Professional Documents
Culture Documents
averstak@kermetico.com
www.kermetico.com
www.kermetico.com averstak@kermetico.com 2
HVAF Application Development
www.kermetico.com
3
averstak@kermetico.com
Kermetico HVAF Gun Design
Fuel Gas
Powder +
carrier gas
Air
www.kermetico.com
4
averstak@kermetico.com
Combustion Temperature: HVAF vs. HVOF
Adiabatic combustion temperature of fuels
in oxygen and air (a=1, 20oC, 1 Bar)
T, oC 3500
Oxygen 3200
3052 3109
Air
3000 2927
Metals,
2526
T boiling 2500
2210
2093
1960 1980 2010
2000
1500
Metals,
T melting
1000
500
0
Methane Propane MAPP Hydrogen Kerosene
www.kermetico.com
5
averstak@kermetico.com
Lower Gas Temperature in HVAF:
HVOF:
The combustion temperature is more than 1,000oC
higher than the melting temperature of metals;
The combustion temperature may exceed the metal
boiling point.
HVAF:
The combustion temperature is just slightly higher
than the metal melting temperature.
www.kermetico.com
6
averstak@kermetico.com
Lower Gas Temperature in HVAF:
www.kermetico.com
7
averstak@kermetico.com
Combustion Temperature: Design AF vs. OF
Ability to use heating in long/ slow-gas
combustion chambers =
long time for “soft” heating
High pressure in the chamber =
better heat transfer
Result:
High energy efficiency of HVAF
(same or lower power while higher spray
rates than HVOF)
www.kermetico.com
8
averstak@kermetico.com
Kermetico HVAF Gun Design
Fuel Gas
Powder +
carrier gas
Air
www.kermetico.com
9
averstak@kermetico.com
Energy Efficiency = Coating COST
State-of-the-Art HVOF:
JP 5000 270 kW spray rate 5 kg/hour
DJ 2600 115 kW spray rate 4 kg/hour
Kermetico HVAF:
AK6 130 kW spray rate 28 kg/ hour
AK5 80 kW spray rate 15 kg/hour
AK-ID 30 kW spray rate 5 kg/hour
www.kermetico.com
10
averstak@kermetico.com
Acceleration of spray particles in the nozzle:
Gas velocity & density
Time (nozzle length)
Particle size
www.kermetico.com
11
averstak@kermetico.com
Note on nozzle wall influence on a particle
velocity:
HVOF – dramatic
(more so – in radial injection)
HVAF – no influence
www.kermetico.com
12
averstak@kermetico.com
A Particle Acceleration:
the Influence of the Nozzle Walls
HVOF (kerosene) per A. Voronetsky et. all, ITSC2004
Nozzle Nozzle
axis wall
Kermetico HVAF:
D powder jet / D nozzle = 0.1-0.2
www.kermetico.com
averstak@kermetico.com 14
Uniformity of HVAF Coatings Properties:
Hardness of HVOF and Kermetico HVAF WC-10Co-4Cr coatings (Schlumberger, UK)
HVAF
HVOF
www.kermetico.com averstak@kermetico.com 15
WC-10Co-4Cr Coating Characterization
Propane
1,470 HV300
www.kermetico.com
16
averstak@kermetico.com
WC-10Co-4Cr Coating Characterization
www.kermetico.com
17
averstak@kermetico.com
Kermetico HVAF:
Carbides are Hard, but… Ductile
1
2000 1 1:WC
2:Co3W3C
3:Co
1500
Internsity/a.u.
1000 1
500 1 1
2 2 1 1 1
3 2 3 C4 Coating 1
2 2
3 2 2 3 Powder
0
30 40 50 60 70 80 90
2/degree
WC-12Co
Propane
1,540 HV300
www.kermetico.com
18
averstak@kermetico.com
Data of Central Power Research Institute
Bangalore, India
Comparison of WC-10Co-4Cr coatings,
deposited with HVOF (JP5000) and
Kermetico HVAF (AK6)
Notes:
HVOF optimized for the best cavitation resistance
www.kermetico.com
19
averstak@kermetico.com
WC-Co-Cr Spray Particle Characteristics
in HVOF and HVAF Processes
