March 2017 Superior hard & tough coatings for new markets - - PowerPoint PPT Presentation

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March 2017 Superior hard & tough coatings for new markets - - PowerPoint PPT Presentation

May 22, 2023 422 likes •1.06k views

Andrew Verstak averstak@kermetico.com kermetico.com Kermetico High Velocity Air-Fuel Thermal Spray March 2017 Superior hard & tough coatings for new markets Gas-tight WC-based 1350-1600+ HV 300 Cr 3 C 2 -based 1050-1100 HV 300 ,

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Kermetico High Velocity Air-Fuel Thermal Spray March 2017

Andrew Verstak averstak@kermetico.com kermetico.com

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Superior hard & tough coatings for new markets

 Gas-tight  WC-based 1350-1600+ HV300  Cr3C2-based 1050-1100 HV300, service up to 900oC  MoB-based 1200 HV300, service up to 1100oC  Thin coatings (40-70 micron) for:

High and alternating stress, impact, etc. Economy grades for “flash chrome” replacement

March 2, 2017 kermetico.com averstak@kermetico.com 2

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SLIDE 3

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HVAF Application Development

  • 2. Economical “currently specified quality” coatings

for existing and new markets 1200 HV300 /<0.8% porosity WC-coatings, sprayed at 65-70% DE with spray rates 33+ kg/hour (73 lbs./hr.)

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Kermetico HVAF Gun Design

Fuel Gas Air Powder + carrier gas Nozzle Combustion chamber Ceramic insert

1100-1500 m/s 850 m/s 40-50 m/s Gas velocity <1500oC ~1600oC 1900oC Gas temperature Spray particle Acceleration Heating

March 2, 2017 kermetico.com averstak@kermetico.com 4

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Combustion Temperature: HVAF vs. HVOF

Adiabatic combustion temperature of fuels in oxygen and air (a=1, 20oC, 1 Bar)

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3052 2526 2927 3200 3109 1960 1980 2010 2210 2093 500 1000 1500 2000 2500 3000 3500 Methane Propane MAPP Hydrogen Kerosene

T, oC

Oxygen Air

Metals, T melting Metals, T boiling

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SLIDE 6

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HVOF:

Combustion temperature is higher by more than 1000oC than melting temperature of metals; Combustion temperature may exceed metal boiling temperature.

HVAF:

Combustion temperature only slightly higher than metal melting temperature.

Lower Gas Temperature in HVAF

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Lower Gas Temperature in HVAF

Affects Coating Properties

Prevention of oxidation of metals and oxidation/ thermal deterioration of carbides Note: oxygen activity is 5-times lower in HVAF

Influences Gun Design

HVAF ability to use heating in long/ slow-gas combustion chambers = long time for “soft” heating High pressure in the chamber = better heat transfer

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Combustion Temperature: AF vs OF Design

Ability to use heating in long/ slow-gas combustion chambers => long time for “soft” heating High pressure in the chamber => better heat transfer Result: High energy efficiency of HVAF (same or lower power while higher spray rates than HVOF)

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Energy Efficiency = COST

State-of-the-art HVOF: JP 5000 270 kW spray rate 5 kg/hour DJ 2600 115 kW spray rate 4 kg/hour Kermetico HVAF: AK6 130 kW spray rate 28 kg/ hour AK5 80 kW spray rate 15 kg/hour AK-ID 30 kW spray rate 5 kg/hour

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Acceleration of spray particles in the nozzle: Gas velocity & density Time (nozzle length) Particle size Smaller particles are accelerated to higher velocities. HVAF uses smaller particle size without material

  • xidation/ thermal deterioration

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Note on nozzle wall influence on particle velocity: HVOF – dramatic (more so – in radial injection) HVAF – no influence

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Particles Acceleration: Influence of the Nozzle Walls

HVOF (kerosene) per A. Voronetsky et. all, ITSC2004

Influence of Rp on the mean particles velocity at LS=250 mm. (pсс =0.9 MPa, dp=30 μm, Lb=100 mm)

Rp= D powder jet / D nozzle

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Nozzle wall Nozzle axis

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Particle Acceleration in the Nozzle

Kermetico HVAF: D powder jet / D nozzle = 0.1-0.2 I. There is practically no restriction on the nozzle length to reach necessary acceleration of spray particles II. Uniform acceleration = uniform coating structure and properties

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Uniformity of HVAF Coating Properties:

Hardness of HVOF and Kermetico HVAF WC-10Co-4Cr coatings (Schlumberger, UK)

HVAF HVOF

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Relative standard deviation, % HVAF: 3.9 % HVOF: 15.7-17.8%

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WC-10Co-4Cr Coating Characterization

Propane 1470 HV300

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WC-10Co-4Cr Coating Characterization

Propane- 60% Butane 1,500 HV300 Propylene 1,650 HV300

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Kermetico HVAF:

Carbides are hard, but… ductile

30 40 50 60 70 80 90 500 1000 1500 2000

2

C4 Coating

Powder 3 3 2 2 2 1 1 1 1 1 1 1 1

1:WC 2:Co3W3C 3:Co

1

2/degree Internsity/a.u.

