, acidic and petrochem environment.

* Wear and corrosion factor rating 5 = extremely good, 4= good, 3 = Fair , 2 = moderate, 1 = poor

Coatings’ properties: Obtainable harndess.

Sprayed material Spraying technology Hardness, HV

Chrome steel Flame spraying (wire) 500 – 600

PTA 800 – 850

NiAl alloy Flame spraying 200 – 250

Copper Flame spraying (powder) 150

Stellite Flame spraying (powder)/HVOF 460 – 770

PTA 290 – 590

MCrAlY Plasma spraying 400

Self-fluxing alloy (NiCrSiB) Flame spraying/HVOF 250 – 780

PTA 360 – 820

WC-Co

Cr3C2-NiCr

HVOF spraying (powder) 1100 – 1300

750-900

Al2O3 Plasma spraying 1800 – 200019

Ball valve

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Metal seated valve industry

Ball valve

Ball and seat Components : fully manufactured, coated , ground and lapped and Pressure tested. Supplied as ready to use pair. ½”- 14” capability

Ball valve Customers :

Schuff

KOSO

WEIR

BRAY

OLIVER

SCOPE :

A) Fully Manufacture Ball and seat as a Set

B) Coating , grinding and Lapping as a set

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API Gate valve

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GATE VALVE API 6A

Manufactured gate valve slab gate and seat

base material : 4140, SS 410 WITH Coating OF tungsten carbide

Industry : all API 6A valve manufacturers

Slab gate and seat – As coated TC coated Body Bushing

Slab gates finished /for NDT Fully lapped to 2 Light Band

Plug valve and Control valve

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Plug valve

Cast steel component, fully machined, coated ground and lapped. Ball vlave coating 14” Ball valve TC coated

Pung valve –TC coating Plug valve inspection Control valve CNC machined items with coating

Control valve stems Helix valve stem

Control valve Cage : ID coated with carbide and ground

Other applications

Plug valve carbide coating plug carbide or stellite possible

Control vale cage Ball valve carbide coating

Extrusion screw coating Valve disc stellite 6 PTA

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* Severe service Applications *

Think of us

Thank You

Bangalore : A 413, 9th main, 2nd stage,Peenya Indl area ,Bangalore 5600058

spraymet@gmail.com , Tel : 080-28364565 mobile : 9886116400

………………

Pune Unit : T 180, T Block, MIDC, Bhosari, Pune 411026

spraymetpune@gmail.com , Mobile : 8149046272

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SPRAYMET