JP5000 HVOF Kermetico AK6 HVAF
Nozzle 5L Nozzle 5E Nozzle 5O
Average Particle size, micron 27 18
Particle velocity, m/s 740 895 960 1,010
+/-2 +/-3 +/-4
Particle temperature, oC 1,790-1,840 1,470 1,460 1,470
+/-10 +/-10 +/-10
Particle kinetic energy, mJ 29.4 12.7 14.7 16.2
Energy density, GJ/m3 = 3.8 5.6 6.4 7.1
= Contact pressure, GPa
www.kermetico.com
20
averstak@kermetico.com
Mechanical Properties: WC-10Co-4Cr
1473
AK06-N 5O
54
1439
AK06-N 5E
58
1308
AK06-N 5L
70
1180
JP5000 HVOF
140
www.kermetico.com
21
averstak@kermetico.com
Mechanical Properties: WC-10Co-4Cr
5,60
AK06-N 5O
0,15
6,86
AK06-N 5E
0,80
6,33
AK06-N 5L
0,50
3,86
JP5000 HVOF
0,70
www.kermetico.com
22
averstak@kermetico.com
Mechanical Properties: WC-10Co-4Cr
450
AK06-N 5O
20
452
AK06-N 5E
20
411
AK06-N 5L
21
290
JP5000 HVOF
21
www.kermetico.com
23
averstak@kermetico.com
Cavitation Resistance
of WC-10Co-4Cr HVOF and HVAF coatings
Nozzle 5E
( dw/dt ) HVOF = > 3.26 mg/h
www.kermetico.com
24
averstak@kermetico.com
Surface SEM Micrographs of
WC-10Co-4Cr Coatings after Cavitation Testing
Test duration: 1 hour
www.kermetico.com
25
averstak@kermetico.com
Surface SEM Micrographs of
WC-10Co-4Cr Coatings after Cavitation Testing
Test duration: 9 hours
www.kermetico.com
26
averstak@kermetico.com
Resistance to Silt Erosion
WC-10Co-4Cr HVOF and HVAF coatings
Weight loss of WC-10Co-4Cr coatings during silt erosion testing
50,0
30,0 AK06-N 5O
25,0
20,0
15,0
10,0
5,0
0,0
0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5
Tets time, hour
www.kermetico.com
27
averstak@kermetico.com
Other Third-Party Data,
Comparing Kermetico HVAF WC-10Co-4Cr
Coatings to HVOF ones
www.kermetico.com
28
averstak@kermetico.com
www.kermetico.com averstak@kermetico.com 29
Hunan University
Changsha, Hunan, China:
WC-10Co-4Cr HVOF & HVAF Coatings Cavitation Test
12
AISI316:y=0.0156x-0.4789
DJ Coating:y=0.0121x+0.4744
10 AK Coating:y=0.0047x+0.0922
8
Volume loss (mm )
3
0
0 60 120 180 240 300 360 420 480 540 600 660 720
Time (minutes)
www.kermetico.com
30
averstak@kermetico.com
Erosion Rate vs. an Attack Angle:
WC-10Co-4Cr HVAF coatings perform as a ductile material
0,250
Volume loss, mm3/min
0,200
0,150
0,100
0,050
0,000
AK06-HVAF: WC-Co-Cr HVOF MTS: WC-Co-Cr SHS8000, fused
Angle 30 deg. Angle 90 deg.
www.kermetico.com
31
averstak@kermetico.com
Erosion Rate vs. an Attack Angle:
WC-10Co-4Cr HVAF coatings perform as a ductile material
0,170
0,160
0,150
0,140
0,130
0,120
0,110
0,100
www.kermetico.com
32
averstak@kermetico.com
Gesellschaft für innovative Materialtechnik Stellba AG
InnoMat GmbH Wohlerstrasse 51
Annaberger Str. 240, 09125 Chemnitz CH - 5605 Dottikon
2,5
2,0
1,5
1,0
0,5
0,0
GTV K2 HVOF GTV K2 UHVOF Kermetico AK6 HVAF
ASTM G75-07: Slurry Erosion Test, mg/hour
ASTM G65-04 (B): Rubber Wheel Test, mg/min
Ball-On-Disc Test, micron/10,000 cycles
www.kermetico.com
33
averstak@kermetico.com
Salt Spray Test: All the Samples Passed 312-Hour Test
K2 HVOF K2 UHVOF AK6 HVAF
Before testing
After 312-hours
testing
Note: the HVAF samples were tested after Pin-On-Disc Wear Test
www.kermetico.com
34
averstak@kermetico.com
The Kermetico HVAF WC-10Co-4Cr
Coatings Compared to HVOF Ones:
www.kermetico.com
35
averstak@kermetico.com
Economic Aspects of Kermetico HVAF
Spraying:
