HVAF vs HVOF: high velocity thermal spray equipment to deposit metal and carbide coatings. Technological effectiveness basics, comparison of scientific data, Hardness, ductility, Young modulus, cavitation resistance.

1. Kermetico High Velocity Air-Fuel Thermal Spray
2017
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2. 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 particleAcceleration Heating
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3. What is the difference?
Jet Kote
Kermetico C6, C7
1700-
2100 °C
DJ 2600
JP 5000
2982 °C
2982 °C
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4. The Result
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Gun
Hardness,
HV300
Poro-
sity,
%
Fracture
Tough-
ness K1C
Ratio
W2C
to WC
AK 1,326 ± 98 0.3 5.97 ±0.7 0
JP 1,289 ± 108 0.6 4.87 ±0.6 0.12
JK 1,047 ± 112 1.7 3.01 ±0.6 0.7
Source: Wear and corrosion performance of
WC-10Co-4Cr coatings deposited by different
HVOF and HVAF spraying processes
Qun Wang etc., Hunan University, 2013
JP 5000
AK7
Jet Kote
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5. 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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6. 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%

7. WC-10Co-4Cr Coating Characterization
Propane
1470 HV300
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8. WC-10Co-4Cr Coating Characterization
Propane- 60% Butane
1,500 HV300
Propylene
1,650 HV300
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9. Kermetico HVAF:
Carbides are hard, but… ductile
30 40 50 60 70 80 90
0
500
1000
1500
2000
2
C4 Coating
Powder
33 222 1
1
1
1
1
1
1
1
1:WC
2:Co3
W3
C
3:Co
1
2/degree
Internsity/a.u.
3
3 2
22
WC-12Co
Propane
1,540 HV300
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10. 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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11. 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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12. Mechanical Properties 1/3
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13. Mechanical Properties 2/3
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14. Mechanical Properties 3/3
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15. Cavitation Resistance
of 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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16. Surface SEM Micrographs of
WC-10Co-4Cr Coatings after Cavitation Testing
Test duration: 1 hour
JP5000 HVOF AK6 HVAF
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17. Surface SEM Micrographs of
WC-10Co-4Cr Coatings after Cavitation Testing
Test duration: 9 hours
JP5000 HVOF AK6 HVAF
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18. Resistance to Silt Erosion
WC-10Co-4Cr HVOF and HVAF Coatings
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19. Other Third-Party Data,
Comparing Kermetico HVAF WC-10Co-4Cr
Coatings to the Best HVOF and Detonation
Systems
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21. Erosion Rate vs. an Attack Angle:
WC-10Co-4Cr HVAF coatings perform as a ductile material
Midwest Thermal Spray (MI, USA)
0,000
0,050
0,100
0,150
0,200
0,250
0,300
AK06-HVAF: WC-Co-Cr HVOF MTS: WC-Co-Cr SHS8000, fused
Volumeloss,mm3/min
Dry erosion rate of hard coatings
Angle 30 deg. Angle 90 deg.
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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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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

25. 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

26. 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)
0
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

27. HVAF and HVOF WCCoCr Cost, USA
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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%

28. Examples of Kermetico HVAF Applications
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29. Mud Rotors, Oil Drilling:
WC-20Cr7Ni, WC-10Co-4Cr
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30. Hydro-Power:
Francis Turbine Runner and Head Cover
WCCoCr Application by Plackart CJSC, Russia
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31. Hydro-Power:
Metering Needle Valve and Seat
Application by RenCoat Ltd., China
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32. Sliding Gate of Catalyst Tower
Spraying Upper Sliding Gate
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33. 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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34. A Refinery Sulfur Condenser Vessel
Application of Hastelloy C HVAF coating
DIA 1.8 m x L 2.4 m
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35. Refinery: Automated Coating with the Rotating
AK5 Gun Inside the Processing Vessel
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Diameter: 1.8 m
Length: 11.8 m

36. Refinery: Heat Exchanger Vessels
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37. Double-Elbow, Coke Transport Line
12-inch ID,
6-feet long
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38. Double-Elbow, Spraying with Rotating AK5 Gun
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39. Coke Line Cyclone:
Application of WC-10Co-4Cr Coating with the
Rotating AK5 Gun
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40. Coke Line Cyclone:
Application of WC-10Co-4Cr Coating
with the Rotating AK5 Gun
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41. Small ID Transport Pipe Line Components:
Application of WC-10Co-4Cr Coating with the
Rotating AK-IDR Gun
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42. Oil Refinery:
ID Spraying Pump Casing
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43. Oil Drilling:
Fluid-End Pump Casing, 5-inch (125 mm) ID
Application of coating with AK-IDR rotating gun
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44. Wear Rings on HT Pump Housings and
Impeller Hubs
AK7 Stellite 6 coating
over 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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45. Geothermal Power:
Turbine Rotor
WC-10Co-4Cr
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46. Titanium: HVAF
Titanium:
Shrouded HVAF
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47. Spraying Tin with HVAF SL Gun
for Low-Melting Point Metals
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48. WC-Co-Cr
1 mm thick
Kermetico HVAF
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49. Tensiometer Roll:
AK7 HVAF, WC-10Co-4Cr, 1.8 mm Thick
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50. AK-HH: Hand-Held HVAF
Kermetico HVAF Blast & Spray Systems
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