Fundamentals of Flame Spray For Reconditioning Components

Media Search - SEBF9240 - Fundamentals of Flame Spray for Reconditioning Componen...
Page 1 of 25
Shutdown SIS
Previous Screen
Product: NO EQUIPMENT SELECTED

Model: NO EQUIPMENT SELECTED
Configuration: NO EQUIPMENT SELECTED
Reuse And Salvage Guidelines

Fundamentals of Flame Spray for Reconditioning Components {0100, 0599, 0679}
Media Number -SEBF9240-05 Publication Date -21/09/2015 Date Updated -08/06/2016
i06721959
Fundamentals of Flame Spray for Reconditioning Components

{0100, 0599, 0679}
SMCS - 0100; 0599; 0679
Agricultural Tractor
All
Articulated Truck
All
Asphalt Paver
All
Backhoe Loader
All
Challenger
All
Cold Planer
All
Combine
All
Compact Track Loader
All
Compact Wheel Loader
All
Continuous Haulage
FH330 (S/N: FHY1-UP)
Continuous Miner
CM340 (S/N: GEZ1-UP)
CM345 (S/N: GE21-UP)
CM445 (S/N: GE51-UP)
Dragline
All
Earthmoving Compactor
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/... 11/4/2019
Media Search - SEBF9240 - Fundamentals of Flame Spray for Reconditioning Componen... Page 2 of 25
All
Electric Rope Shovel
All
Engine
3300
3400
3400 All, 3300 All, 3200 All, 3100 All, 3000 All, and D-series All
3500 and G3500 Engines
All 3600 Engines
All C280 Engines
C-10 All
C-9 and C9 All
C11 All
C12 and C-12 All
C13 and C-13 All
C15 and C-15 All
C16 and C-16 All
C175 Engines
C18 and C-18 Engines
C27 Engines
C32 Engines
C7 All
Excavator
All
Forest Products
All
Hydraulic Shovel
All
Integrated Toolcarrier
All
Landfill Compactor
All
Load Haul Dump
All
Mini Hydraulic Excavator
All
Motor Grader
All
Multi Terrain Loader
All
Off-Highway Truck/Tractor
All
794 AC (S/N: MN51-UP; MT51-UP)
MT4400D AC (S/N: MH41-UP; MT41-UP)
Paving Compactor
All
Pipelayer
All
Road Reclaimer/Soil Stabilizer
All
Roof Support Carrier
SH630 (S/N: RS31-UP)
Scoop
SU482 (S/N: LAP1-UP)
SU488 (S/N: LAX1-UP)
SU488 Series DM (S/N: LA41-UP)
SU488 Series DN (S/N: LA31-UP)
SU488 Series L (S/N: LA51-UP)
SU488D (S/N: LA21-UP)
Skid Steer Loader
All
Soil Compactor
All
Telehandler
All
Track Feller Buncher
Caterpillar
Track-Type Loader
All
Track-Type Skidder
All
Track-Type Tractor
All
Underground Articulated Truck
All
Unit Rig Mining Truck
MT3300 (S/N: SE21-UP)
MT3700 (S/N: SE31-UP)
MT4400 (S/N: SE41-UP)
MT5500 (S/N: SE51-UP)
MT6300 (S/N: SE61-UP)
Wheel Dozer
All
Wheel Feller Buncher
All
Wheel Loader
All
Wheel Skidder
All
Wheel Tractor-Scraper
All
Introduction
Table 1
Revision Summary of Changes in SEBF9240
05 Removed St. Louis Metallizing and corrected Repair Process Engineering web
address.
Added two new documents, SEBF9274 (Thermal Spray Procedures for D7-D11 TTT
Pivot Shafts) and SEBF9385 (Thermal Spray Procedures for Motor Grader Spindle) to
04
table of Flame Spray Procedure Documents. Removed outdated Cost Justification and
Cost Considerations sections.
Added new document, SEBF9340 (Thermal Spray Procedures for MT Series OHT
03 Front Spindle) to table of Flame Spray Procedure Documents. Changed supplier name
from Sulzer Metcoto Oerlikon Metco.
02 Added Expanded Mining Products.
Added confidentiality statement and Think Safety graphic. Removed outdated media
01
reference and replaced with a list of Flame spray procedure documents.
Information Removed from "SERF8799 "Thermal Spray General Information Guide
00
CD"".
© 2016 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only.
Unauthorized use of this document or the proprietary processes therein without permission may be
violation of intellectual property law. Information contained in this document is considered
Caterpillar: Confidential Yellow.
The purpose of this Reuse and Salvage Guideline is to provide information on the basic process
fundamentals of Flame Spray for reconditioning components. Successful utilization of the Flame
spray process depends on incorporating other support types of equipment. All processing, equipment,
and installation requirements must be understood for performance and safety reasons. Included in this
document is information, including cost, on the required tools and equipment necessary to perform the
described process.
The manual either provides or references all the necessary information to achieve an understanding of
the Flame spray process.
For specific Flame spray reconditioning procedures, refer to the following list of documents.
Table 2
Flame Spray Procedure Documents
SEBF2101 Thermal Spray Procedures for Turbocharger Compressor Housing - Contour Bore
SEBF2102 Thermal Spray Procedures for Turbocharger Compressor Housing - Outlet Bore
SEBF2103 Thermal Spray Procedures for Turbocharger Exhaust Housing - Outlet Bore
Thermal Spray Procedures for Turbocharger Turbine Wheel and Shaft Assembly -
SEBF2104
Bearing Diameter
SEBF2105 Thermal Spray Procedures for Clutch Housing Piston Bore
SEBF2106 Thermal Spray Procedures for Clutch Housing Piston Inside Diameter
SEBF2107 Thermal Spray Procedures for Torque Converter Output Flange

