High Velocity Oxygen Fuel

BEST PRACTICE SERIES
Service Operations
Service Processes & Repair Facilities, Tools
Personnel
Measures/Mgmt Systems Procedures & Equipment
CSA & Condition
Services Contamination Customer Sustainable
Monitoring
Marketing Control Satisfaction Development
Operations
High Velocity Oxygen Fuel (HVOF)

1.0 Introduction & Executive Summary……………. 2
2.0 Best Practice Description .................................. 3
3.0 Implementation Steps ........................................ 5
4.0 Benefits/Measures ............................................. 7
5.0 Resources Required ........................................ 13
6.0 Supporting Attachments .................................. 21
7.0 Related Best Practices .................................... 22
8.0 Acknowledgements ......................................... 22
Marketing & Product Support Center of Excellence Rev. 20090203

501 SW Jefferson Avenue, Peoria, IL 61630 U.S.A. dealerbestpractices.cat.com
1.0 Introduction & Executive Summary
Sustainable Development – High Velocity Oxygen Fuel (HVOF)
Description:
HVOF is a revolutionary product that greatly extends the life of wear-prone metal parts. HVOF-coated
surfaces have an even porosity and constant Rc70 hardness, which significantly retards surface wear
caused by friction and rubbing. This best practice describes the procedure used by Empire to prepare
and coat a component, the equipment needed to complete the work, and reasons for eliminating the
use of chrome coatings.
Scope:
HVOF is ideal for components such as: Cylinder rods, Stainless steel pins, Laminating rollers,
Deburring machine rollers, Strut rods, Rotating shafts, Linkage pins, and any other application where
uniform hardness, corrosion resistance and extended performance are desirable.
Background:
Even when new, most metal coatings reveal micro-cracks under magnification. With time and use,
these cracks allow rust and corrosion to invade the surface, adversely affecting the performance and
wear life of the component. However, the homogeneous properties inherent in HVOF dramatically
retard corrosion, so surfaces, and any seals which come in contact with them, last more than twice as
long.
Impacts:
Implementing HVOF Coatings will reduce emission of Hexavalent Chrome and eliminate a toxic
environment. HVOF coating is five times more corrosive resistant than chrome plate, two times more
wear resistant than chrome and it requires a smaller investment than chrome plate, there is less
maintenance of equipment, it is environmentally friendly, has less waste disposal, and damaged
HVOF coatings can be patched rather than recoating the entire part.
Actions and Resources Required:

Capital expenditure will be required to implement this best practice. A dealer will need to purchase
HVOF, grinding, and other equipment listed in section 5.0 Resources Required, as well as, create
space in their current facility or build another facility for all of the new equipment.
dealerbestpractices.cat.com
Sustainable Development – High Velocity
Oxygen Fuel (HVOF) BEST PRACTICE SERIES
2.0 Best Practice Description

High Velocity Oxygen-Fuel (HVOF) spraying is a process where fine metallic materials are
deposited onto a prepared surface. HVOF is considered a "warm" part salvaging method when
compared to flame spray "cold" or welding and brazing (both "hot" processes). It is considered a
warm process because the surface temperature of the piece part is kept below 205o C (400o F)
when a coating is applied. Therefore, the part itself experiences no metallurgical or physical
changes.
The Caterpillar HVOF spray salvage process uses an oxygen-fuel mixture. The Sulzer Metco
2700 Hybrid system utilizes either propylene, propane or natural gas as a fuel. The fuel gases are
mixed in a nozzle system in the front portion of the spray gun. The mixed gases are ejected from
the nozzle of the gun and ignited externally. The ignited gases form a circular flame, which
surrounds the powdered spray material as it flows through the gun.
The circular flame shapes the powder stream to provide uniform heating and acceleration of the
spray material. Combustion temperatures approach 2760o C (5000o F).
Pre-selected oxygen, fuel and airflow values optimize the dwell time of the spray material in the
flame.
The gas exhaust velocities of the Hybrid Diamond Jet System approach 2134 m/sec (7000 ft/sec)
[3 to 4 times the speed of sound]. Elevated particle velocities, optimized powder feed rates and
internal central powder injection impart both thermal and kinetic energy to the powder particles.
The high velocity particles flatten when impacting on the substrate to form dense tightly bonded
coatings.
Nitrogen is used as a carrier gas for

