Bro-0008.7 Hvofsolutions en
Bro-0008.7 Hvofsolutions en
Bro-0008.7 Hvofsolutions en
(HVOF) Solutions
Issue 7
Introduction
A Continuing Tradition of Excellence
Innovative technology…
Perfect coatings…
It’s the performance and value package you’ve been looking for!
Metal Processing Steel mill guides and rolls, wire-drawing capstans, forming dies,
sheet metal cutters
General Industry Pump housings, impellors and shafts, plastic extruders, cam
followers, wear rings, machine bedways, press fits, restoration of
machinery components
Coatings produced using HVOF have short dwell time and lower tempera- nnExcellent Wear Resistance: HVOF
outstanding characteristics, even tures of HVOF can produce wear coatings can exhibit superior resis-
above other thermal spray processes, resistant coatings with excellent im- tance to sliding / adhesive wear, fret-
that include: pact resistance. ting, erosion or cavitation depending
nnHigh density: Typical coatings have nnHigher Coating Thickness: Coatings on the material and process param
less than 2 % porosity and some exhibit greater coating thickness eters chosen.
coatings as low as 0.5 % porosity. limits than plasma, combustion or nnSuperb Corrosion Resistance: The
nnHigh bond strength: For example, wire coatings of the same coating high density and exceptional metal-
typical carbide coatings sprayed material. These high thickness limits lurgical properties of HVOF coatings
with HVOF exhibit bond strengths in are attributed to a stress-relieving provide enhanced resistance to the
excess of 69 MPA (10,000 psi). ‘shot-peening’ effect produced by effects of corrosion, including hot
Other coating materials sprayed the high velocity particles impacting corrosion, oxidation and the effects
with HVOF have significantly higher upon the previous layers of coating. of corrosive media such as acidic
bond strengths than the same ma- Some tungsten carbide coatings and alkaline atmospheres and
terials applied using other atmo can have a thickness greater than liquids.
spheric thermal spray processes 6.4 mm (0.250 inches). nnFine Surface Finishes: Smooth sur-
such as air plasma spray. nnBeneficial Residual Stress: Com- faces finishes allow HVOF-produced
nnOptimum Hardness: A 12 % tung- pressive residual stresses and, in coatings to be used in the as-
sten carbide / cobalt coating will some cases, very low tensile stress- sprayed condition for many applica-
have a typical micro hardness of es enhance the fatigue life of a coat- tions. Coatings can be machined,
1100 to 1350 DPH300. ed component, reduce the suscep- ground, lapped, honed or super
nnImproved Toughness: Depending on tibility of cracking and permit greater finished to produce very high sur-
chemistry and other factors, the coating thickness limits. face finishes to precise tolerances.
Optimum hardness
High density
The HVOF process efficiently combusts cap) to produce supersonic gas and High particle velocities, uniform heating
oxygen and a gaseous or liquid fuel to particle velocities, which propel the and low dwell time combine to produce
produce high kinetic energy with con- powder particles toward the substrate coatings that are very dense and tightly
trolled heat input. The coating material, to be coated. bonded to the substrate. Coating
in powder form, is introduced into and chemistries are more predictable and
uniformly heated by the hot gas stream The powder particles flatten plastically coatings have fine, homogeneous
to a molten or semi-molten condition. upon impact with the substrate; cooling microstructures.
The flame and powder are accelerated and solidifying to form the coating.
by a converging / diverging nozzle (air
Cooling water
Compressed air Spray deposit
Fuel gas
oxygen
Powder &
Spray stream
carrier gas
Oxygen
fuel gas
Compressed air
Substrate
Kerosene
Oxygen
Cooling water Substrate
Flexibility
Flexible Process Choices Result in Surfaces Engineered
for Specific Applications
At Oerlikon Metco, we know our cus- metallic alloys, metallic blends, car- requirements, economics and coat-
tomers have unique needs and applica- bides and self-fluxing materials, tai- ing quality needed.
tion goals, so we offer the widest range lored to gas or liquid fuel systems. nnSystem Options: Choose the sys-
of process choices to ensure we meet nnFuels: Gas-fueled systems can use tem configuration that fits your bud-
your exact expectations. hydrogen, ethylene, propane, pro- get and production requirements,
pylene or natural gas. Liquid-fueled with a choice of standard and cus-
nnChoice of Coating Materials: systems can use Jet-A or kerosene. tomized part manipulators and gun
Choose from a wide variety of coat- Choose the fuel process that is suit- manipulators.
