ball valve , plug valve, control valve , pump hvof carbide coating applications

1. 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

2. SPRAYMET
1
5Schematic of 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

3. Thermal energy vs. kinetic energy
in thermal spray
3
ThermalEnergy
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/sec 1200mts/sec
High energy Hi velocity PlasmaHE
Plasma
600mts/sec
HVAF
High velocity AIR fuel
1960 1980 2005

4.  Process Flow
SPRAYMET

5. How coating bonds?

6. Plasma spraying
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• plasma temperature: up to 30000 ºC.
• virtually all existing materials.

7. 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.

8. HVOF – Exclusive process for carbides
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9. Plasma transfered arc spraying (PTA)
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• Fe, Ni, Co, Cr based alloys,
stainless steels, cermets

10. Laser cladding
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• virtually all metal alloys, cermets and
ceramics.

11. 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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12. Process and prosperities
comparison
Adhesion
Strength
(Mpa)
Processes
Particle speed
m/s (km/h)
Spray rate
kg/h
Porosity
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*

13. 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 surface
3-6 Ra
Unmolten particle
3 % maxEmbedded grit blasting
pieces-10% or area
max
“over-blasted”
area

14. HVAF sprayed WC-10Co-4Cr Coating

15. 15

16. HVOF carbide hardness
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17. ASTM G 65 abrasion test
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18. 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
1
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
stellitegrades
1,12,21
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

19. 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 – 2000
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20. 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

21. 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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22. 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

23. 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

24. 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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25. * 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