SEBF2109 Thermal Spray Procedures for Torque Converter Carrier - Bearing Diameter
SEBF2110 Thermal Spray Procedures for Pump Drive Gear Inside Diameter
SEBF2111 Thermal Spray Procedures for Transmission Manifold - Seal Ring Bore
SEBF2112 Thermal Spray Procedures for Torque Converter Turbine Wheel
SEBF2113 Thermal Spray Procedures for Torque Converter Impeller
Thermal Spray Procedures for Transmission, Torque Converter, and Torque Divider
SEBF2114
Shafts
SEBF2115 Thermal Spray Procedures for Torque Converter Carrier - Taper Bearing Diameter
SEBF2116 Thermal Spray Procedures for Torque Converter Carrier - Seal Ring Bore
SEBF2117 Thermal Spray Procedures for Splined Shaft
SEBF2118 Thermal Spray Procedures for Torque Converter Input Housing
SEBF2119 Thermal Spray Procedures for Cylinder Head
SEBF2120 Thermal Spray Procedures for Engine Cylinder Block Top Surface
SEBF2121 Thermal Spray Procedures for Crankshaft Main Bearing Saddle Area
SEBF2122 Thermal Spray Procedures for Main Bearing Cap
SEBF2124 Thermal Spray Procedures for Connecting Rod
SEBF2125 Thermal Spray Procedures for Exhaust Manifold (I.D. and O.D.)
SEBF2126 Thermal Spray Procedures for Water Pump Housing Bore
SEBF2127 Thermal Spray Procedures for Oil Pump Shaft
SEBF2128 Thermal Spray Procedures for Water Pump Shaft
SEBF2129 Thermal Spray Procedures for Tyrone Drive Shaft (Pump Gear)
SEBF2133 Thermal Spray Procedures for Hydraulic Swivel
SEBF2134 Thermal Spray Procedures for Steering Clutch Housing
SEBF2135 Thermal Spray Procedures for Wheel Loader Trunnion Support
SEBF2136 Thermal Spray Procedures for Brake Piston Housing
Thermal Spray Procedures for Wheel Loader, Wheel Dozer, Integrated Toolcarrier,
SEBF2137
Articulated Truck, and Wheel Tractor Scraper - Differential Carrier Assembly
SEBF2138 Thermal Spray Procedures for Brake Housing
SEBF2139 Thermal Spray Procedures for Brake Sleeve
SEBF2140 Thermal Spray Procedures for One Piece Brake Anchor

SEBF2141 Thermal Spray Procedures for 992 Brake Anchor
SEBF2142 Thermal Spray Procedures for Wheel Loader Trunnion
SEBF2144 Thermal Spray Procedures for Manifold - Oil Pump
SEBF2145 Thermal Spray Procedures for Idler Shaft - Transmission Transfer Gear Group
Thermal Spray Procedures for Wheel Loaders, Off-Highway Trucks and Tractors,
SEBF2146 Articulated Trucks, Wheel Tractors, Compactors, and Integrated Toolcarriers
Differential - Bearing Support Journal
SEBF2147 Thermal Spray Procedures for Differential Case - Housing Face/Pinion Thrust Face
Thermal Spray Procedures for Wheel Loaders, Off-Highway Trucks and Tractors,
SEBF2148 Articulated Trucks, Wheel Tractors, Compactors, and Integrated Toolcarriers
Differential Case - Flange End
SEBF2149 Thermal Spray Procedures for Wheel Loader - Wheel Bearing ID Bore
SEBF2150 Thermal Spray Procedures for TTT Sprocket Hub Bearing Bores
SEBF2151 Thermal Spray Procedures for Wheel Loader Spindles (OD)
SEBF2152 Thermal Spray Procedures for Transmission and Torque Converter Yokes
SEBF2155 Thermal Spray Procedures for Track Loader Pivot Shaft
SEBF2156 Thermal Spray Procedures for Gear Shafts for Gear Pumps
SEBF2157 Thermal Spray Procedures for D9H Water Pump Housing
SEBF2158 Thermal Spray Procedures for 3400 Engine - Fuel Pump Mounting Surface
SEBF2159 Thermal Spray Procedures for Track Loader - Sprocket Hubs
SEBF2160 Thermal Spray Procedures for Bevel Gear Shafts
SEBF2161 Thermal Spray Procedures for 3500 Engine - Oil Pump
SEBF2163 Thermal Spray Procedures for 3500 Engine Turbocharger Outlet Adapter
SEBF2164 Thermal Spray Procedures for Engine Front Cover
SEBF2167 Thermal Spray Procedures for OHT Rear Spindle
SEBF2168 Thermal Spray Procedures for OHT and WTS Rear Wheel Bearing Bores
SEBF2169 Thermal Spray Procedures for OHT Front Spindle
SEBF2170 Thermal Spray Procedures for OHT and WTS Front Wheel Bearing Bores
SEBF2171 Thermal Spray Procedures for WTS Front Spindle
SEBF2173 Thermal Spray Procedures for WTS Rear Spindle