ing materials including pure metals, able to your production
Which is right for your application? Your General comparison of gas fuel and liquid fuel HVOF technologies:
choice of a gas fuel or liquid fuel sys-
tem will depend on many factors that Comparison Gas fuel HVOF Liquid fuel HVOF
can include: Gun Water-cooled Diamond Jet Gun WokaJet-410 Gun
nnConfiguration / geometry of the part
General characteristics
to be coated
Fuel options H2, CH4, C2H4, C3H6, C3H8 Jet-A or Kerosene
nnSubstrate composition
nnCoating material to be applied Combustion pressure ~ 0.55 MPa (80 PSI) 0.55 to 0.83 MPa
(80 to 120 PSI)
nnDesired coating thickness
nnApplicable customer coating Gas velocity 1800 to 2100 m/s 2000 to 2200 m/s
specifications (5900 to 6900 ft/s) (6500 to 7200 ft/s)
nn Desired as-sprayed surface Particle velocity 450 to 600 m/s 475 to 700 m/s
roughness (1475 to 1975 ft/s) (1550 to 2300 ft/s)
nnDesired finished surface roughness Powder injection Axial feed (hotter zone) Radial feed (cooler zone)
nnDesired coating internal stresses Powder injection pressure Higher Lower
nnNumber of parts to be coated Spray rate up to 120 g/min (16 lb/h) up to 200 g/min (26.5 lb/h)
nnSize of coated area Consumption comparison (typical utility consumption per hour of operation)
nnUtilities to be used (process media, Fuel 43800 l (1670 ft3) H2, or 28 l (7.3 gal) kerosene
air, water, etc.) 5280 l (200 ft3) C3H6, or
5280 l (200 ft3) C3H8
Let us help you decide on the technol- Oxygen 18420 l (700 ft3) 61400 l (2335 ft3)
ogy that’s right for you. Only Oerlikon
Water 600 l (160 gal) 2375 l (625 gal)
Metco has the experience you need for
both gas fuel and liquid fuel HVOF
technologies. Using our broad portfolio
of HVOF coating materials, our Coating
Solution Center specialists can develop
your surface solution using the best
HVOF process technology for your ap-
plication. Our System integration ex-
perts will design an HVOF system that
is exactly suited to your production and
budget requirements. It’s the Oerlikon
Metco difference!
Key components: Key elements are Handling equipment: In all but the Peripheral equipment: Most HVOF
required for all HVOF spray systems. most simple of manual spray systems, spray installations require a cooling wa-
These include the coating material to be handling equipment precisely controls ter system for the spray gun and it is of-
applied, a powder feeder to deliver the the movement of the spray gun and ten necessary to have cooling air to con-
coating material to the spray gun, the workpiece, and the position of the gun trol the temperature of the workpiece. In
HVOF spray gun that will heat the coat- relative to the workpiece. addition, a soundproof cabin and an air
ing material and propel it to the work- filtration and exhaust system protect
piece, and a control system that accu- both personnel and the environment.
rately controls the gas flows required for
HVOF combustion.
Peripheral components
Handling components
Workpiece
manipulator
Key components
Material
Gun
manipulator
Spray
controller
HVOF
spray gun
Spray
cabin
Powder
feeder
Water
Handling
chiller
controller
Filter
Oerlikon Metco’s portfolio of HVOF ideal candidate for your application Metco? You can still benefit from an
coating materials is designed to from our diverse line of material Oerlikon Metco HVOF material solution!
achieve optimum results, with each chemistries. Many of our HVOF products are avail-
product sized and formulated for the able in a variety of particle sizes opti-
selected HVOF process. Our specialists Do you already own a system with an mized for popular HVOF spray guns.
will consult with you to determine the HVOF gun not produced by Oerlikon
1
6
5
6
1
3b
3a
1
3c
2a
2b
1 UniCoatPro LF controller
2a WokaJet-410-Sz liquid fuel HVOF gun, or
2b WokaStar-610-Sz liquid fuel HVOF gun
3a Powder feeder Twin-140, or
3b Powder feeder 5MPE-HP, or
3c Powder feeder 9MPE-DJ
4 Water chiller
6b
6a
7
5b
5a
1
2
3a 3b 3c 3d 3e
Liquid fuel
WokaJet-410**, WokaJet-410-S, WokaJet-410-Sz WokaStar-610**, WokaStar-610-S, WokaStar-610-Sz
nnProduces quality coatings nnHigh-quality coatings, improved
nnMinimal carbon build-up thermal efficiency
nnAutomatic (machine-mount) nnExtended spare part life
nnUses kerosene fuel nnAutomatic
nnUses kerosene fuel
* used with automatic models; can be used with hand-held water cooled DJ gun if ordered with an optional hydrogen ignition kit, available on a special order basis.
** WokaJet-410 and WokaStar-610 with hydrogen ignition
Training
Let our staff professionally train your personnel on the safe
operation and maintenance of your thermal spray systems.
Field service
Qualified, factory-trained field service technicians will keep
your systems in peak operating condition. Our field services
include flexible maintenance contracts, emergency break-
down repairs and troubleshooting help.
Traceability
Fully traceable calibrations, including gas flows and pres-
sures, ensure the accuracy and repeatability of your spray
facilities.
Simplified sourcing
Simplify your purchasing decisions with Oerlikon Metco qual-
ity consumable parts and materials for competitive HVOF
spray guns.
www.oerlikon.com/metco
BRO-0008.7 – HVOF Solutions info.metco@oerlikon.com
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