Metallization, thermal spraying

GAZMASHPROEKT provides a wide range of services for the protection of surfaces from the effects of external factors, allowing the surface to recover fully and increase service life.
Coatings can be applied to virtually all types of surfaces (metals, ceramics, plastics), without changing the structure of the material, and have heat resistance, wear resistance, corrosion, and other properties.
Restore coverage, as well as the geometry and the number of products places the methods of high-speed, flame, plasma spraying allows to repair as soon as possible, in some cases directly on-site.

Our Customers: Ltd. “Gazprom mining Astrakhan”, LLC “Gazprom Transgaz Moscow”, “Gazprom Transgaz Samara” OOO “Gazprom Transgaz Tchaikovsky” LLC.

Applicable equipment

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Metallizer – a set of equipment for arc metallization of surfaces of parts and equipment to protect against corrosion and wear recovery sprayed metallic coatings. For operation using aluminum, zinc, steel and their alloys. The resulting coating has a higher wear-resistant, anti-corrosion properties.

Assign sets of equipment arc spraying:

The main purpose – the application of corrosion-resistant coatings on large surfaces: bridges, steel structures, machines, tanks, exhaust shafts GPA, chimneys. With this kit you can carry aluminizing and galvanizing designs after installation. Installing different performance, high reliability, ease of setup. Widely ispolzuetsyadlya protect structures against corrosion in sea and fresh water and in the atmosphere. The design includes a power supply unit, remote unit with push-engines and the burner control system. Use is possible both in a workshop, and in the field

Materials:
Zinc Zn, aluminum Al, Monel, Aluminum Zinc ZnAl15, magnesium aluminum AlMg5.

See how it works in the shop conditions

See how it works in the field

Another video work of professionals

Specialists

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The staff consists GAZMASHPROEKT 5 teams providing services for gas-thermal surface treatment.
Qualifications and experience of the staff to the highest standards.

Sectors of application

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The gas and oil industry, oil refining, rocket and space, defense, automotive, etc.

Depending on the applied technology and the type of material, the following types of coatings

• Anti-corrosion coatings
• Anti-Friction coatings
• Release coating
• Restoring spraying and welding
• The dielectric coating
• Heat-resistant and heat-resistant coating
• Wear-resistant coating
• Thermal barrier coating
• Seal coating
• The conductive coating

 

Overview and coating methods

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The main methods of coating

Chemically resistant metal coating is widely used in industrial practice to protect the metal from corrosion.

Anti-corrosion coatings

Corrosion-resistant metal coatings are divided into two types:

– Isolation. Perform corrosion protection function, limiting environmental influences
– Tread. Corrode, protecting the base metal due to electrochemical processes

The advantages of coatings for corrosion protection:

– High hardness. Corrosion-resistant coating is not damaged and podplenochnuyu prevent corrosion even in aggressive environments
– The absence of welds and their potential isolation by coating
– No thermal influence on the base. The substrate temperature during the work does not exceed 120 ° C
– Maintainability. The coating can be easily repaired in the field of wear
– A wide range of sprayable materials

Anti-Friction coatings

Antifriction coating – materials used for machine parts (bearings, bushings, rollers, etc.), Operated at the slip friction and having a low friction coefficient. Hard anti-friction materials have a high resistance to wear after prolonged friction.
Characterized by the following enhancements:

-Reduce Energy losses and improve reliability when working in environments containing abrasive
-Iznosostoykost Low energy dissipation in friction pairs
-High Damping capacity under the influence of cyclical and shock

Release coating

The release coating is designed to protect metal and other surfaces from sticking.
Anti adhesive wear-resistant coatings provide:

– Long-term protection from sticking
– High transporting properties
– Protection against scratches and cuts
– The structure conducive to the air outlet

Restoring spraying and welding

Restoring parts spraying and welding – a process to eliminate by evaporation and deposition invalid defects generated during operation of the equipment.
Various deposition techniques allow return detail to their original characteristics, and sometimes significantly increase their performance and extend service life.

The dielectric coating

Dielectric ceramic wear-resistant coatings can provide the necessary electrical properties of the surface with high wear resistance. Dielectric coatings are applied by plasma spraying.

Heat-resistant and heat-resistant coating

Heat-resistant coatings used in industry to protect the shaft equipment, furnaces etc., In the thermal energy to prevent corrosion of superheater tubes at high temperatures. Heat-resistant coating – it is solid and resistant to aggressive media coverage, without impairing the technological characteristics of the base metal and can withstand temperatures up to 1000 ° C without loss of performance properties.

