Spraymet Surface Technologies provides various surface modification processes at its plants in Bangalore and Pune, India, including thermal spray coatings, cladding, plating, and nitriding. Thermal spray processes include flame spray, robotic plasma spray, robotic high-velocity oxy-fuel spray (HVOF), and cold spray. Cladding techniques include plasma transferred arc spraying and high-energy tungsten inert gas welding. The company's services can be used to coat components for oil/gas, valves, pumps, and other industrial applications.

1. SURFACE TECHNOLOGIES
Bangalore and Pune
Surface Modification Technologies
Bangalore Plant :
A 413, 9th
ain, 2nd
stage,Peenya Indl area
Bangalore 5600058 , spraymet@gmail.com
Tel : 080-28364565 , mobile : 9916903701
Pune Plant :
T 180, T Block, MIDC , Bhosari, Pune
Tel 020- 27110020 Mobile ; 8149046272
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SPRAYMET

2. xtausraxx
Various surface Modification
processes
SPRAYMET

3. Core Surface Modification Technologies
operated by Spraymet

Flame Spray : Powder / Wire

Robotic Plasma Spray

Robotic High Velocity Spray (HVOF)

Cold Spray ( future Planning )

Cladding : PTA / TIG

HWTIG /Laser ( future Planning )

Plating : Electroless ( ENP)

Nitriding ( liquid-QPQ and Gas)
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4. 1
5Schematic of thermal spray coating
Heat source,
spray gun
Acceleration Impacting Spreadening
and cooling
Feedstock
materials
Stick
Wire
Powder

5.  Thermal Spray : Process Flow

6. Gun-
Flsme/Plasma/HVO
FFlame Temp 3000-
15000*C
Semi molten particle
temp t
Particle velocity V ~ 400-
1200m/sec
Spray dist 6-15 inches – No
heat transfer to base
Grit blasted surface
Hot particle
quenches @surface
to give Hardness
Splat ~ D= 3X d
Adhesion : Micro
welding + mechanical
bonding
Practical size ~d 15-106
micronsSpherical in shape
D
-- = 3.5
d
SPRAYMET
SURFACECOATING
Heated particles
propelled
Impact force =
1/2mv2
Concept and
Schematic of
THERMAL SPRAY
Layer by layer coating builds up

7. Plasma spraying
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• Most versatile process in
terms of range of coatings
•plasma temperature: up to 15000 ºC.
• virtually all existing materials
including ceramics. Flame spray 350-
500m/sec

8. High-velocity oxy fuel spraying (HVOF)
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9. Cold spraying
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• gas temperature: under the
phase transition temperature ~ 800,1000C
• sprayed materials: pure Al, Zn, Cu, Ni
Alloys : NiCr, Cr- Carbide/NiCr

10. Process and prosperities
comparison
Adhesion
Strength
(Mpa)
Processes
Particle speed
m/s (km/h)
Spray rate
kg/h
Porosity
Levels
%
Thickness
capablity
mm
Flame Temp
°C
Powder Flame 70 (144) 1...8 10...15 0,2...5 3000 10...30
Wire Flame 70 (144) 5...8 0,2...0,4 0,2...5 3000+1100 n. 300
Arc Spray 220 (790) 6...40 10...20 0,2...10 3000 10...30
Plasma 600 (2160) 1...6 2...8 0,2...2 16500 20...70
HVOF 800 (2880) 2...9 0,5...2 0,2...2 2800 60...120*
HVAF 800 (2880) 10...30 0,1...1,5 0,1...1.5 1800 60...120*
Detonation 900 (3240) 2...6 0,1...1,5 0,1...0.50 4500 75...120*

11. Characteristics of thermally sprayed coating structures
(Typical Expected values)
As
sprayed
(3-5Ra)
Oxide-(max 3%) Cracks-(Not allowed)Pores
(1-2%)
t
Grit blasted surface
3-6 Ra
Unmolten particle
3 % maxEmbedded grit blasting
pieces-10% or area
max
“over-blasted”
area

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13. 13

14. 14

15. Plasma transfered arc spraying (PTA)
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• Fe, Ni, Co, Cr based alloys,
stainless steels, cermets
•Dilution ~ 2 %

16. HW/TIG bore cladding
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Common Base Material Grades API 5L X52 to X70, A106 Gr. B, ASTM
A333 Gr.6, A182, A350, A694, AISI
4130, 8630
Common Weld Overlay Grades STAINLESS Steel 316L, 410, 904L,
Duplex/Super Duplex, MONEL Alloy 200,
400; INCOLOY 825, INCONEL 625,
C22; C276, Copper Nickel Alloy and
others on customer requirement.
CRA Clad Pipe, Tubular Components Weld overlay of pipe in up to 6m lengths,
extended to 12m by “double jointing”
Flanges and Connectors Flanges / Swivel Ring Flange :1-1/2”NB
(min)
Bends (3D-5D) or on customer
requirement, SR/LR Elbows, Tees,
Reducers, Hubs /Caps
Weld overlay can be carried out on
elbows prior
to forming or after induction bending
depending on
the dimensions.
Pressure Vessel Components CRA clad nozzles, vessel strakes, tube
sheets
Valves & Valve Components Blocks, Manifolds, Gates, Seats,
Bonnets, Ball Plug,
Xmas Trees
Working Capabilities - Pipe cladding start from 4” diameter

17. Laser cladding
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• virtually all metal alloys,
cermets and ceramics. Dilution
< 1 %

18. Laser cladding process –
Dilution/distortion negligible
Laser cladded stabilizer
Rotor repairHyd. Ram and piston guides

19. Pump and valve applications
Pump and valve applications
Cage carbide coated Knife Gate valve body carbide
coated
Sleeve ceramic coated& Impeller ceramic coated
Ground
Ceramic coated sleeves Hardfaced pump sleeve
For Food industry
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20. 24” Ball valve coating
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Measurement After blasting HVOF coating

21. 20” Ball tungsten carbide coated – Metal
Seated Severe service application .

22. Ball HVOF coated and Lapped
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23. Plug valve, feed screw and Other applications
Plug valve carbide coating plug carbide or stellite possible
Control vale cage Ball valve carbide coating
Extrusion screw coating Valve disc stellite 6 PTA
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24. Oil and gas applications
BOP Double Ram piston BOP single ram piston
7” gate
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25. Metal seated gate vlave
Pune plant facility

26. Metal seated - Seat rings

27. Other 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

28. BOP Piston rod carbide coated and
Ground

29. Pump plungers

30. Super finish 0.05 Ra

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

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

33. Plunger Ceramic coated

34. SPRAYMET
Thank You
SPRAYMET SURFACE TECHNOLOGIES PVT LTD.
A413, 9th
Main, 2nd
Stage, Peenya Industrial area,
Bangalore . Email spraymet@gmail.com
www.spraymet.com
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