SEBF2175 Thermal Spray Procedures for D3B - D6H TTT Pivot Shaft
Thermal Spray Procedures for OHT Differential Housing - Housing & Side Thrust
SEBF2177
Face
SEBF2178 Thermal Spray Procedures for OHT Cage - Bearing
SEBF2179 Thermal Spray Procedures for OHT Differential Carrier Assembly
SEBF2180 Thermal Spray Procedures for 789 OHT Final Drive Planet Gear
SEBF2185 Thermal Spray Procedures for Wheel Dozer and IT Axle Housing
SEBF2188 Thermal Spray Procedures for TTT Hub - Sprocket Support
SEBF2191 Thermal Spray Procedures for ADT Hitch
SEBF2192 Thermal Spray Procedures for IT and Wheel Dozer Spindle
SEBF2193 Thermal Spray Procedures for IT and Wheel Dozer Wheel
SEBF2194 Thermal Spray Procedures for OHT Differential Carrier
SEBF2195 Thermal Spray Procedures for OHT Planetary Carrier - Pin Bores
SEBF2198 Thermal Spray Procedures for 3500 Engine - Flywheel Housing
SEBF2200 Thermal Spray Procedures for 772 - 797B OHT Brake Anchor
SEBF9261 Thermal Spray Procedures for ADT Hub
SEBF9262 Thermal Spray Procedures for ADT Spindle and Wheel Bearing Bores
SEBF9267 Thermal Spray Procedures for C27 & C32 Engine - Water Pump
SEBF9274 Thermal Spray Procedures for D7-D11 TTT Pivot Shafts
SEBF9292 Thermal Spray Procedures for OHT Hub - Pinion Drive
Thermal Spray Procedures for Wheel Dozer, Integrated Toolcarrier, and Wheel
SEBF9301
Tractor Scraper Hub
SEBF9340 Thermal Spray Procedures for MT Series OHT Front Spindle
SEBF9385 Thermal Spray Procedures for Motor Grader Spindle
For questions or additional information concerning this guideline, submit a form for feedback in the
Service Information System. to address an urgent issue, use the following resources to communicate
your request to Caterpillar Repair Process Engineering:
• Cat dealer Technical Communicator
• Dealer Solution Network
• Caterpillar Technical Representative
• Knowledge Network
For further information and background on the flame spray process or related preparation and
finishing processes, refer to the following publications:
Reference: "Thermal Spray Manual"
American Welding Society

www.aws.org
Miami, Florida
Reference: "Thermal Spraying: Practices, Theory, Application, and Safety"

www.aws.org
Miami, Florida
Safety
Illustration 1 g02139237
Cat dealers are requested to read the safety sections of equipment operation manuals cited in this
guide.
Note: Refer to operation manuals for Oerlikon Metco equipment as primary source of operating and
safety information. Other references for operating and safety information are:
Reference: "Thermal Spraying: Practices, Theory, Application, and Safety"

www.aws.org
Miami, Florida
Reference: "Welding Handbook, 7th ed., Vol. 3"

www.aws.org
Miami, Florida
Reference: "Flame Spraying Handbook Vol. II, Powder Process"
Oerlikon Metco
www.oerlikon.com/metco
Westbury, New York
Like any process that generates dust and fumes, the thermal spray process involves a potential hazard
to personnel. All personnel involved in this process must become familiar with operating practices
and regulations. Local, state, and federal health regulations (OSHA standards) must be understood for
compliance.
The following information is derived from the sources mentioned above.
Fire Prevention and Protection
Precautions for thermal spray are essentially the same as for welding and cutting. Airborne metal dust,
or finely divided solids, should be treated as a possible explosive. Adequate ventilation must be
provided to minimize the danger of dust.
U.S. Federal EPA emission standards require that exhaust systems for the thermal spray industry have
an efficiency of 99.99%.
Federal, state, and local exhaust emission requirements in North America have become more
demanding.
The Dry Cartridge Dust Collection System is the most effective method for exhaust collection in the
flame spray industry.
A wet collector system may meet requirements but must also meet local requirements.
Good housekeeping must be practiced to avoid the accumulation of metal dust. Paper, wood, oily
rags, and flammable solvents must be removed from the spraying area.
Operating Considerations
Like welding, the thermal spray process involves gas cylinders. Improper storage, handling, and use
of gas cylinders can create a safety hazard.
Do not use oil or grease on oxygen equipment. Never over-tighten or

force a connection. A fire hazard can result and cause injury to the
operator. Only the hoses recommended by the manufacturer should be
used with the spraying system. Acetylene pressure must never exceed
Media Search - SEBF9240 - Fundamentals of Flame Spray for Reconditioning Compo... Page 10 of 25
103 kPa (15.0 psi). Only use recommended lubricants as specified by the
manufacturer. Use proper tools to connect regulators to cylinders.
For further detail on these operating hazards, refer to the following.
Reference: "Safety in Welding and Cutting"
ANSI/AWS Code Z49.1