3 3 2 2 2

WC-12Co Propane 1,540 HV300

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Cr3C2-25NiCr Coating Characterization

AK7, Propane WOKA 7210 (25/5 mm) 1082 HV300 AK6, Propane Amperit 588.059 (30/5 mm) 1068 HV300

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Data of Central Power Research Institute Bangalore, India

Comparison of WC-10Co-4Cr coatings, deposited with HVOF (JP5000) and Kermetico HVAF (AK06)

Notes: HVOF optimized for the best cavitation resistance HVAF applied in different modes, targeting different particle velocity (coating hardness)

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Spray Parameters: Normalized

JP5000 HVOF Kermetico AK6 HVAF Balanced Ultra 1 Ultra 2 Oxidizer flow, SLPM O2: 873.1 Air: 2,104 (O2: 421.0) Fuel, g/sec 5.01 2.65 O2/Fuel Ratio vs. Stoichiometric 1.16 (Oxidizing) 1.03 (~Neutral) Carrier Nitrogen, SLPM 10.85 21 Combustion pressure, Bar 7.56 5.25 Powder feed rate, g/sec 1.50 2.22 Particle average size, micron 27 18 Particle velocity, m/s 740 895 +/-2 960 +/-3 1010+/-4 Particle temperature, oC 1790-1840 1470 +/-10 1460 +/-10 1470 +/-10 Particle kinetic energy, mJ 29.4 12.7 14.7 16.2 Energy density, GJ/m3 = = Contact pressure, GPa 3.8 5.6 6.4 7.1

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Mechanical Properties 1/3

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Mechanical Properties 2/3

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Mechanical Properties 3/3

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Cavitation Resistance

  • f WC-10Co-4Cr HVOF and HVAF coatings

( dw/dt ) AF1 (U2) = 0.23 mg/h ( dw/dt ) AF3 (U1) = 0.71 mg/h ( dw/dt ) AF2 (B) = 0.96 mg/h ( dw/dt ) HVOF = > 3.26 mg/h ( dw/dt ) 16Cr-5Ni steel = 2.0 - 2.5 mg/h

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Surface SEM Micrographs of WC-10Co-4Cr Coatings after Cavitation Testing

Test duration: 1 hour JP5000 HVOF AK6 HVAF

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Surface SEM Micrographs of WC-10Co-4Cr Coatings after Cavitation Testing

Test duration: 9 hours JP5000 HVOF AK6 HVAF

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Resistance to Silt Erosion

WC-10Co-4Cr HVOF and HVAF Coatings

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Other Third-Party Data, Comparing Kermetico HVAF WC-10Co-4Cr Coatings to the Best HVOF and Detonation Systems

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Hunan University Changsha, Hunan, China:

WC-10Co-4Cr HVOF & HVAF coatings. Cavitation test

60 120 180 240 300 360 420 480 540 600 660 720 2 4 6 8 10 12 Volume loss (mm

3)

Time (minutes) AISI316:y=0.0156x-0.4789 DJ Coating:y=0.0121x+0.4744 AK Coating:y=0.0047x+0.0922

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0,0 0,5 1,0 1,5 2,0 2,5 3,0 GTV K2 HVOF GTV K2 UHVOF Kermetico AK6 HVAF

InnoMat GmbH Report on WCCoCr coatings for Stellba AG (2016)

ASTM G75-07: Slurry Erosion Test, mg/hour ASTM G65-04 (B): Rubber Wheel Test, mg/min Ball-On-Disc Test, micron/10,000 cycles Gesellschaft für innovative Materialtechnik InnoMat GmbH Annaberger Str. 240, 09125 Chemnitz Stellba AG Wohlerstrasse 51 CH - 5605 Dottikon

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Slat Spray: All WCCoCr Samples Passed 312-Hour Test

Before testing After 312-hours testing

K2 HVOF K2 UHVOF AK6 HVAF

Note: HVAF samples were tested after Pin-On-Disc Wear Test

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SLIDE 33

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Economic Aspects of Kermetico HVAF Spraying: Your Choice of Cost and Quality

HVAF-E (Economy) – meets HVOF specs HVAF-B (Balanced) – exceeds HVOF specs HVAF-U (Ultra) – substantially exceeds HVOF specs

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Economic Aspects of Kermetico HVAF

