- Spraymet Surface Technologies provides thermal spray coatings and cladding services using techniques like HVOF and plasma spraying. - They have facilities in Bangalore and Pune equipped with robotic sprayers, grinding, blasting and other processing equipment. - Thermal spray coatings offer benefits over hard chrome plating like lower capital costs, selective application, and no hazardous waste generation. HVOF spraying in particular produces very dense coatings with high bond strength. - Spraymet evaluates coatings for properties like hardness, porosity, bond strength and corrosion resistance to validate coating performance for applications in industries like automotive, steel, pumps, and oil & gas.

1. Thermal sprayThermal spray
Technology , concept andTechnology , concept and
Hard chrome ReplacementHard chrome Replacement
ApplicationsApplications
Spraymet Surface Technologies Pvt LtdSpraymet Surface Technologies Pvt Ltd
Bangalore and PuneBangalore and Pune
spraymet@gmail.comspraymet@gmail.com

2. Spraymet BackgroundSpraymet Background
Started in 1996, by Sulzer Metco/Advani Oerlikon Manager with 18 yearsStarted in 1996, by Sulzer Metco/Advani Oerlikon Manager with 18 years
experience in thermal spray and weldingexperience in thermal spray and welding
Objective : To provide TOTALObjective : To provide TOTAL SURFACE TECHNOLOGY SOLUTIONS :SURFACE TECHNOLOGY SOLUTIONS :
PRODUCTS :PRODUCTS : Equipment and Materials for thermal spray , PTA claddingEquipment and Materials for thermal spray , PTA cladding
SERVICES : Thermal spry : Plasma , HVOF, MetallizingSERVICES : Thermal spry : Plasma , HVOF, Metallizing
PTA : Co and Ni alloy claddingPTA : Co and Ni alloy cladding
For Repair and OEM coatingsFor Repair and OEM coatings
Spray shop : 1998 BangaloreSpray shop : 1998 Bangalore
Spray Shop : 2013 PuneSpray Shop : 2013 Pune

3. SPRAYMETSPRAYMET
PRODUCTS AND SERVICESPRODUCTS AND SERVICES
Some of the industries presently served areSome of the industries presently served are
AutomotiveAutomotive Piston rings, Synchro ring, Rocker arm pin, etc.Piston rings, Synchro ring, Rocker arm pin, etc.
SteelSteel CRM rolls,Briddle rolls, Sink rolls, Guide rolls, etc.CRM rolls,Briddle rolls, Sink rolls, Guide rolls, etc.
Pulp and PaperPulp and Paper Rewinder rolls,Traction rolls, Various sleeves & shaftRewinder rolls,Traction rolls, Various sleeves & shaft
Pump and valvePump and valve Plungers, sleeves,Wedges, Seat rings, Balls for globe valves.Plungers, sleeves,Wedges, Seat rings, Balls for globe valves.
Turbine and powerTurbine and power Thermal barrier coating , blade coating, inconel weld repairThermal barrier coating , blade coating, inconel weld repair
rotor bearing area repairrotor bearing area repair
Oil and GasOil and Gas Metal seated Slab gate and seat, Ball and seat, BOP Rams,Metal seated Slab gate and seat, Ball and seat, BOP Rams,
CRA cladding of flow areas.CRA cladding of flow areas.

4. FacilitiesFacilities
BangaloreBangalore
ROBOTIC Plasma(2) , HVOF(2), Wire Metallizing , PTA, ENP,ROBOTIC Plasma(2) , HVOF(2), Wire Metallizing , PTA, ENP,
Blasting and other auxillary opeartions /capacities like :Blasting and other auxillary opeartions /capacities like :
Crane : 10 Tons Grinding : 800diaX6mts Diamond belt superCrane : 10 Tons Grinding : 800diaX6mts Diamond belt super
finsihsingfinsihsing
PUNEPUNE
ROBOTIC HVOF, Wire Metallizing , (ENP) Blasting and otherROBOTIC HVOF, Wire Metallizing , (ENP) Blasting and other
auxillary opeartions /capacities like :auxillary opeartions /capacities like :
Crane : 2 Tons, Surface Grinding and LappingCrane : 2 Tons, Surface Grinding and Lapping

5. TheoryTheory
How thermal spray works and its placeHow thermal spray works and its place
amongst other surface treatmentamongst other surface treatment
processes ?processes ?

