FAMILIARIZATION WITH THERMAL SPRAY

SYSTEM
by MEHUL N. DAVE
 INTRODUCTION

• Wear and Tear caused due to abrasion, corrosion and

impact cause damage of billions of money every year
worldwide, could be avoided if the proper preventive
measure of wear and corrosion protection were
taken. These preventative measures also mean
precautions to regenerate the equipment, which
means repair and re-integration into the economic
cycle.
 MAJOR INDUSTRIES SERVICED
 
• Steel Industries
• Paper Plants
• Thermal ,Hydro Power Plants
• Refineries
• Sugar Industries
• Chemical And Fertilizers Plants
• Cement Plants
• Mining Industries And Equipment Manufacturers
• OEM’s Of Steel, Power, Cement,
• General Engineering Industries
 Applications
• Circulating Fluidized Bed Boilers (CFB)
• Pulverized Coal Fired Boilers Biomass Boilers
• Black Liquor Recovery Boilers Digesters
• Evaporators Flash Tanks
• Process Vessels Tanks
• Roller Journal/Shaft Pump Sleeve
• Steel Structures
• Dimensional Restoration
 WEAR

• Wear is the progressive damage, involving

material loss, which occurs on the surface of a
component as result of its motion relative to the
adjacent working parts.

 
 
 OCCURRENCE OF WEAR DEPENDS ON

• Geometry of the surface

 
• Applied load
 
• The rolling and sliding velocities
 
• Environmental conditions
 
• Mechanical, Thermal, Chemical and Metallurgical properties

• Physical, Thermal and Chemical properties of the lubricant  

 METHODS TO IMPROVE WEAR RESISTANCE

• Geometry of the surface

• Alloying
• Heat Treatment
• Weld Overlays
• Surface Coatings – (1) Cold Repair Products 
(2) Thermal Spray
 PROBLEMS

• Erosion:- Erosive nature of sorbent Lime stone

in fuel particles at high velocity go and hit the
combustor major up to one meter & at the
corners of boiler at 18 to 22 meter elevation
above refractory transit zone during the
process of combustion leads to sever erosion
of combustor tubes. This causing tubes failure
at early stage.
 WHAT IS THERMAL SPRAY

• Thermal spraying, also known as metal

spraying or metallizing is a surface engineering
/ coating process where a wide range of
metals, carbides and ceramics can be applied
(sprayed) onto the surface of a component.
 CONVEYANCE TECHNOLOGY OF THERMAL
SPRAY

• Oxygen/Acetylene Wire & Powder Process

• TWIN Wire Arc Spray Process

• Plasma Spray Process

 
• HVOF (High Velocity Oxy-Fuel)
 TWIN Wire Arc Spray Process

• Two wires of desired materials act as electrodes when

they're fed thru a spray gun.  The gun is connected to a
high-current (DC) power source to facilitate an arc
between them.  An air stream thru the back of the gun
atomizes and  propels  the molten particles towards a
prepared surface.  With adjustable parameters including
voltage and amperage arc temperatures can reach
5000° C, enough to melt any material, at the same time
the part surface remains cool.  The process is considered
energy efficient because all of the input energy is used to
melt the spray materials.
SCHEMATIC OF TWIN WIRE ARC SPRAYING SYSTEM
 Steps of TWAS

• Surface preparation
• Thermal spraying
 Surface preparation
• Alumina Al2O3 Grit Blasting (16 Grit)
• RLA (roughness value = 50 before blasting, approx 250 after
blasting of water wall tubes)
• This stage involves exposure to high velocity Alumina grit
particles. This stage is essential to remove the worn out tube
particles and to judge the adherence of the coating on the
Boiler tube material.
• This also enables removing corrosive media from the tubes.
Alumina Grit Blasting is done by projecting a stream of
Alumina Grit with high pressure compressed air.
• Blast cleaned steel surfaces shall not be touched by bare
hands.
Image of surface preparation/Blasting
ALUMINA GRIT IMAGES
ALUMINUM GRIT BLASTING
BEFORE BLASTING TUBE
FURNACE AREA WERE COATING APPLY
Location where coating process carriedout
 Thermal spraying
• Armour 63 Twin wire Arc Spray Coating
• Chemical Composition:
• Fe Bal C <5% B<3.7% Cr <29% Si<1.4% Mn<1.7% Other<2%
• Atomizing Air Pressure: 50-75 psi
• Nozzle Cap: Blue
• Nozzle Positioner: Long +
• Arc Load: 29-32 V
• Current: 175-250 A
• Coating Thickness Per Pass: 1.2-1.3 mil
• Coating Texture: < 300 μ-inch
• Spray Rate: 16 lbs/hr.
• Deposition Efficiency: <65%
• Wire Size: 1/16”
• Coverage: 0.7 oz/ft2/0.001”
 PROCEDURE

• 3 layers applied with different concentration of

nickel 95 %,80 %, pure tungsten carbide
respectively.
• Armour 63 coating applied on up to one meter & at
corners 18 to 22 meter elevation above refractory
transit zone of the boiler tube by application of High
velocity dense arc coating @ 500 microns thick
which is being recommended mainly for very high
erosion wear taking place at the refractory zone.
Thermal spray
FINAL VIEW OF COATED TUBE
EQUIPMENTS: MINI SILO
AIR RECEIVER TANK
TWAS
SPRAY GUN
ID FAN COVER COATING
MUD PUMP BODY
THANK YOU