feeding the spray materials through the
system. The Diamond Jet Hybrid system
uses 9.5 L/min (2.5 gallons/min) of
water to cool the nozzle of the gun.
Powder Feed
All Hybrid Diamond Jet Systems are
feed by a pressurized feeding system.
The powder is transported and delivered
to the gun by an inert gas (pre purified Cross Section of the Hybrid Diamond Jet Gun
Nitrogen) at a constant rate,
independent of the spray gun's orientation or movement. The feed unit provides a real-time
powder feed rate, to assist in coating process control.
Through the High Velocity Oxygen Fuel (HVOF) spray process, a fine metallic uniformly heated
material is deposited onto a prepared surface. When the particles strike a surface, they flatten
(elongate), rapidly cool and quench to form micro-thin platelets. The platelets conform to the
surface of the substrate and to each other. The bond between the base material and the HVOF
coating is mechanical.
THE INFORMATION HEREIN IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN
PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS INTENDED, IS PROHIBITED.
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As the sprayed particles continue to impinge onto the surface, they form a layer or lamella
structure. The lamella structure of HVOF coatings is very dense and uniform. HVOF coatings
have the following characteristics:
High density
High bond strength [in excess of 83 MPa (12,000 psi)]
Essentially stress free
Very low porosity (less than 3%)
Fine as-sprayed finishes
Greater hardness (DPH300 1000-3000)
Metal working capabilities
Excellent wear and corrosion resistance
Greater thickness
Since multiple particles are needed to create a coating, a number of transverse passes of the gun
are required to produce the desired coating thickness. These multiple passes should be
performed at a constant rate by mechanical manipulation. The actual thickness of a coating
depends on the run out of the component being salvaged plus an allowance for finishing. The
finishing allowance is generally 0.05-0.076 mm (0.002-0.003 in) on a side.
The formed coating is used for “surface” type applications. The coating will not provide any
strength to a part. Its only function is to add some desirable characteristic to the surface that is
currently lacking in the work piece part. Desirable HVOF spray characteristics include:
Corrosion protection
Better wear characteristics
Dimension restoration
Electrically conductive or resistive
Because of the nature and structure of HVOF spray coatings, they should not be used when the
coatings will be subjected to line or point-to-point contact and severe, sharp and repeated type of
impact.
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3.0 Implementation Steps

For the purpose of describing the implementation steps, a hydraulic rod will be followed through
Empire’s process.
The HVC supervisor fields a telephone call or email, from an H ig h L e ve l P ro ce ss M a p fo r

external (mine site) or internal (Empire Hydraulics Shop) R e fin ish in g a H yd ra u lic R o d
customer, requesting a quote to recondition a hydraulic rod.
H V C S u p e rv is o r T e c h n ic ia n
Given the length and diameter of the rod, he works up a quote
and communicates the cost to the customer. When the rod
arrives at Empire Precision Machining, the supervisor enters Q u o te jo b fo r
c u s to m e r
information about the rod into Empire’s Service Process
Integrator (SPI) tracking database.
In s p e c t a n d
The technician inspects the rod for damage and measures it R e c e iv e ro d
m e a s u re ro d
fro m c u s to m e r
using a micrometer to determine how it compares to the a s re c e iv e d
published specifications. All measurements and inspection

notes are recorded in SPI.
E n te r jo b
S trip ro d
in fo rm a tio n
He mounts the rod in the in to S P I
c o a tin g
lathe and indicates it to

ensure it will rotate on center.
Using a 3M 966F aluminum
G rit b la s t ro d
oxide 24 grit belt, the current
coating is stripped from the
rod. This belt is yellow in
color. Rotation speed (rod) S p ra y w ith
and traverse speed, direction, HVOF
and depth (grinding belt) are set on the control panel. The
technician measures the rod again and records the findings.
When the coating and any surface imperfections are completely G rin d ro d to
s p e c ific a tio n
removed, the rod is taken out of the lathe and moved to the grit a n d fin is h
blast booth. p o lis h
F in a liz e jo b P a c k a g e ro d to
in fo rm a tio n s h ip b a c k to
in S P I c u s to m e r
S h ip ro d to
c u s to m e r
LeBlond Grinder Control Panel
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The rod is mounted vertically in the grit blast booth,

and the technician uses an electronic surface analyzer
to determine the best grit texture to prepare the
surface of the component to achieve the optimum
surface for coating. Rotation speed (rod) and traverse
speed/direction (grit blast gun), blast start/stop points,
and number of passes over the rod are set on the
control panel. When the blasting cycle is complete, the
rod is brushed with a wire brush to remove any grit
remaining on the rod. The technician removes the rod
from the grit blast booth and places it in the HVOF
spray booth taking care not to touch the grit blasted
surface of the rod. If touched, the oil and greases on Grit Blast Control Panel
your hand will transfer to the rod and the HVOF will not
adhere to the surface.
Note: HVOF’s chemical formulas can be customized to each component’s application and the
number of coats applied varies with each piece. The result is a dramatic improvement in
component performance and wear life.
The rod mounts in the HVOF booth in the same