American National Standards Institute and American Welding Society
www.aws.org
Miami, Florida
Thermal Spray Equipment
Maintain and operate thermal spray equipment only to standards set by the equipment manufacturer.
All operators must be instructed to become familiar with the operation of the spray equipment.
Never use an open flame to light the thermal spray gun. Serious burns
or other personal injury could result. Equip the gun with an electric
ignition system or use a spark lighter.
If a thermal spray gun malfunctions or backfires, the cause of the trouble must be investigated. When
thermal spraying is completed, the system must be properly "shut down" as follows:
1. Close all gas cylinder valves.
2. Open the gun valves to release hose gases.
3. Back out all regulator screws until free.
4. Close gun valve.
5. Check all (first stage) regulators to ensure that no pressure buildup is taking place. Pressure
buildup would indicate a bottle valve has not been tightly closed.
Abrasive Blasting Equipment
Maintain blasting equipment according to manufacturers specifications. Replace worn parts for
efficient operation. Replace deteriorated hoses and nozzles.
Grit blasting produces airborne particulates that can act as respiratory

irritants. If inhaled, these particulates can cause serious injury or death.
Additionally, the grit from this process can be abrasive to the skin and
eyes of the operator and can cause serious injury. If grit blasting is
performed manually or outside of a grit blast cabinet, operators must be
provided with respiratory protection, face shields, and helmets.
Information on face shields and helmets can be found in ANSI/ISEA
Z87.1 (American National Standard for Occupational and Educational
Eye and Face Protection Devices) and ANSI/ISEA Z89.1 (American
National Standard for Industrial Head Protection). Information on the
selection, operation, and maintenance of a respiratory device can be
found in ANSI/AIHA Z88.2 (Practices for Respiratory Protection) or
other local approval authority documentation.
Process Fundamentals
Thermal spraying is a term used to describe a group of processes in which fine molten or semi-molten
metallic or nonmetallic materials are deposited onto a prepared surface. Flame spraying is considered
to be a relatively "cold" method of part salvaging when compared to welding or brazing. Thermal
spraying is considered a cold process because the surface temperature of the piece part is kept below
150° - 175°C (300° - 350°F) when a coating is being deposited. As a result, the part experiences no
metallurgical or physical changes.
The term "thermal spraying" encompasses six different types of processes:
1. Powder flame spray using an oxygen-fuel gas mixture for the flame and powder as the
consumable.
2. Wire flame spraying using an oxygen-fuel gas mixture for the flame and wire as the
consumable.
3. Arc spraying using electrical (DC) current and wire as the consumable.
4. Plasma using a non-transferred (DC) arc and powder consumable and nitrogen or hydrogen as a
fuel.
5. High Velocity Oxygen Fuel (HVOF) using a very high velocity of oxygen-fuel gas-air flame
and a very fine powder as the consumable.
6. Plasma Transferred Wire Arc (PTWA) using a plasma arc and wire as a consumable.
These thermal spray methods differ from one another due to the following considerations:
1. Equipment requirements
2. Material utilization capabilities/limitations
3. Means and methods used for heating and propelling the molten material
4. Metallurgical structure of the deposit
All Caterpillar salvage applications and process orientation in this guide are for the flame (powder
combustion) spray process. Applications detailed in this guide assume the use of Oerlikon Metco 6P
II spraying equipment and materials.
Cross section of a powder flame spray gun
Note: Distance between nozzle and substrate depends on type of powder and equipment used. Consult
equipment manufacturers operating manual for further information.
There are two types of thermal spraying systems:
• Gravity feed
• Pressure feed
Both systems use the same type of powder material but differ in methods of powder delivery.
Gravity Feed
With the gravity feed system, a powder canister is attached directly to the body of the gun. Powder is
then gravity fed into the flame. Since the material flow is solely related to gravity, this type of system
is susceptible to inconsistent material feeding because of the following conditions:
• Movement of the spray gun and/or orientation to the work
• Wear and/or fouling of the internal feed mechanism of the gun
• Variation in material classification (particle size)
• Powder condition (moisture content)
Pressure Feed
In a pressurized feeding system, powder is transported and delivered to the gun by an inert gas (pre-
purified nitrogen or argon) at a constant rate. The delivery is independent of the orientation or
movement of the spray gun. In addition, the material feed rate (measured in kg/hour (lb/hour)) can
easily be set, monitored, and controlled by the operator. As a result, pressurized feeding offers more
process control and deposits high quality, repeatable coatings.
Coating Fundamentals
Through the flame-spraying process, fine metallic or non-metallic materials are deposited in a molten
or semi-molten condition onto a prepared surface. When molten particles strike a surface, the particles
flatten (elongate), rapidly cool, and quench to form micro-thin platelets. The platelets conform to the
surface and to each other. The bond between the base material and flame spray particles may be
mechanical, metallurgical, chemical, or a combination in nature.
As the sprayed particles continue to impinge onto a surface, particle-by-particle, a layer, or lamellar
structure is formed.
Typical coating cross section illustrates lamellar structure (At 500X magnification)
Since multiple particles are needed to create a coating, a number of transverse passes of the gun,
applying 0.10 - 0.15 mm (0.004 - 0.006 in) of coating material per pass is required to produce the
desired coating thickness. These multi-gun passes can be performed by hand holding the unit or
mechanical (lathe) movement of the spray gun. In general, a coating can be applied greater than
2.54 mm (0.100 in) per side in thickness. The actual thickness of a coating depends on the amount of
wear of the part plus an allowance for finishing. The finishing allowance is generally 0.51 - 0.64 mm
(0.020 - 0.025 in) on a side.
The formed coating is used for "surface" type applications. The coating will not provide any strength
to a part. The only function of the coating is to add desirable characteristics to the surface that are
currently lacking in the worn piece of the part. Desirable flame spray characteristics include:
1. Better wear characteristics
2. Dimension restoration
3. Corrosion protection
4. Electrical conductivity or electrical resistivity
Because of the nature and structure of flame spray coatings, they should not be used when the coating
will be subjected to line or point-to-point contact and severe, sharp, and repeated types of impact.
Surface Finishing and Post-Coating Treatment

