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Kermetico HVAF vs HVOF technology technical presentation

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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.

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Kermetico HVAF vs HVOF technology technical presentation

  1. 1. Kermetico High Velocity Air-Fuel Thermal Spray 2017 v@kermetico.com kermetico.com April 20, 2017 kermetico.com v@kermetico.com 1
  2. 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 April 20, 2017 kermetico.com v@kermetico.com 2
  3. 3. What is the difference? Jet Kote Kermetico C6, C7 1700- 2100 °C DJ 2600 JP 5000 2982 °C 2982 °C April 20, 2017 kermetico.com v@kermetico.com 3
  4. 4. The Result April 20, 2017 kermetico.com v@kermetico.com 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 4
  5. 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 April 20, 2017 kermetico.com v@kermetico.com 5
  6. 6. Uniformity of HVAF Coating Properties: Hardness of HVOF and Kermetico HVAF WC-10Co-4Cr coatings (Schlumberger, UK) HVAF HVOF April 20, 2017 kermetico.com v@kermetico.com 6 Relative standard deviation, % HVAF: 3.9 % HVOF: 15.7-17.8%
  7. 7. WC-10Co-4Cr Coating Characterization Propane 1470 HV300 April 20, 2017 kermetico.com v@kermetico.com 7
  8. 8. WC-10Co-4Cr Coating Characterization Propane- 60% Butane 1,500 HV300 Propylene 1,650 HV300 April 20, 2017 kermetico.com v@kermetico.com 8
  9. 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 April 20, 2017 kermetico.com v@kermetico.com 9
  10. 10. Cr3C2-25NiCr Coating Characterization AK7, Propane WOKA 7210 (25/5 mm) 1082 HV300 AK6, Propane Amperit 588.059 (30/5 mm) 1068 HV300 April 20, 2017 kermetico.com v@kermetico.com 10
  11. 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) April 20, 2017 kermetico.com v@kermetico.com 11
  12. 12. Mechanical Properties 1/3 April 20, 2017 kermetico.com v@kermetico.com 12
  13. 13. Mechanical Properties 2/3 April 20, 2017 kermetico.com v@kermetico.com 13
  14. 14. Mechanical Properties 3/3 April 20, 2017 kermetico.com v@kermetico.com 14
  15. 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 April 20, 2017 kermetico.com v@kermetico.com 15
  16. 16. Surface SEM Micrographs of WC-10Co-4Cr Coatings after Cavitation Testing Test duration: 1 hour JP5000 HVOF AK6 HVAF April 20, 2017 kermetico.com v@kermetico.com 16
  17. 17. Surface SEM Micrographs of WC-10Co-4Cr Coatings after Cavitation Testing Test duration: 9 hours JP5000 HVOF AK6 HVAF April 20, 2017 kermetico.com v@kermetico.com 17
  18. 18. Resistance to Silt Erosion WC-10Co-4Cr HVOF and HVAF Coatings April 20, 2017 kermetico.com v@kermetico.com 18
  19. 19. Other Third-Party Data, Comparing Kermetico HVAF WC-10Co-4Cr Coatings to the Best HVOF and Detonation Systems April 20, 2017 kermetico.com v@kermetico.com 19
  20. 20. April 20, 2017 kermetico.com v@kermetico.com 20
  21. 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. April 20, 2017 kermetico.com v@kermetico.com
  22. 22. April 20, 2017 kermetico.com v@kermetico.com 22 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
  23. 23. April 20, 2017 kermetico.com v@kermetico.com 23 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
  24. 24. April 20, 2017 kermetico.com v@kermetico.com 24 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. 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 April 20, 2017 kermetico.com v@kermetico.com 25 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. 26. HVOF vs HVAF WC-10Co-4Cr Costs April 20, 2017 kermetico.com v@kermetico.com 26 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. 27. HVAF and HVOF WCCoCr Cost, USA April 20, 2017 kermetico.com v@kermetico.com 27 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. 28. Examples of Kermetico HVAF Applications April 20, 2017 kermetico.com v@kermetico.com 28
  29. 29. Mud Rotors, Oil Drilling: WC-20Cr7Ni, WC-10Co-4Cr April 20, 2017 kermetico.com v@kermetico.com 29
  30. 30. Hydro-Power: Francis Turbine Runner and Head Cover WCCoCr Application by Plackart CJSC, Russia April 20, 2017 kermetico.com v@kermetico.com 30
  31. 31. Hydro-Power: Metering Needle Valve and Seat Application by RenCoat Ltd., China April 20, 2017 kermetico.com v@kermetico.com 31
  32. 32. Sliding Gate of Catalyst Tower Spraying Upper Sliding Gate April 20, 2017 kermetico.com v@kermetico.com 32
  33. 33. Hydraulic Rods of Dock Cranes Hard chrome performance: 0.5 year max (pitting) HVAF WC-Co-Cr coating performance: 5+ years April 20, 2017 kermetico.com v@kermetico.com 33
  34. 34. A Refinery Sulfur Condenser Vessel Application of Hastelloy C HVAF coating DIA 1.8 m x L 2.4 m April 20, 2017 kermetico.com v@kermetico.com 34
  35. 35. Refinery: Automated Coating with the Rotating AK5 Gun Inside the Processing Vessel April 20, 2017 kermetico.com v@kermetico.com 35 Diameter: 1.8 m Length: 11.8 m
  36. 36. Refinery: Heat Exchanger Vessels April 20, 2017 kermetico.com v@kermetico.com 36
  37. 37. Double-Elbow, Coke Transport Line 12-inch ID, 6-feet long April 20, 2017 kermetico.com v@kermetico.com 37
  38. 38. Double-Elbow, Spraying with Rotating AK5 Gun April 20, 2017 kermetico.com v@kermetico.com 38
  39. 39. Coke Line Cyclone: Application of WC-10Co-4Cr Coating with the Rotating AK5 Gun April 20, 2017 kermetico.com v@kermetico.com 39
  40. 40. Coke Line Cyclone: Application of WC-10Co-4Cr Coating with the Rotating AK5 Gun April 20, 2017 kermetico.com v@kermetico.com 40
  41. 41. Small ID Transport Pipe Line Components: Application of WC-10Co-4Cr Coating with the Rotating AK-IDR Gun April 20, 2017 kermetico.com v@kermetico.com 41
  42. 42. Oil Refinery: ID Spraying Pump Casing April 20, 2017 kermetico.com v@kermetico.com 42
  43. 43. Oil Drilling: Fluid-End Pump Casing, 5-inch (125 mm) ID Application of coating with AK-IDR rotating gun April 20, 2017 kermetico.com v@kermetico.com 43
  44. 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 April 20, 2017 kermetico.com v@kermetico.com 44
  45. 45. Geothermal Power: Turbine Rotor WC-10Co-4Cr April 20, 2017 kermetico.com v@kermetico.com 45
  46. 46. Titanium: HVAF Titanium: Shrouded HVAF April 20, 2017 kermetico.com v@kermetico.com 46
  47. 47. Spraying Tin with HVAF SL Gun for Low-Melting Point Metals April 20, 2017 kermetico.com v@kermetico.com 47
  48. 48. WC-Co-Cr 1 mm thick Kermetico HVAF April 20, 2017 kermetico.com v@kermetico.com 48
  49. 49. Tensiometer Roll: AK7 HVAF, WC-10Co-4Cr, 1.8 mm Thick April 20, 2017 kermetico.com v@kermetico.com 49
  50. 50. AK-HH: Hand-Held HVAF Kermetico HVAF Blast & Spray Systems April 20, 2017 kermetico.com v@kermetico.com 50

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