manner as in the grit blast booth. Once mounted,
rotation speed (rod) and traverse speed/direction
(grit blast gun), spray start/stop points, and number
of passes over the rod are set on the control panel.
While spraying the rod, the technician monitors the
temperature of the rod. The rod must not get to hot
or the properties of the material will change.
Multiple spray cycles may be needed in order to
get the desired coating thickness on the rod.
Empire sprays ten-thousandths over spec size to
allow for finish grinding and polishing of the rod.
After each spray cycle, the technician takes a
HVOF Control Panel
temperature reading on the rod with a hand-held
infrared thermometer, and measures the rod at multiple points to ensure an even coating
thickness. When the desired coating thickness is reached and the rod has cooled, he removes the
rod from the spray booth and takes it back to the lathe.
The technician mounts the rod in the lathe and indicates it in

order to ensure it will rotate on center. Using a 3M 663FC 70
mic. diamond belt, the new coating is ground to the desired
specification. This belt is a light green color. Rotation speed
(rod) and traverse speed, direction, and depth (grinding belt)
are set on the control panel. The technician checks the
rotation and measures the rod between grinding cycles to
ensure the coating is ground evenly over the entire surface of
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the rod. When the rod measures in the specification range, he changes the grinding belt for a final
polish.
Final finishing is a two step process performed on a computer-

controlled lathe using a 3M 6456J 20 mic. flexible diamond role
and a 3M 675L 20 mic. diamond lapping film role. These belts are
white or grayish color. Rotation speed (rod) and traverse speed,
direction, and depth (grinding belt) are set on the control panel.
After polishing, the technician measures and inspects the rod.
When the desired specification and smoothness is reached, the
technician measures the hardness and thickness of the surface
coating.
Abbott Grinder Control Panel
When all measurements are within the specifications, the technician records the measurements,
wipes down the rod, and removes it from the lathe. Once the rod is packaged for shipping, the
supervisor arranges the shipping and informs the customer of the shipping information and any
details related to the completed work order.
4.0 Benefits/Measures
To demonstrate the benefits listed below, this section includes five documented examples
covering corrosion resistance, seal wear life, coating wear life, and coating damage repair:
5 times more corrosive resistant than chrome plate

2 times more wear resistant than chrome plate
Smaller investment than chrome plate
Less maintenance of equipment
Environmentally friendly, reduces emission of Hexavalent Chrome
Less waste disposal
Damaged HVOF coatings can be patched instead of recoating the entire part
Example One: Seal Wear Test at Caterpillar Pioneer Park Facility

Four rods with various degrees of roughness
Ra = 0.036, 0.2, 0.146, 0.04 μm (1.44, 8, 5.84, 1.6 μin)
Seal failure = 0.005g/stroke, 3 days in row
Replace seals, and rerun
Ra = 0.036 μm (1.44 μin) rod @7.27 mil cycles other rods @ 5.33 mil cycles
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Rod # Location Ra um (uin) Rp um Rvk Tp% Rk Cycles to Seals run against chrome
plate average life only
leakage (ave)
350,000 cycles.
14 1 0.036 (1.44) 0.092 0.201 98.3 0.086 1,876,000
Empire 2 0.2 (8) 0.574 0.552 80 0.593 645,333
3 3 0.146 (5.84) 0.622 0.411 88.71 0.339 1,249,000
4 4 0.04 (1.6) 0.119 0.107 99 0.118 2,796,000
HVOF surface texture does not change; 67% better B50 Seal life.
Example Two: 793 OHT: HVOF -vs- Chrome Hours (Empire Machinery Data)
Front Struts
2
Total Hrs. Times Avg. Hrs. With Hrs. With HVOF HVOF/Chrome
1 2
With Chrome Chromed Chrome (Since Last Hrs. Ratio
Rebuild in 1999) (Life Improvement)
40752 4 10188 25089 2.5
31375 3 10458 19042 1.8
33813 3 11271 19296 1.7
Average results for 14 struts including above

35860 2.78 12966 16402 1.3
1. Including original chrome; 2. HVOF components are still running
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Rear Struts
2
1 2
15862 2 7931 37247 4.7
20275 3 6758 16551 2.4
17510 2 8755 16995 1.9
Average results for 12 rear struts including above

29898 3.33 10838 18172 1.7
Steer Rods
2
1 2
27127 4 6782 16365 2.4
17511 2 8756 16993 1.9
17512 2 8756 16992 1.9
30258 3 10086 17477 1.7
Average results for 5 steer rods including above