Surface Finishing
Finishing techniques for flame sprayed deposits differ from practices followed for standard machined
surfaces and for solid materials. Since spray deposited coatings consist mainly of mechanical bonds,
excessive tool pressure or a high feed rate can result in premature and excessive tool wear. The stress
from excessive tool wear will cause the coating to crack, craze, or pit.
The technique used for finishing a spray coating depends on the type of material applied, hardness,
and the desired surface finish.
Excellent machine finishes can be achieved with C-2 grade carbide insert type tools. Follow
recommended parameters for RPM, depth of cut, and surface feet per minute requirements.
Although dry grinding can be performed for a coating, wet-type grinding is recommended. When
grinding a coating, selecting the proper wheel is critical. Open structured "green" grit (46-60) wheels
are preferred over "white" wheels because the grit wheel structure constantly breaks down and
exposes clean, sharp wheel abrasive. This breakdown prevents wheel loading tendencies.
Post-Coating Treatment
All sprayed coatings are considered to be porous. Porosity is the measurement of the density of a
coating when compared to the same type of material in solid or cast form. Generally, the porosity of a
coating will be found to be beneficial for bearing type applications since the coatings will retain
lubrication. When a lubrication function is not desired or where the coating will be exposed to a
corrosive type of environment or where fluid leakage is not desired, the coating should be treated with
a sealer. The recommended sealers are: Loctite 290, a wick type air drying sealer, or Oerlikon Metco
185 crystalline wax sealer. Both types of sealers are easy and simple to apply.
Support Equipment and Operations