6. COMMON SURFACECOMMON SURFACE
TREATMENT METHODSTREATMENT METHODS
Plating – Hard chrome,Anodising, ENP etcPlating – Hard chrome,Anodising, ENP etc
Thermal Spraying – Plasma , HVOFThermal Spraying – Plasma , HVOF
Weld Cladding –TIG,PTA,LaserWeld Cladding –TIG,PTA,Laser
Gas Nitriding /Plasma nitridingGas Nitriding /Plasma nitriding
Physical Vapor Deposition TechnologyPhysical Vapor Deposition Technology

8. How coating bonds?How coating bonds?

9. Coating formationCoating formation

10. Features of thermal sprayFeatures of thermal spray
Wide Materials ChoiceWide Materials Choice
Metals , Alloy blends, carbides,ceramics..Metals , Alloy blends, carbides,ceramics..
Uniform Coating Thickness - 0.02 to few mmUniform Coating Thickness - 0.02 to few mm
Selective coating capability by maskingSelective coating capability by masking
In situ coating capability- paper /powerIn situ coating capability- paper /power
Coatings with high perfomance :60Rb-72RcCoatings with high perfomance :60Rb-72Rc
No metallurgical change in Base materialNo metallurgical change in Base material

11. Benefits of Thermal SprayingBenefits of Thermal Spraying
Low Capital Investment - Compared to a plating andLow Capital Investment - Compared to a plating and
vacuum coating installation.vacuum coating installation.
Competitive Application Costs – Selective coating allowsCompetitive Application Costs – Selective coating allows
cost controlcost control
When parts are large enough and the coatingWhen parts are large enough and the coating
performance requirement is high, thermal sprayingperformance requirement is high, thermal spraying
becomes very cost competitive.becomes very cost competitive.
Environmental : Most importantly the effluent treatmentEnvironmental : Most importantly the effluent treatment
plant is not required. All required is a good dustplant is not required. All required is a good dust
collector.collector.

12. Schematic of thermal spray processesSchematic of thermal spray processes

13. Plasma Spraying ProcessPlasma Spraying Process
A high temperature plasma stream is created by non-transferred plasmaA high temperature plasma stream is created by non-transferred plasma
arc within the torch. Many gases may be ionized this way, argon orarc within the torch. Many gases may be ionized this way, argon or
nitrogen with small additions of hydrogen and helium are popularnitrogen with small additions of hydrogen and helium are popular
choices.choices.
In an ionized gas, free electrons have been stripped from the atoms andIn an ionized gas, free electrons have been stripped from the atoms and
recombination releases very significant thermal energy. The plasmarecombination releases very significant thermal energy. The plasma
stream can reach temperatures of 10,000-50,000 degrees Fahrenheit.stream can reach temperatures of 10,000-50,000 degrees Fahrenheit.
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14. HVOF (High Velocity Oxygen Fuel) spray processHVOF (High Velocity Oxygen Fuel) spray process
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15. HVOF (High Velocity Oxygen Fuel) spray processHVOF (High Velocity Oxygen Fuel) spray process
The HVOF thermal spray process uses the highThe HVOF thermal spray process uses the high
pressure (8-10bar)combustion of gases, such aspressure (8-10bar)combustion of gases, such as
propane, propylene, hydrogen, or a liquid fuel such aspropane, propylene, hydrogen, or a liquid fuel such as
kerosene.kerosene.
The process creates a very high velocity >1200m/sThe process creates a very high velocity >1200m/s
Propel the particles at near supersonic speeds ~800-Propel the particles at near supersonic speeds ~800-
1000m/s1000m/s
High impact force results in Bond strength >12000PSIHigh impact force results in Bond strength >12000PSI
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16. Comparison of Thermal spray ProcessesComparison of Thermal spray Processes

17. HVOF carbide coating
Typical micrographTypical micrograph

18. Evaluation of coatingsEvaluation of coatings
Micro Hardness HV 0.3Micro Hardness HV 0.3
Porosity ASTMPorosity ASTM
Micrograph 400X voids, oxides etcMicrograph 400X voids, oxides etc
Bond strength ASTM C 663Bond strength ASTM C 663
Bend testBend test
Salt Spray TestSalt Spray Test
Surface rough nessSurface rough ness

19. Reports and DocumentationReports and Documentation
Powder compositionPowder composition ( WcCoCr 86/10/4 for slab gate and seat)( WcCoCr 86/10/4 for slab gate and seat)
Coating Hardness HV 0.3( On cuopon)Coating Hardness HV 0.3( On cuopon)
Bond test at IMR SingaporeBond test at IMR Singapore
Bend test ( at request and as per customer criterion)Bend test ( at request and as per customer criterion)
Porosity test at NABL LabPorosity test at NABL Lab
Salt spray ( at request) on test result enclosed upt 700Salt spray ( at request) on test result enclosed upt 700
hourshours
Demention report 100%Demention report 100%
Flatness ( Light Band) sampling as per customerFlatness ( Light Band) sampling as per customer
DP ( NDT) test : sampling as per customerDP ( NDT) test : sampling as per customer