29247 3.4 12258 15968 1.3
Hoist Tubes
2
1 2
23096 4 5774 20326 3.5
19670 4 4918 14834 3.0
17512 2 8756 25117 2.9
17500 3 8750 20469 2.3
41341 3 13780 25854 1.9
41341 3 13780 25854 1.9
22370 2 11185 20259 1.8
32315 3 10772 19465 1.8
32315 3 10772 19465 1.8
33424 3 11141 18902 1.7
32925 3 10995 18270 1.7
Average results for 39 hoist tubes including above

33629 2.79 13374 17317 1.3
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Hoist Rods
2
1 2
19670 4 4918 14834 3.0
17512 2 8756 25117 2.9
17512 2 8756 25117 2.9
17500 2 8750 20469 2.3
22370 2 11185 20259 1.8
32315 3 10772 19465 1.8
32985 3 10995 18270 1.7
Average results for 30 hoist rods including above

32013 2.67 12674 17189 1.3
Overhaul cost with 2 sets of front and rear struts, and hoist cylinders
Total Cost of 2 Overhauls with Chrome: $30,090 O v erh au l S av in g s

Total Cost of 1 Overhaul with Cat HVOF: 17,519 In terv a l C o st/H r.
Savings: $12,671 W ith C at H V O F
1 2 ,0 0 0 $ 1 .0 8
Approximately $60,000 savings over the life of a 1 4 ,0 0 0 $ 0 .8 8
truck 1 6 ,0 0 0 $ 0 .8 0
Example Three: 988F Tilt Lever Pilot and Tilt Link Pins with 9,110 Hours HVOF -vs- Chrome
Left: 4V2120 Tilt Lever Pivot Pin with HVOF Coating –

measured in spec, no sign of wear, reinstalled
Middle: 4V2122 Tilt Link Pin with HVOF Coating –

measured in spec, no sign of wear, reinstalled
Right: 4V2122 Tilt Link Pin with Chrome Coating –

chrome worn through to base material, replaced
Example Four: Damage Repair, 793 OHT Front Strut with HVOF Coating at 33,721 Hours
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Bottom end Top end
Dent in coating (to small to feel) Polished to remove dent
Strut measured in spec when received, so it was polished and measured. Polishing removed the
dent and the strut still measured within spec so it was able to be reused. Cost to customer was
$450 as opposed to full reconditioning with HVOF, or full price for a new strut.
Example Five: Corrosion Resistance, 950F Wheel Loader in Mexican Salt Mine
Lift Cylinder Rods
HVOF Coating at 3,200 Hours Chrome Coating at 682 Hours
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5.0 Resources Required

HVOF Spray Equipment
The Caterpillar HVOF spray salvage program will use
the Sulzer Metco Hybrid Diamond Jet System. The
Hybrid Diamond Jet System consists of the following
basic components:
Hybrid Diamond Jet Gun (DJ-A Automatic)
DJC Diamond Jet Control Unit
9MPDJ or DJP Powder Feed Unit
2DJR Diamond Jet Gas Regulators and
Manifolds
4AC Air Cleaner
7GNR Nitrogen Regulator DJ2700 Hybrid Gun
DJC 2600 Water Sensing Interface Box
DJ 2700 Hybrid Air Cap Assembly (designed for
propylene, propane, or natural gas as a fuel)
Note: Hydrogen assist is required when using propane,

propylene, and natural gas.
Note: The Tafa JP5000 is an option for the Diamond Jet

System.
HVOF Spray Nozzle
DJC Diamond Jet Control Unit on left

Vertical Spray Cabinet 9MP-DJ Powder Feed Unit on right
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Sound Suppression Equipment

The acoustical spray room should meet the following
minimum parameters:
Walls and roof shall have a minimum Sound
Transmission Class (STC) rating of 40 as
tested in accordance with ASTM E90-75 and
noise Reduction Coefficient (NRC) of 0.95
tested in accordance with ASTM C423-77. See
table below.
Windows should be provided with a number six
filter to prevent glare when viewing the thermal
spray process in operation. Windows should
also be thermopane glazed and supplied with a
desiccant material between the panes to
prevent fogging.
HVOF Cabinet on Left