Gun Setup Coating Hardness , HV300 Coating Porosity, % Deposition Efficiency, % Economy (E) 1050-1250 <0.8 65+ Balanced (B) 1250-1350 <0.5 48 - 58 Ultra (U) 1350-1600+ <0.3 36 - 42

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O.D. 38 mm: Rate 25 kg/hour O.D. 330 mm: Rate 32 kg/hour High spray rates are applicable for large and small parts

Data for WC-10Co-4Cr, agglomerated & sintered powder

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HVOF vs HVAF WC-10Co-4Cr Costs

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Comparison of HVAF and HVOF operating costs, USD per hour (prices in Texas, USA) 50 100 150 200 250 300 DJ2600 HVOF (Hydrogen) JP5000 HVOF (Kerosene) HVAF -E HVAF-B HVAF-U

Oxidant Fuel Spare parts Power, etc. Labor+Overhead Amortizing

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Comparison of HVAF and HVOF Cost

(prices in Texas, USA)

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50 100 150 200 250 300 350 DJ2600 HVOF JP5000 HVOF HVAF -E HVAF-B HVAF-U

Operating cost per kg deposited Powder cost per kg deposited

1000 1100 1200 1300 1400 1500 1600 DJ2600 HVOF JP5000 HVOF HVAF -E HVAF-B HVAF-U

WCCoCr Coating Hardness, HV300 DJ2600 HVOF JP5000 HVOF HVAF-E HVAF-B HVAF-U

Spray Rate, kg/hour 4 5 32 26 26 Deposition Efficiency 50% 43% 65% 46% 38%

Cost per WCCoCr kg deposited, USD

Note: Cost of WC-Co-Cr powder: $81.4 per kg

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WC-Co-Cr powder cost: 81.4 USD/kg DJ2600 HVOF JP5000 HVOF AK7 HVAF (E) Total operating cost, USD/hour 260 223 160 Spray rate, kg/hour 4 5 32 Deposition efficiency, % 50 43 65 Deposition rate, kg/hour 2.2 2.2 20.8 Cost per KG of sprayed coating, USD 293 293 133 AK7 savings per KG of deposited coating, USD 160 160

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HVOF vs HVAF WC-10Co-4Cr Costs

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Examples of Kermetico HVAF Applications

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Mud Rotors, Oil Drilling: WC-20Cr7Ni, WC-10Co-4Cr

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Hydro-Power: Francis Turbine Runner and Head Cover

WCCoCr Application by Plackart CJSC, Russia

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Hydro-Power: Metering Needle Valve and Seat

Application by RenCoat Ltd., China

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Sliding Gate of Catalyst Tower

Spraying Upper Sliding Gate

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Hydraulic Rods of Dock Cranes

Hard chrome performance: 0.5 year max (pitting) HVAF WC-Co-Cr coating performance: 5+ years

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A Refinery Sulfur Condenser Vessel

Application of Hastelloy C HVAF coating DIA 1.8 m x L 2.4 m

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Refinery: Automated Coating with the Rotating AK5 Gun Inside the Processing Vessel

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Diameter: 1.8 m Length: 11.8 m

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Refinery: Heat Exchanger Vessels

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Double-Elbow, Coke Transport Line

12-inch ID, 6-feet long

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Double-Elbow, Spraying with Rotating AK5 Gun

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Coke Line Cyclone: Application of WC-10Co-4Cr Coating with the Rotating AK5 Gun

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Coke Line Cyclone: Application of WC-10Co-4Cr Coating with the Rotating AK5 Gun

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Small ID Transport Pipe Line Components: Application of WC-10Co-4Cr Coating with the Rotating AK-IDR Gun

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Oil Refinery: ID Spraying Pump Casing

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Oil Drilling: Fluid-End Pump Casing, 5-inch (125 mm) ID

Application of coating with AK-IDR rotating gun

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Wear Rings on HT Pump Housings and Impeller Hubs

AK7 Stellite 6 coating

  • ver Stellite weld overlay

Housing ring: Stellite 6 Impeller ring: WCCoCr HT (400oC) Pump coating solutions: Housing ring: Stellite 6 Impeller ring: Stellite 1

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Geothermal Power: Turbine Rotor WC-10Co-4Cr

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Titanium: HVAF

Titanium: Shrouded HVAF

March 2, 2017 kermetico.com

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Spraying Tin with HVAF SL Gun for Low-Melting Point Metals

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WC-Co-Cr 1 mm thick

Kermetico HVAF

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Tensiometer Roll: AK7 HVAF, WC-10Co-4Cr, 1.8 mm Thick

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AK-HH: Hand-Held HVAF

Kermetico HVAF Blast & Spray Systems

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Press Pistons, Winemaking

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