Your Choice of Cost and Quality
www.kermetico.com
36
averstak@kermetico.com
Kermetico HVAF Gun Design
Fuel Gas
Powder +
carrier gas
Air
www.kermetico.com
37
averstak@kermetico.com
Economic Aspects of Kermetico HVAF Spraying
Gun Setup Coating Coating Deposit
Hardness , HV300 Porosity, % Efficiency, %
High spray rates are applicable for large and small parts
www.kermetico.com
38
averstak@kermetico.com
HVOF vs. HVAF WC-10Co-4Cr Costs
300
250
200 Oxidant
Fuel
150
Spare parts
100 Power, etc.
Labor+Overhead
50
Amortizing
0
DJ2600 JP5000 HVAF -E HVAF-B HVAF-U
HVOF HVOF
(Hydrogen) (Kerosene)
Comparison of HVAF and HVOF operating costs, USD per hour
(prices in Texas, USA)
www.kermetico.com
39
averstak@kermetico.com
HVOF vs. HVAF WC-10Co-4Cr Costs
www.kermetico.com
40
averstak@kermetico.com
Comparison of HVAF and HVOF costs
(the prices in Texas, USA)
Cost per WCCoCr kg deposited, USD WCCoCr Coating Hardness, HV300
350 1600
300
1500
250
1400
200
1300
150
1200
100
50 1100
0 1000
DJ2600 JP5000 HVAF -E HVAF-B HVAF-U DJ2600 JP5000 HVAF -E HVAF-B HVAF-U
HVOF HVOF HVOF HVOF
Operating cost per kg deposited
Powder cost per kg deposited
www.kermetico.com
41
averstak@kermetico.com
HVOF vs HVAF WC-10Co-4Cr Costs
WC-Co-Cr powder cost: DJ2600 HVOF JP5000 HVOF AK7 HVAF (E)
81.4 USD/kg
Total operating cost,
$260 $223 $160
USD/hour
Spray rate, kg/hour 4 5 32
Deposit efficiency, % 50 43 65
Deposition rate, kg/hour 2.2 2.2 20.8
Cost per KG of sprayed
$293 $293 $133
coating, USD
AK7 savings per KG of
$160 $160
deposited coating, USD
www.kermetico.com
42
averstak@kermetico.com
Kermetico HVAF Equipment
www.kermetico.com
43
averstak@kermetico.com
Kermetico HVAF Guns
AK7 200 kW
AK6 130 kW
C7 200 kW
C6 130 kW
www.kermetico.com
44
averstak@kermetico.com
AK HVAF Guns
AK5 80 kW
AK-HH 80 kW
www.kermetico.com
45
averstak@kermetico.com
AK-HVAF Guns : Internal Diameter Spraying
AK-ID 30 kW
Spraying internal
diameters as small as
80 mm (3.15-inch)
www.kermetico.com
46
averstak@kermetico.com
Rotating HVAF Gun
www.kermetico.com
47
averstak@kermetico.com
Some Examples of
Kermetico HVAF Applications
www.kermetico.com
48
averstak@kermetico.com
Mud Pump Rotors, Oil Drilling:
WC-20Cr7Ni, WC-10Co-4Cr
www.kermetico.com
49
averstak@kermetico.com
Paper Machines:
Corrugating Rolls
Application by GZRINM, Guandong China
www.kermetico.com
50
averstak@kermetico.com
Paper Machines:
an Helix Extractor
Application by GZRINM, Guandong China
AK7 HVAF
O.D. .99 m x L 5.65 m
www.kermetico.com
51
averstak@kermetico.com
Hydro-Power:
a Francis Turbine Runner and Head Cover
Application by Plackart Ltd., Russia
www.kermetico.com
52
averstak@kermetico.com
Hydro-Power:
Metering Needle Valve and Seat
Application by RenCoat Ltd., China
www.kermetico.com
53
averstak@kermetico.com
Geothermal Power:
Turbine Rotor
WC-10Co-4Cr
dimensional coating
in sealing area
www.kermetico.com
54
averstak@kermetico.com
A Sliding Gate of a Catalyst Tower
Spraying Upper Slide Gate
www.kermetico.com
55
averstak@kermetico.com
Hydraulic Rods of Dock Cranes
Hard chrome coating performance: 0.5 year max (pitting)
HVAF WC-Co-Cr coating performance: 4+ years
www.kermetico.com
56
averstak@kermetico.com
Refinery: Automated Coating Application with
the Rotating AK5 Gun Inside a Closed-End Vessel
Diameter: 1.8 m
Length: 11.8 m
www.kermetico.com
57
averstak@kermetico.com
Refinery: Heat Exchanger Vessels
www.kermetico.com
58
averstak@kermetico.com
A Double-Elbow Spraying with the Rotating AK5 Gun
www.kermetico.com averstak@kermetico.com 59
Double-Elbow, Coke Transport Line
12-inch ID,
6-feet long
www.kermetico.com averstak@kermetico.com 60
A Coke Line Cyclone:
Application of a WC-10Co-4Cr Coating
with the Rotating AK5 Gun
www.kermetico.com
61
averstak@kermetico.com
Small ID Transport Pipe Line Components:
application of WC-10Co-4Cr coating
by the rotating AK-IDR gun
www.kermetico.com
62
averstak@kermetico.com
Oil Drilling:
Fluid-End Pump Casing, 5-inch ID
Application of coating with the AK-IDR rotating gun
www.kermetico.com
63
averstak@kermetico.com
AK4-ID Spraying of WC-10Co-4Cr Coatings
ID=3.5” ID=4.0”
ID=4.625” ID=6.0”
www.kermetico.com
64
averstak@kermetico.com
Separation Equipment:
Press pistons, upper/lower bowls
WC-CrC-Ni and WC-10Co-4Cr coatings
65
www.kermetico.com averstak@kermetico.com
Separation Equipment:
Tin Spraying with the SL HVAF gun onto
Lock Rings and Bowl ACME Threads
www.kermetico.com
66
averstak@kermetico.com
A Tensiometer Roll:
AK7 HVAF, WC-10Co-4Cr, 1.8 mm thick
www.kermetico.com
67
averstak@kermetico.com
Kermetico HVAF Blast & Spray Systems
www.kermetico.com
68
averstak@kermetico.com