Blast Cabinet on right
Acoustic Performance
Sound Transmission Loss dB E-90-75
Octave Band
Center Freq. Hz 63 125 250 500 1k 2k 4k 8k STC
Noise Shield
20 21 27 38 48 52 56 - 40
Regulate
Noise Lock Door - 26 42 43 47 61 61 67 47
Noise Lock
27 28 31 47 55 61 61 67 47
Windows
Sound Absorption Coefficients *
Noise Shield
- 0.89 1.20 1.16 1.09 1.01 1.03 0.93 0.95
Regulator
Noise Reduction - 15 19 24 34 41 46 45 50
* ASTM C423-81A Standard test method for sound absorption and absorption coefficient via reverberation
method, mounting method A, formally mounting number four.
Note: Consult your local environmental laws for exact sound regulations.
Powder Recommendations
SLM 3010 powder is the recommended material for chrome replacement. SLM 3010 has a
thickness limitation of 0.46 mm (0.018 in) per side. The coating shall be deposited in layers of
0.0127 mm (0.0005 in) per pass. If the total coating thickness is greater than 0.25 mm (0.010 in),
then SLM 3210 shall be used as a bond/buildup layer. SLM 3210 has a thickness limitation of
0.76 mm (0.030 in) and shall be applied in layers of 0.0127 mm (0.0005 in) per pass. These
materials can be ordered through St. Louis Metallizing or Sulzer Metco.
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Powder Delivery
Sulzer Metco's
The Blue Powder Feed Hose should be requested when
Standard Powder Feed Hose
ordering equipment. Cat dealers that use Sulzer Metco
equipment and Caterpillar's Research people have both Hose Type Inside Diameter
seen fewer powder feed problems when using this Blue 2.29 mm (0.090 in
powder feed hose. Orange 3.18 mm (0.125 in)
Black 4.76 mm (0.188 in)
Fuel Delivery Natural Gas Arrangement
Bulk fuel storage tanks must be heated to prevent fuel
gases from liquefying. Also, it is important to have gas
lines from the bulk storage tanks to the Sulzer Metco
equipment heated to prevent gas condensation
If your spray booth or shop area is not climate

controlled, it is also recommended to heat the
fuel gas lines from the Sulzer Metco controller
to the HVOF gun to prevent gas condensation.
Oxygen Tanks Nitrogen Tanks
Shop Air
Dry, clean shop air is extremely critical to the quality
of a thermally sprayed coating. Separate air filters
and an air dryer should be used prior to the shop air
entering the HVOF system.
The preferred system configuration is shown on the

right in the HVOF Shop Air Schematic. The air dryer
[2] should have a filter [1] placed up steam and two
filters [3, 4] down steam.
1. Particulate Filter (5 micron) HVOF Shop Air Schematic

Wilkerson: FC35-OC-F00 or equivalent
2. Air Dryer
Pneumatech AD-1500, AD-1700 or equivalent (based on air consumption and the
shop's ambient climate)
3. Coalescing Filter (0.5 micron)
Wilkerson: M35-OC-FS0 or equivalent
4. Coalescing Filter (0.01 micron)
Wilkerson: M35-OC-F00 or equivalent
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Water Chiller
A water chiller for the Sulzer Metco 2700 Hybrid water cooled nozzle must meet the following
parameters:
Flow: 7.6 L/min (2.0 Gal/min)
Temperature: Below 26.6° C (80° F) (Inlet to Gun)
Pressure: 275.6 kPa (40 psi)
Cooling: 31,650 kJ/hour (30,000 BTU/hour)
Cleanliness: Tap water
Tap water can be used to cool the nozzle in most locations and then diverted to drain. If water
recycling is required, the recommended chiller is a Sulzer Metco 5MK Heat Exchanger or
equivalent.
Exhaust/Ventilation
For environmental control and personnel safety, a
proper dust and fume exhaust system is required.
EPA (U.S.) rules dictate exhaust systems be 99.9%
efficient. Both Torit and Sulzer Metco can supply the
required equipment.
The waste collected in the 55 gallon drums under

the exhaust/dust collector system is considered
Hazardous Material. Empire pays a hazardous
waste disposal company to properly remove and Exhaust System for HVOF on left, grit blast
dispose of the material. Under typical operations, all on right
four barrels are changed once a year.
Manipulators/CNC
The HVOF/ Grit Blast cells are computer controlled to
provide high quality coatings via a controlled process.
Vertical or horizontal booths can be used to blast and
spray the cylinder rods.
Design/Support
Caterpillar Dealer Support and Research can provide
the necessary information for planning an installation.
Working with suppliers, a turnkey package can be HVOF coating being applied to a hoist
created to fit a dealer’s requirements. cylinder using a robot to control the
spray gun
Progressive Technologies Design