Wear-resistant coating

Types and features of wear-resistant coatings:
– Diamond-like. They possess the highest hardness, but do not provide sufficient for most industrial coating thickness
– Ceramic. They are used for thermal barrier or insulating properties
– Wear. Are applied by high speed flame spraying and provides a high hardness and good corrosion resistance, but can not withstand shock loads.
– Fusing. It provides reliable protection against wear even under heavy loads, but are subject to cracking and can not be machined
– Molybdenum. It has a good anti-friction characteristics paired with steel
– Cobalt-based materials (Stellite). Possess high wear and corrosion resistance
– A nickel-based. Characterized by ease of application and the general scope of the
– Train-based. They have a high resistance, plasticity and provide a high degree of resistance to wear

Thermal barrier coating

Thermal barrier coating – (TBC, TBP) type coatings used for isolating components, in particular, parts of gas turbine engines operating at elevated temperatures. Typical examples of the application of the coatings – a turbine blade, combustor, and nozzle piping system guide vanes. TBP made it possible to increase the operating temperature of gas turbines, and thus increase their efficiency.
TBC characterized by a very low thermal conductivity coating is supporting a large temperature gradient when exposed to heat flow. The most commonly used material for the TBC – zirconia, stabilized zirconia (YSZ), that shows resistance to thermal shock and thermal fatigue to 1150 ° C. YSZ generally applied by plasma spraying, and electron beam physical vapor deposition (EBPVD [en]). Also, high-speed flame spraying HVOF can be used, in particular wear-resistant properties of this material are also used to prevent wear of the blades.

Seal coating

O, they’re sealing or wear coatings are used to improve the efficiency of gas turbine engines. Task burnished coatings is to reduce gas leaks through the gap between the blade and the fixed part of the turbine.

The conductive coating

An electrically conductive coating is intended to allow the passage of electric current or discharge occurring from the surface of static electricity when it is necessary to avoid the danger of explosion in the presence or spark wear factors. Application of the methods of flame spraying of antistatic coatings of copper allows you to create on the surface of metal and a layer of material with high electrical conductivity, which prevents the accumulation of static electricity.

The main applications of antistatic coatings:
– Production facilities, where possible “strong dusting” (eg, coal, cement, gypsum, etc.)
– Industrial warehouses where explosives are stored and materials
– Elevators, flour mills, sugar mills
– Sterile clean production and other special clean rooms

Electric arc metallization

Method arc spraying is wire spraying material melting electric arc spraying and applying it to the substrate with compressed air.
The thickness of the coating – 0.1-3 mm. Material coating – steel, aluminum alloys, bronze, babbitt, molybdenum and others.
The method is applicable to restore worn parts hardening and reduced stiffness, as heating the base metal during the coating does not exceed 80-100 ° C.
Typical details restored by electric arc spraying: seating surfaces of shafts, bronze bushings, bearings, cylinder liners (outside), aluminum head and other internal combustion engine blocks.

Flame spraying

Flame spraying involves the formation of droplets (particles) of the small size of the molten metal and transfer them onto the surface, where they are held, thereby forming a continuous coating. The metal polymer powder, wire or cord material is fed into the flame of acetylene-oxygen or propane-oxygen torch, melts and is transferred by compressed air is sprayed on the surface, which forms the coating cools.

Benefits:
– The ability to create materials with properties that can not be achieved with conventional plating techniques. The ability to protect equipment surfaces not only from corrosion, but also on the hydraulic and gas-abrasive wear
– Possibility of application of materials with low plasticity
– Ability to coating parts and hardware with a complex configuration of surfaces (the outer surfaces of the tube bundles of heat exchangers, etc.)
– Ability coating on site with the use of mobile systems for surfaces of any size
– Cost-effective use of thermal spray coatings, the persistence of high levels of protection during prolonged exposure to corrosive environments
– Ability to repair or restore the full coverage, the availability of technology of restoration works at minimal cost
– No, after the application of stress, surface defects and the microstructure of the material due to the exclusion of high temperatures and pressures
These features provide the benefits of thermal spraying technology, both economic efficiency and cost indicators.

Plasma spraying

Plasma coating – reliable way to protect steel and other materials. Plasma coating may be used to create a thermal barrier coating and sealing, to decrease friction parts of the chassis, giving them a greater wear resistance, for the creation of insulating and protective coatings. This type of spray can be applied in aviation, gas transport, thermal and nuclear power generation, oil production, hydraulics, metallurgy, transport engineering and many other industries. With the help of special equipment creates a plasma jet of a high temperature, which is used for coating products refractory ceramics – oxides of aluminum, zirconium, yttrium, chromium. Through such processing is improved wear resistance, heat resistance, corrosion resistance of the products.

High-speed spraying

High-speed flame spraying is considered the most modern technologies of spraying. Formed in the carbide coating, all the characteristics are superior to electroplating, and have many advantages over conventional coating paint.
As a result, powder coating is formed sturdy, durable coating with excellent performance properties, including corrosion resistance, abrasion resistance, shock and other external factors that increases the service life of products for decades.