Grit Blasting
Grit blasting for flame spraying should be considered surface texturing. Clean, dry compressed air,
and a 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: pressure and suction systems. 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 steel
angular grit.
In grit blasting for surface preparation, a coarse type grit of the following materials should be used
(G40 through G16).
• Aluminum Oxide: Aluminum oxide is a hard and brittle abrasive used primarily on 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 into the surface pores. Because this type
of grit is light in weight, it can be used at low air pressures [between 276 - 413 kPa
(40.0 - 60.0 psi)]. When used in a suction blaster system, the minimum air pressure must be
517 kPa (75.0 psi). Using higher than recommended pressures results in rapid breakdown of grit
and more grit usage.
• Steel Angular Grit: This grit is recommended for use on softer steel materials, up to a hardness
of Rc35, and for those substrates where aluminum oxide cannot be used on aluminum and cast
materials. The effective operating pressure for this grit is between 620 - 689 kPa
(90.0 - 100.0 psi). This type of grit cannot be used in a suction type blast system. Steel angular
grit must be kept free of any moisture or oil contamination.
Note: With either type of grit, visually inspect to ensure grit sharpness. Dull or contaminated grit
must be replaced because poor surface preparation results and contaminants in the grit will be blasted
into the surface and will lower bond strength.
Masking Aids
Masking is required to protect critical surfaces and holes from the effects of the grit blasting and
spraying. Any type of material that can withstand the effects of either operation is considered a
suitable masking material.
The mask can be permanent sheet metal or a temporary material. Temporary-type masking materials
are:
• Hard rubber
• High temperature silicon rubber
• Several layers of duct or masking tape
• High temperature fiber type materials
• Liquids
Spray Booths and Rooms
Any flame spraying process generates some amount of dust and fumes. For environmental control and
personnel safety, an enclosed or segregated area is appropriate. Oerlikon Metco can provide exhaust
equipment and rooms for dust and fume removal. The following standard units are available from
Oerlikon Metco:
• Type SME 12-35. Exhaust equipment is available from Torit as in the 2DF-16 3500 CFM Dry
Cartridge Dust Collection System
• Type 4BWH Flame Spray Booth. The booth has a front opening that measures
1.27 x 0.79 x 1.07 m (50.0 x 31.0 x 42.0 in). The booth is drilled and bracketed for lights.
Rotational equipment is optional.
• Type 3BL Lathe Exhaust Unit. This unit consists of two parts: an exhaust hood, designed to
fasten onto the lathe carriage which will travel with the carriage, and a 25 cm (10.0 in)
diameter, 244 cm (8.0 ft) long flexible duct which connects to the Dry Cartridge Dust
Collection System.
Flame spray rooms are available to fit your needs either from Oerlikon Metco or from Industrial
Acoustics Company.
Rotational/Transverse Equipment
Rotating cylindrical parts can be sprayed manually by hand or fixtured onto a transverse mechanism.
Some type of rotational device, dedicated solely to the flame spraying process, is strongly
recommended. Rotational equipment may be found to have limited capabilities, but must have some
type of variable rotational control to provide relatively high rpm capability. Specially designed
rotating systems manufactured by Oerlikon Metco and other companies can withstand the dusty spray
environment and provide the part rotational requirements.
The rotational requirement of a part is provided in the salvage guideline specific to that part. The
following formulas can be used to calculate rotations per minute (rpm), surface meters per minute
(SMPM), or surface feet per minute (SFPM) for a part.
31.8 x SMPM ÷ diameter (mm) = rpm
3.82 x SFPM ÷ diameter (inch) = rpm
For example, if a cylindrical part is coated at 300 SFPM and has a diameter of 2 inch, then the rpm is
(3.82 x 300 ÷ 2) = 573 rpm.
The formula for calculating SMPM and SFPM are:
0.00314 x rpm x diameter (mm) = SMPM
0.262 x rpm x diameter (inch) = SFPM
Example 2: a cylindrical part with an 86 mm diameter and a rotation speed of 600 rpm would be
(0.00314 x 600 x 86) = 162 SMPM
Example 1: a cylindrical part with a 3 inch diameter and a rotation speed of 600 rpm would be (0.262
x 600 x 3) = 472 SFPM.
For traverse motion of the flame spraying gun, the following guidelines should be used to apply an
even coating deposit:
• Flat Work (Non-rotating): Traverse at a rate of 15 - 75 cm (0.5 - 2.5 ft) per second, making
6.3 mm (0.25 in) gun increments per pass.
• Round/Rotating Work: Traverse the gun at a 6.3 - 12.6 mm (0.25 - 0.50 in) per revolution.
Equipment
4MP Powder Feeder by Oerlikon Metco
Type 6P II Gun by Oerlikon Metco
For the Cat dealer flame spray program, all salvage applications will use the oxygen-acetylene 6P II
Thermal Spray System by Oerlikon Metco. The 6P II system consists of the following basic
components:
• 6P II Thermospray Gun
• 4MP Powder Feeder
• 4MP 211 Air Regulator
• 2GF or 3GF Gas Flowmeter Unit
• 3G Gas Control Unit (acetylene and oxygen)
• 5A Air Control Unit
• 7GNR Nitrogen Regulator Unit
• 8H 4 ft Hose Unit
• 2AJ Air Blast Cooler Unit
• 6P 330 Air Jet Assembly
• 4 AC Air Cleaner Unit
The following accessories are optional or part of the 6P II package:
• 6P 7C - "B" Nozzle, Acetylene
• 6P 7C - "K" Nozzle
• 6P 7C - "N" Nozzle Concentrating
• 6P 600 Siphon Plug Assembly - two jets
• 6P 645 Siphon Plug
• 4MP 400 Pedestal
• 40 Surface Pyrometer
Component preparation is important to the success of salvage via flame spray. A grit blast system is
used to prepare surfaces. The grit blast system must be dedicated for flame spray parts preparation
and must not be used for any other shop operation.
Recommended equipment includes:
• Empire Blast Cabinet Model 4848PRC-6 PBV-05U-30L-CP Portable Vacuum Recovery
• Pressure Blaster 914.40 x 1219.20 mm (36.000 x 48.000 in) Optional Cabinet for above
portable blaster
For environmental control and personal safety, proper dust and fume exhaust systems are required.
New EPA rules dictate exhaust systems be 99.9% efficient. For U.S. and Canadian dealers, the
recommended system is the 3500 CFM, Type SME 12-35 Dry Cartridge Dust Collection System
Other types of exhaust systems include:
• Fabricated Hood or Enclosure with Capture Plenum for Lathe or Turntable.
• 8BH Spray Booth
• Sound Proof Rooms either from Oerlikon Metco or from Industrial Acoustics Company (IAC)
Consult your local environmental laws for exact exhaust regulations.
Materials
Every commercially available powder material has different coating characteristics of:
• Shrink
• Wearability
• Particle Size Distribution
• Composition
• Chemistry
• Flow
Consider the following criteria when selecting a coating material:
• Engineering material composition, base metal, temperature and environmental factors, and
piece part geometry.
• User reliability, performance requirements, versatility, reproducibility, finishing requirements,

equipment limitations, and economics.
• Historical application similarities and past application success.
Based on these criteria and application development, the Oerlikon Metco composite type materials
described in this bulletin are recommended. These materials offer the following benefits when thermal
spray is applied:
• Allow self-bonding to any clean substrate
• Exhibit and develop low coefficients of thermal expansion so that thick coatings can be applied
• Are technique independent
• Offer high internal integrity
• Can be used efficiently and economically
Table 3
Metco 445 Self-Bonding "Aluminum Bronze" Powder
Metco 445 is a copper-aluminum composite powder developed to produce self
-bonding, wear resistant, "aluminum-bronze" coatings for self-bearing
applications. The powder was designed to produce coatings with high
Summary
resistance to abrasive wear. The coating resists abrasive wear from hard
surfaces at low temperatures. Recommended for salvage and buildup
applications on copper alloy substrates. An excellent soft-bearing material.
10% Aluminum
Composition
90% Copper
Particle Size -140 +325 mesh (-106 +45 microns)
Melting Point 660° C (1215° F)
Deposit
90%
Efficiency
Powder Required
for 0.25 mm
(0.010 in) 1.91 kg/m2 (6.240 ounce/ft2)
thickness
Spray Rate 4.5 kg/hr (10.00 lb/hr)
Bond Strength 13.8 MPa (2000.00 psi) minimum
Thickness There is no thickness limitation. Heavy buildup of coating can be applied
Limitation without cracking.
Maximum Service
Temperature
230° C (450° F) Similar to other copper base alloys. Excessive temperatures