These design layouts by Progressive Technologies are previewed here but are also available in
full-page .pdf format located under the Tools and Equipment tab of the HVOF CD (SERF8705).
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HVOF and grit blast layout HVOF Facility layout
Grit Blast Facility layout
Support Equipment and Operations
Straightening
A component with more than 0.076 mm (0.0015 in) runout will have
to be straightened before the HVOF salvage process. Straightening
is crucial to conserving spray materials, and in minimizing both
thermal spray and machining cycle times.
The component should be loaded into a straightening press with

adequate gauging to straighten the component to less than 0.038
mm (0.0015 in) runout per every 914 mm (36 in). Reducing overall
component runout, decreases the volume of spray material that must
deposited onto the component to compensate for the out-of-round
condition. Components requiring higher volumes of material will
increase the thermal spray cycle time. Component machining times Straightening Press
will also increase, because of the need to remove the excess spray
material.
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Degreasing
All components should be degreased before the grit blast operation. This operation helps prevent
contamination of the grit, and assures there is no oil or grease on the surface of the component to
be coated. Oil and/or grease on the surface of the component will increase the probability of
finishing problems and coating defects.
Grit Blasting
Grit blasting before the thermal spray process is considered
surface texturing. This operation provides a slightly rough
surface texture that the HVOF metal particles will interlock with.
Clean, dry compressed air and sharp, coarse blasting abrasive
that is free from contaminants must be used to avoid finishing
problems.
Two types of grit blasting systems are found in most shops: Grit Blast Equipment
pressure and suction. For surface preparation of a coating, the
pressure type system is preferred because:
1. Pressure blast systems can handle both aluminum oxide and steel angular grits.
2. A pressure blast system is more efficient and, therefore, more economical.
3. Pressure blast provides the best surface texture and depth using either aluminum oxide or
angular steel grit.
4. A suction head can easily be mounted next to the pressure blast nozzle, to quickly and
efficiently remove blast media as the surface texturing is being completed.
Aluminum oxide 20 mesh is the recommended grit blast media to prepare surfaces for HVOF.
Aluminum oxide is an extremely hard and brittle abrasive, used primarily on heat-treated steel
substrates. It is not used for preparing aluminum or cast type substrates because the fine dust
generated during the blasting operation tends to embed itself into the surface of the component.
Because this type of grit is light in weight, it can be used at very low pressures. The use of lower
operating pressures allows the use of aluminum oxide grit on hard and soft components.
The recommended blast air pressure is 413 kPa (60 psi). Heat-treated rods should be rotated at
61 SMPM (200 SFPM) and non heat-treated rods should be rotated at 122 SMPM (400 SFPM),
with the blast nozzle traversing across the piece at a rate of 5.0 mm (0.1875 in) per revolution.
The blast nozzle to work piece distance should be maintained at a 101 to 127 mm (4 to 5 in)
range in order to obtain a minimum surface profile of 6.0 μm (250 μin).
Using higher than recommended pressures results in rapid breakdown of grit, and more grit
usage. It may be necessary to grit blast chrome from long, small diameter parts due to bending
problems when grinding. This method should only be used when necessary, since the chrome
particles will mix with the grit. Chrome or other grit contaminants can be embedded in the surface
of the component during blasting.
NOTE: Used grit should be visually inspected to ensure sharpness. If dull or

contaminated grit is found, it must be replaced before poor surface preparation results.
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Masking Aids
Masking is required to protect critical surfaces and holes from the effects of the grit blasting and
thermal spraying. Any type of material that can withstand the effects of either operation is
considered a suitable masking material.
The mask itself can be permanent sheet metal or a temporary material. Temporary-type masking
materials are:
Hard Rubber
High temperature silicon rubber
High temperature fiber type materials
Several layers of duct or masking tape
Cloths
Liquids
Spray Booths and Rooms

Any flame spraying process generates dust and fumes. The HVOF process also generates an
extreme amount of noise, due to gas exhaust velocities of 2134 m/sec (7000 ft/sec). The noise
will be in the 135 to 140 dB range.
For environmental control and personnel safety, an enclosed soundproof area is appropriate.
Dealer Support or a local supplier can recommend a variety of dry cartridge exhaust and
soundproof rooms, to meet your local safety standards and regulations.
Rotational/Traverse Equipment
Rotating the cylindrical components should be accomplished
in a lathe or other dedicated rotational device. The standard
lathe or dedicated rotational device should provide variable
rotational settings to relatively high RPM capability. Specially
designed rotating systems manufactured by Sulzer Metco and
other companies can withstand the dusty spray environment,
yet provide the part rotational requirements.
LeBlond Grinder
A part's rotational requirement is provided in the Applications
section of SERF8705. The following formulas can be used to
calculate either RPM (revolutions per minute) or SFPM
(surface feet per minute) for a part.
(3.82 x SFPM)/ rod diameter in inches = RPM
.262 x RPM x rod diameter in inches = SFPM
For traverse motion of the HVOF spray gun, the following

guidelines should be used to apply an even coating deposit:
Flat work (non-rotating): Traverse at a rate of 15-30
cm (0.5-1.0 in) per second, making 6.3 mm (0.25 in) Abbott Grinder
gun increments per pass.
Round/Rotating Work: Traverse the gun at a 5.0 mm (0.1875 in) per revolution.
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Empire created the following reference chart in order to quickly determine the correct rotational
speed for the part being sprayed:
Diameter Diameter Diameter