20. Bend Test ReportBend Test Report

21. Adhesion Strength report as perAdhesion Strength report as per
ASTM C 633ASTM C 633

22. Porocity and Hardness ReportsPorocity and Hardness Reports

23. Main class of MaterialsMain class of Materials
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24. Major properitiesMajor properities

25.
HVOF COATING OPTION FOR HARD in Oil and gas Industry
Carbides Process Hardness Thickness Notes
1 Tungsten
carbide/Cobalt
88/12 or 83/17
HVOF 1100 to 1350
HV 0.3
150-200 to
Microns
Dense and hard Coatings
wear, Applications for
temperatures up to 450
Deg C
2 Tungsten
carbide/Cobalt/Ch
romium
86/10/4
HVOF 1100 HV to
1350 Hv 0.3
150-200 to
Microns
Improved oxidation and
corrosion protection over
WC-Co and WC-Ni.
3 Tungsten
carbide/Chrome
carbide/Nickel
70/23/7
HVOF 1000 to1200
HV 0.3
150-200 to
Microns
Superior oxidation and
corrosion properties than
other tungsten carbide
based material
4 Tungsten
carbide+NiCrBSi
50/50 , 65/35
HVOF 1000 to 1300
Hv 0.3
150-200 to
Microns
A blend of Tungsten
carbide and NiCrBSi for
fretting wear, erosion,
abrasion
5 Chrome carbide
/NiCr (75/25)
HVOF 850-1100 HV 150-200 to
Microns
Good and lower cost
replacement for
Hardchrome temp
resistance 850 C
Ceramics
6 Aluminium Oxide Plasma Spray 55 to 60 RC 200 Mirons High purity Alumina ceramic
coating with good wear and
corrosion resi. But brittle .
7 Chrome Oxide Plasma Spray 65-72 Rc 200 microns Better coating than Allumina with
good wear and corrosion resi. But
brittle.

26. Hardness ComparisonHardness Comparison

27. Abrasion ComparisonAbrasion Comparison

28. Salt Spray test results of Wc/Co/Cr HVOF coatingSalt Spray test results of Wc/Co/Cr HVOF coating
HVOF coatings sustain > 2000 Hrs ( sub sea applicaions )HVOF coatings sustain > 2000 Hrs ( sub sea applicaions )
vs Hard Chrome 200 hrsvs Hard Chrome 200 hrs

29. ACCOUSTIC CHAMBERSACCOUSTIC CHAMBERS

30. JP 5000 HVOFJP 5000 HVOF

31. Metal seated gate vlaveMetal seated gate vlave
Pune plant facilityPune plant facility

32. Metal seated - Seat ringsMetal seated - Seat rings

33. Other coponents oil and gasOther coponents oil and gas
Plug carbide coating
Control valve plug -stellited
Ball and seat TC coated and match lapped
Mud Rotor : Repaired and Tc coated +
super polished

34. BOP Piston rod carbide coatedBOP Piston rod carbide coated
and Groundand Ground

35. HVOF coated BOP Piston rod DP Tested – PassesHVOF coated BOP Piston rod DP Tested – Passes
RDP/LPT testRDP/LPT test

36. Frac Pump plungersFrac Pump plungers

37. Super finish 0.05 RaSuper finish 0.05 Ra

38. PROGRESSIVE PUMP ROTORCARBIDE
COATED and super polised
( Earlier this application was Hard chrome)

39. Carbide coated and Ground Gate ValveCarbide coated and Ground Gate Valve
( Replacement for Nitriding )( Replacement for Nitriding )

40. 20” Ball tungsten carbide coated – Metal Seated
Severe service application .

41. Plunger Ceramic coatedPlunger Ceramic coated

42. Gas compressor piston rod.Gas compressor piston rod.
Wc+CrC coatedWc+CrC coated

43. DP( NDT) test on HVOF coatingDP( NDT) test on HVOF coating

44. S P R A Y M E TS P R A Y M E T
ContactContact
Bangalore :Bangalore :
A 413, 9A 413, 9thth
main, 2main, 2ndnd
stage, Peenya Indl Area,Bangalore 560058,stage, Peenya Indl Area,Bangalore 560058,
Tel/Fax ; 080- 28364565 E mail :Tel/Fax ; 080- 28364565 E mail : spraymet@gmail.comspraymet@gmail.com ,,
S S Joshi : 9916903701S S Joshi : 9916903701
Pune : Plot 244, Sector 7 , PCNTDA, MIDC Bhosari , PunePune : Plot 244, Sector 7 , PCNTDA, MIDC Bhosari , Pune
Tel : 8149046272 E mail : spraymetpune@gmail.comTel : 8149046272 E mail : spraymetpune@gmail.com
Thank youThank you
SPRASURFACECOATING