during service can result in heavy oxide formation. Heavy oxide formation
affects coating strength.
Metco 445 not recommended for general use applications where corrosion
Corrosion resistance is of primary importance. Coated parts stored for any length of time
Resistance should be coated with a film of mineral oil, which is compatible with
aluminum and copper.
Material is self-bonding. Thorough cleaning of the substrate is the only
Surface necessary preparation. Surface oxidation must be removed and the surface
Preparation preheated to prevent condensation from forming. If the deposit is machined to
a feather edge, the substrate should be grit blasted.
Observe spray rate and distance. Excessive spray rates or distances inhibit the
Spraying exothermic reaction that produces desired bond and internal strength. Avoid
excessive spray rate or distance.
Finishing Use standard carbide tools.
Table 4
Metco 447 Self-Bonding Molybdenum-Nickel-Aluminum Composite Powder
Metco 447 is a molybdenum-nickel-aluminum composite powder that was
developed as a general-purpose material to produce medium hard coatings for
hard bearing and wear resistant applications. Produces moderately hard, low
shrink, high strength coatings. Recommended for wear resistance, resistance to
particle erosion, and for salvage and buildup of machinable and grindable carbon
Summary steels. Coating is extremely tough and can withstand impact without cracking.
Flaking and chipping are minimized. Coatings can be ground to fine finishes and
machined finishes can be obtained with conditional technique. Metco 447 can be
sprayed with minimum dependence on technique or need for temperature
control. Coating macrohardness varies with temperature of the application.
Increasing application temperature results in increased hardness.
5% Molybdenum
Composition 5.5% Aluminum
89.5% Nickel
Particle Size -170 +325 mesh (-88 +45 microns)
Melting Point 660° C (1215° F)
Deposit
90%
Efficiency
Powder
Required for
0.25 mm 2.05 kg/m2 (6.720 ounce/ft2)
(0.010 in)
thickness

Material has self-bonding property as a result of exothermic reaction. Bond
strength is attributed to the use of a special molybdenum additive. Heat from
Bond Strength
nickel-aluminum and aluminum-molybdenum reactions results in higher bond
strength and interparticle bonding.
Internal Coating Exhibits excellent internal strength as a result of high interparticle cohesion.
Strength Provides good edge retention after machining.
Thickness There is no thickness limitation. Heavy buildup of coating can be applied
Limitation without cracking and dependence or need of temperature control.
Maximum
Intermittent Operation: 760° C (1400° F)
Service
Continuous Operation: 650° C (1200° F)
Temperature
Corrosion
-
Resistance
Surface Coatings are self-bonding. Remove surface oxidation and preheat surface to
Preparation prevent formation of condensation. Grit blasting of substrate is recommended.
Recommended spraying parameters must be followed to produce the needed
Spraying nickel-aluminum-molybdenum alloy to produce excellent bond and internal
strength.
Grinding: Best finishes are produced by grinding. Excellent finishes are obtained
with aluminum oxide or silicon carbide wheels. Metco 447 coatings are medium
hard. Wheel loading can occur unless coarse grain, low bond strength wheels are
used.
Finishing Machining: Machine coatings using standard tungsten carbide tools. Quality of
finish and tool wear vary with machining technique. Best finish quality is
obtained when a water-soluble oil is used as a coolant lubricator. Coatings
machined dry produce dull appearance, and tool wear can be excessive unless
low work speeds are used.
Table 5
Metco 452 Nickel-Iron Aluminum Composite Powder
Designed to produce coatings with excellent self-bonding properties and to
provide a significant improvement in merchantability, wear, and oxidation
Summary
resistance. Coatings are dense and can be used for oxidation resistance up to
815° C (1500° F).
52% Iron
Composition 38% Nickel
10% Aluminum
Particle Size -120 mesh +15 microns (-125 +15 microns)
85%
Deposit
Efficiency
Powder Required
for 0.25 mm
(0.010 in) 1.98 kg/m2 (6.500 ounce/ft2)
thickness
Bond strengths are 27.6 MPa (4000 psi) Metco 452 does not reliably self-bond
Bond Strength
to copper, high copper alloys, molybdenum, or tungsten metals.
Thickness
-
Limitation
Surface Coating is self-bonding. Clean the substrate and remove any surface oxides.
Preparation Preheat to prevent formation of condensation.
Follow recommended spraying parameters. Magnesium surfaces should never
be preheated because the surface oxidizes too rapidly. Oxidation interferes
with bond strength. Indirectly preheat aluminum surfaces at 64° - 95°C
Spraying (150° - 200°F) to eliminate the formation of surface oxides (preheat back or
side, but never on the surface to be sprayed). Oven preheating is not
recommended because the surface to be sprayed is heated directly. If indirect
preheat cannot be performed, then the substrate should not be preheated.
Finishing Best finish is achieved by machining using standard carbide tools.
Table 6
Metco 453 Iron Nickel-Aluminum Composite Powder
Powder designed to produce coatings with improved finishing properties.
Coatings can be ground to a fine finish. Metco 453 produces extremely tough
Summary coatings from an exothermic nature of aluminum with iron to enhance self-
bonding. Aluminum enhances resistance to oxidation, while molybdenum
enhances high temperature scuff resistance.
55% Iron
35% Nickel
Composition
5% Molybdenum
5% Aluminum
Particle Size -120 + 325 mesh (-117 +44 microns)
Maximum Service
815° C (1500° F)
Temperature
Deposit
90%
Efficiency
1.6 kg/m2 (5.28 ounce/ft2)
Powder Required
for 0.25 mm
(0.010 in)
thickness
Coatings exhibit strengths greater than 31.1 MPa (4500.00 psi) on flat ground
Bond Strength surfaces and 37.9 MPa (5500.00 psi) on Mecolite C grit blasted steel
surfaces.
Thickness Thickness limitations on ground CRS flats range 1.0 - 1.5 mm (0.04 - 0.06 in)
Limitation on blasted surfaces.
Follow recommended spraying parameters. Spray rate and distance are
important parameters. Excessively high spray rates or spraying too close may
Spraying
result in low deposit efficiencies, excess free aluminum, excessive oxides,
poor finish, entrapped particles, and poor cohesive bonding.
Grinding: Best finish is achieved by grinding. Ground finishes are obtained
using 60 grit silicon carbide wheels. Dry grinding is recommended over wet
grinding. Final grinding operations should include belt grinding with a 325 or
400 grit SiC belt to obtain 0.1-0.4 microns Ra (5.00-15.00 microinch Ra)
surface finish. Aluminum oxide wheels may be used. Wheels should be
Finishing
dressed more frequently when using aluminum oxide.
Machining: Coatings may be machined dry with tungsten carbide tool bits
(883 grade carboloy or equivalent). High surface feeds or cuts may be used at
the expense of increased tool bit wear. Refinish bits before making final
machine cut.
Links to Equipment Information and Suppliers

