As rotating assemblies and blades heat and cool, they change in size due to thermal expansion. Manufacturing the assemblies to achieve close clearances during operation is difficult. The solution is to add a thick clearance control coating to the housing. As the blades rotate and heat up, they abrade a path through the coating, making a near perfect fit groove to run in. These coatings can be tailored for both low and high temperature environments. Field testing confirms that industrial coatings have a high degree of abradability with essentially no blade tip wear. Tests also confirm excellent resistance to oxidation at temperatures of to 650°F and good resistance to thermal shock.
Aluminum Polyester Industrial Coating
This is a blend of silicon-aluminum and polyester powders. It was especially developed for machine element clearance control coatings. Field testing confirms that coatings have a high degree of abradability with essentially no blade tip wear. Also, field tests show ab excellent resistance to oxidation at temperature up to 650°F. Good resistance to thermal shock has also been noted.
Aluminum Silicon Coating
Aluminum Silicon coatings are an aluminum alloy-graphite composite powder specifically developed to provide a plasma sprayed abradable clearance control. It is perfect for gas turbine engines with titanium alloy and possibly alloy rotors, operating at 600-800°F. Plasma sprayed aluminum silicon coatings are denser than similar thermal spray industrial coatings. They exhibit greater erosion resistance.
Tungsten carbide powders are most commonly applied using HVOF or atmospheric plasma spray. Chromium carbide materials are blends of chromium carbide and nickel carbide powders. Both are very good at protecting from particle erosion and other forms of stress.
Tungsten Carbide Industrial Coating
Tungsten carbide powders are most commonly applied using HVOF or atmospheric plasma spray. It helps produce very dense, well bonded industrial coatings. These coatings provide excellent resistance against most forms of abrasive wear at lower service temperatures. The materials contain fine-grained carbides for resistance against abrasive grains, hard surfaces, particle erosion, and fretting wear mechanisms. They should be used in dry, non-corrosive environments.
Chromium carbide industrial coating is a blend of chromium carbide and nickel carbide powders. The nickel chromium alloy serves as a matrix that improves overall coating integrity and corrosion resistance. The chromium carbide constituent serves as a hard phase that assures wear resistance. Coatings of this chromium carbide effectively combat solid particle erosion, high temperature wear, and hot corrosion.
Ceramic Industrial Coating
Ceramic coatings are most commonly applied for dielectric strength, sliding wear, thermal barriers, and corrosion protection. Common coatings include Alumina, Zirconia, Chromium Oxide, Titania, and, Yttria stabilized Zirconia. The most common uses for thermal sprayed ceramic materials are diesel engine pistons. It also works well for thermal barrier coatings for industrial gas turbine combustion liners, blades, and vanes. Ceramic coatings are perfect for industrial applications such as hydraulic cylinders and mechanical seals.
Chromium Oxide Coating
Chromia-Silica composite powders are designed to produce thermal spray coatings that are hard, dense, and extremely wear resistant. The industrial coatings exhibit a degree of impact resistance not normally associated with sprayed ceramic coatings. Coatings of this powder are insoluble in most acids, alkalis and alcohol. When properly sealed they can be utilized in corrosive chemical environments at temperatures up to 400°F.
Metal and Metal Alloy Coating
Metal and metal alloy coatings can be used as bonds for other thermal spray coatings. They are commonly utilized to restore dimensions for improved wear and corrosion. The dimensional buildup of parts for ease of machining. The coatings work well against high temperature wear resistance and sliding wear. The alloys are perfect for applications requiring lubricity. Common coatings include Nickel Aluminum alloys, Nichrome, Titanium, Stainless Steel, Bronze, Zinc and Babbit.
Stainless steel wire forms a dense, well bonded coating, with excellent wear resistance and good corrosion resistance. It is specifically designed for arc spray processes. Stainless steel coatings are widely used for machine element repair, dimensional restoration, and wear resistant application. With low shrink rate characteristics, it allows for increased coating thickness on parts requiring heavier industrial coatings.
Nickel Aluminum Coating
Nickel aluminum industrial coating is a solid wire designed specifically for arc spray systems. It is self-bonding to most materials and requires minimal surface preparation. This wire exhibits good resistance to impact and bending. Nickel Aluminum is widely used as a bond coat for subsequent thermal spray topcoats. The coating is perfect as a one step build up material for dimensional restoration.
Aluminum bronze industrial coating is an inert gas atomized powder. It is golden in color. Aluminum is the main element along with other alloying elements such as iron. The presences of aluminum in the bronze helps enhance the corrosion resistance of coating. The formation of a thin tenacious surface oxide that acts as a protective layer to the copper-rich alloy is a primary characteristic. Coatings of this material are easily machined and excellent finishes are achievable. It has good resistance to fretting and galling at low to moderate temperatures. Aluminum Bronze has excellent resistance to abrasion and cavitations. This coating is recommended for soft bearing applications.
Nickel Iron Aluminum
Nickel Chromium / Molybdenum / Aluminum composite powder was especially developed to produce machinable “stainless” type industrial coating. It has good wear and excellent corrosion resistance properties for hard bearing applications. This industrial coating offers two major advantages. It features one step spraying and high integrity coatings. Nickel Iron Aluminum was designed to produce machinable, low shrink, high strength coatings. These are recommended for applications requiring resistance to abrasive wear, fretting, cavitation, and particle erosion. It’s perfect for the salvage and buildup of machinable corrosion resistant steels and machinable carbon steels.
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