RPM RPM RPM
mm in mm in mm in
50.8 2.00 560 165.1 6.50 177 279.4 11.00 104
57.15 2.25 510 171.45 6.75 170 285.75 11.25 102
63.5 2.50 460 177.8 7.00 164 292.1 11.50 100
69.85 2.75 420 184.15 7.25 158 298.45 11.75 98
76.2 3.00 380 190.5 7.50 153 304.8 12.00 96
82.55 3.25 350 196.85 7.75 148 311.15 12.25 94
88.9 3.50 330 203.2 8.00 144 317.5 12.50 92
95.25 3.75 310 209.55 8.25 139 323.85 12.75 90
101.6 4.00 285 215.9 8.50 135 330.2 13.00 88
107.95 4.25 270 222.25 8.75 131 336.55 13.25 87
114.3 4.50 255 228.6 9.00 128 342.9 13.50 85
120.65 4.75 242 234.95 9.25 124 349.25 13.75 84
127 5.00 230 241.3 9.50 121 355.6 14.00 82
133.35 5.25 219 247.65 9.75 118 361.95 14.25 81
139.7 5.50 209 254 10.00 115 368.3 14.50 79
146.05 5.75 200 260.35 10.25 112 374.65 14.75 78
152.4 6.00 191 266.7 10.50 109 381 15.00 77
158.75 6.25 184 273.05 10.75 107
Grinding Belts
3M Belts
Purpose Type Color
Removing original coating 966F 24 grit Yellow
Grinding to specification
(After spraying with HVOF) 663FC 70 mic. Diamond belt Light Green
Super Finish Step 1: 3M 6456J 20 mic. Flexible Diamond role
(Polisher) Step 2: 3M 675L 20 mic. Diamond lapping film role White / Gray
Micrometers
Coating thickness and hardness testers
Elcometer 355 Coating Thickness System

Hand-held measuring system is packed with time-saving and cost-cutting features.
True 1% Accuracy
Flexible Probe Modular System
Printer or PC Output
Statistical Analysis
Rugged Aluminium Case
Traceable Thickness Standards
Conforms to BS, ISO DIN, ASTM & SSPC methods of measurement
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KB Microdor 10 w/ Probe Kit Hardness Tester

Method of measurement: Vickers penetration with indentation evaluation by
the UCI method under load (diamond angle 136°)
Range: 20 - 1740 HV
Conversion:
HV, HB, HRC, HRB
N/mm² (only with the 10 kgf handheld probe) according to DIN 50150,
ASTM E 140
Data Logger (for version MIC 10 DL): Internal memory for 1800
measurements, memory card for 590 measurements.
6.0 Supporting Attachments

This document has no attachments, but additional information can be found by following the links
listed below:
Empire Cat http://www.empire-cat.com/cm/
Sulzer Metco http://www.sulzermetco.com/en/desktopdefault.aspx
Progressive Technologies http://www.ptihome.com/
St. Louis Metallizing http://www.stlmetallizing.com/
Global Dealer Extranet - Repair Process Engineering
https://productsupportglobalcontent.cat.com/cda/layout?m=19982&x=7
Dealer Best Practices https://dealerbestpractices.cat.com/cda/layout?m=148161&x=7
Facility Planning and Development Overview
https://productsupportglobalcontent.cat.com/cda/layout?m=19948&x=7
Available for purchase is the High Velocity Oxygen Fuel (HVOF) Spray Guide CD – SERF8705.
The applications contained in the guide provide dealers with the necessary background
information, instructions, and specifications to repair hydraulic cylinder rods as well as OHT, TTT,
and Wheel Loader components using HVOF technology. The following is a list of the application
files on the current HVOF Spray Guide CD:
Rods with Eyes Pins-Wheel Loaders