Reference: Caterpillar
Repair Process Engineering Metal Restoration

https://dealer.cat.com/en/ps/service/rpe/c/metal-restoration.html
Reference: 3M
www.3m.com
Reference: Torit Products
www2.donaldson.com/torit
Reference: Oerlikon Metco
www.oerlikon.com/metco
Reference: TAFA
www.praxair.com/thermalspray
Reference: Eitel Presses
www.eitelpresses.com
Reference: Progressive Surface
www.progressivesurface.com
Reference: Abbott Machine Co.
www.abbottmachineco.com
Reference: Supfina
www.supfina.com
Reference: IMPCO Machine Tools
www.impco.com
Reference: Grinding Equipment & Machinery Company, LLC
www.gem-usa.com
Reference: Industrial Acoustics Company (IAC)
www.industrialacoustics.com
Copyright 1993 - 2019 Caterpillar Inc. Mon Nov 4 10:07:54 UTC+0330 2019
All Rights Reserved.
Private Network For SIS Licensees.

Fundamentals of Flame Spray For Reconditioning Components

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Fundamentals of Flame Spray For Reconditioning Components

Uploaded by

Copyright:

Available Formats

Media Search - SEBF9240 - Fundamentals of Flame Spray for Reconditioning Componen...

Product: NO EQUIPMENT SELECTED

Reuse And Salvage Guidelines

Fundamentals of Flame Spray for Reconditioning Components

SEBF2107 Thermal Spray Procedures for Torque Converter Output Flange

SEBF2140 Thermal Spray Procedures for One Piece Brake Anchor

SEBF2173 Thermal Spray Procedures for WTS Rear Spindle

• Cat dealer Technical Communicator

• Dealer Solution Network

• Caterpillar Technical Representative

Reference: "Thermal Spray Manual"

American Welding Society

Reference: "Thermal Spraying: Practices, Theory, Application, and Safety"

American Welding Society

Reference: "Thermal Spraying: Practices, Theory, Application, and Safety"

American Welding Society

Reference: "Welding Handbook, 7th ed., Vol. 3"

American Welding Society

Reference: "Flame Spraying Handbook Vol. II, Powder Process"

The following information is derived from the sources mentioned above.

Fire Prevention and Protection

Do not use oil or grease on oxygen equipment. Never over-tighten or

For further detail on these operating hazards, refer to the following.

Reference: "Safety in Welding and Cutting"

ANSI/AWS Code Z49.1

Thermal Spray Equipment

1. Close all gas cylinder valves.

2. Open the gun valves to release hose gases.

3. Back out all regulator screws until free.

4. Close gun valve.

Abrasive Blasting Equipment

Grit blasting produces airborne particulates that can act as respiratory

The term "thermal spraying" encompasses six different types of processes:

2. Material utilization capabilities/limitations

4. Metallurgical structure of the deposit

There are two types of thermal spraying systems:

• Movement of the spray gun and/or orientation to the work

• Wear and/or fouling of the internal feed mechanism of the gun

• Variation in material classification (particle size)

• Powder condition (moisture content)

1. Better wear characteristics

4. Electrical conductivity or electrical resistivity

Surface Finishing and Post-Coating Treatment

Support Equipment and Operations

2. A pressure blast system is more efficient and, therefore, more economical.

• High temperature silicon rubber

• Several layers of duct or masking tape

• High temperature fiber type materials

Spray Booths and Rooms

31.8 x SMPM ÷ diameter (mm) = rpm

3.82 x SFPM ÷ diameter (inch) = rpm

The formula for calculating SMPM and SFPM are:

0.00314 x rpm x diameter (mm) = SMPM

0.262 x rpm x diameter (inch) = SFPM

• 4MP Powder Feeder

• 4MP 211 Air Regulator

• 2GF or 3GF Gas Flowmeter Unit

• 3G Gas Control Unit (acetylene and oxygen)

• 5A Air Control Unit

• 7GNR Nitrogen Regulator Unit

• 2AJ Air Blast Cooler Unit

• 6P 330 Air Jet Assembly

• 4 AC Air Cleaner Unit