OHT Front Struts OHT Rear Spindles
OHT Rear Struts OHT Front Spindles
D7-D11 TTT Pivot Shafts Ejector Cylinder
Rods with Yokes SLM3010 Increased Deposition Spray
Rods with Sockets Parameters
Rods with Square Ends TTT Bearing Sleeves
Rods with Miscellaneous or Special Ends Riper Pins
Rods with Eyes - Step in Pin Bore Dozer Pins
Rods with Eyes - Snap Ring Grooves Dozer Yokes
Rods with Eyes - Multiple Coated Diameter Motor Grader Blade Lift Yokes
Rods with Eyes - Telescoping (Hoits) WTS Pan Lift Yokes
SLM3010 Spray Parameters D3B-D6R TTT Pivot Shafts
SLM3210 Spray Parameters 776-793 OHT Strut Cap Pin
Sulzer Metco 1008 Spray Parameters D3-D5G TTT Track Adjuster Yoke Shafts
Pins-Hex
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7.0 Related Best Practices

Related best practices will be determined at a future date. Please visit the Dealer Best Practices
website for more information.
8.0 Acknowledgements
We would like to acknowledge the contributions of the following dealer in the creation of this Best
Practice:
Shad Smith, Supervisor – HVC Empire Cat
shadsmith@empire-cat.com 37 W. Iron Ave
(480)633-4710 – Desk Mesa, AZ 85210, USA
(602)622-4710 – Cell (800)Empire-1
(800)367-4731
This Best Practice was written by:

J. Ryan Hubbard, Senior Project Engineer Caterpillar Inc
hubbard_j_ryan@cat.com LC2125 Repair Process Engineering
(309) 494-5634 501 S.W. Jefferson
Peoria, IL 61630, USA
QUESTIONS: For questions or implementation assistance, please contact your Caterpillar Service
Operations representative or consultant.
FEEDBACK: For comments about this Best Practice, click the following link and fill out the
feedback form. The feedback form can also be accessed from the Dealer Best Practices website.
Feedback Form
DATE CHG
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BEST PRACTICE SERIES

High Velocity Oxygen Fuel (HVOF)

Marketing & Product Support Center of Excellence Rev. 20090203

Actions and Resources Required:

2.0 Best Practice Description

Nitrogen is used as a carrier gas for

3.0 Implementation Steps

The HVC supervisor fields a telephone call or email, from an H ig h L e ve l P ro ce ss M a p fo r

published specifications. All measurements and inspection

lathe and indicates it to

blast booth. p o lis h

LeBlond Grinder Control Panel

The rod is mounted vertically in the grit blast booth,

The rod mounts in the HVOF booth in the same

The technician mounts the rod in the lathe and indicates it in

Final finishing is a two step process performed on a computer-

Abbott Grinder Control Panel

5 times more corrosive resistant than chrome plate

Example One: Seal Wear Test at Caterpillar Pioneer Park Facility

Average results for 14 struts including above

1. Including original chrome; 2. HVOF components are still running

Average results for 12 rear struts including above

1. Including original chrome; 2. HVOF components are still running

Average results for 5 steer rods including above

1. Including original chrome; 2. HVOF components are still running

Average results for 39 hoist tubes including above

1. Including original chrome; 2. HVOF components are still running

Average results for 30 hoist rods including above

1. Including original chrome; 2. HVOF components are still running

Total Cost of 2 Overhauls with Chrome: $30,090 O v erh au l S av in g s

Left: 4V2120 Tilt Lever Pivot Pin with HVOF Coating –

Middle: 4V2122 Tilt Link Pin with HVOF Coating –

Right: 4V2122 Tilt Link Pin with Chrome Coating –

Bottom end Top end

Dent in coating (to small to feel) Polished to remove dent

Lift Cylinder Rods

HVOF Coating at 3,200 Hours Chrome Coating at 682 Hours

5.0 Resources Required

Note: Hydrogen assist is required when using propane,

Note: The Tafa JP5000 is an option for the Diamond Jet

DJC Diamond Jet Control Unit on left

Sound Suppression Equipment

HVOF Cabinet on Left

If your spray booth or shop area is not climate

Oxygen Tanks Nitrogen Tanks

The preferred system configuration is shown on the

1. Particulate Filter (5 micron) HVOF Shop Air Schematic

The waste collected in the 55 gallon drums under

Progressive Technologies Design

HVOF and grit blast layout HVOF Facility layout

Grit Blast Facility layout

Support Equipment and Operations

The component should be loaded into a straightening press with

NOTE: Used grit should be visually inspected to ensure sharpness. If dull or

Spray Booths and Rooms

For traverse motion of the HVOF spray gun, the following

Diameter Diameter Diameter

Coating thickness and hardness testers

Elcometer 355 Coating Thickness System

KB Microdor 10 w/ Probe Kit Hardness Tester

6.0 Supporting Attachments

Rods with Eyes Pins-Wheel Loaders

7.0 Related Best Practices

This Best Practice was written by: