Electric Arc Spraying for advanced industrial applications
Two metal wires, pushed to the end of the gun, they generate an electric arc which melts the material into drops subsequently accelerated by compressed air or gas and projected onto the support. The result is a high-performance technical coating, designed for protection, reconstruction and increase in the useful life of components.
Solid wires normally used
Industrial applications of electric arc metallization cover numerous materials and alloys. The choice of wire depends on the operating environment, by the level of corrosion, by the wear required and the working temperature.
Zinc coatings are particularly suitable for protecting steel from corrosion, thanks to their excellent resistance in low acid atmospheres and in industrial and marine environments. Applications include cast iron pipes, iron bridges, torri eoliche, capacitors and numerous components exposed to aggressive agents.
Main advantages
- Highly reliable anti-corrosion protection
- Excellent behavior in marine and industrial environments
- Possibility of anti-friction and anti-wear coatings
- High adhesion on technical supports and substrates
- Specific solutions for high temperature and reconstruction
| Fili | Applications |
|---|---|
| Al/Mg | Corrosion-resistant coatings in marine atmospheres |
| In | Coatings with excellent adhesion |
| Steels 13% Cr | Wear-resistant coatings, with limited corrosion resistance |
| Fe Cr Al | Excellent corrosion resistance at high temperatures |
| Mo | Coatings excellent fretting fatigue |
| Ni Cr 80/20 | Corrosion-resistant coatings and binder for ceramic tiles surface |
Applications by material
Aluminum and its alloys
Aluminum is used in acidic and basic environments, in the food industry, in marine structures and in liquid gas tank pipes and vaporizers. The bequeaths AlMg 5% offers excellent corrosion resistance offshore and in marine atmospheres.
Bronzes to aluminum
The addition of small percentages of aluminum in copper alloys improves corrosion resistance. The integration of Ni and Fe further increases performance, especially in sea water.
Nickel and its alloys
Used as anti-corrosion protection for desalination components and in marine atmospheres. Ni Cu30 Fe and Ni Cr80-20 coatings offer excellent resistance in the presence of moisture and oxidizing or reducing fluids.
Anti-friction coatings
Tin and bronze-based coatings have a low friction index and excellent resistance to rubbing. They can be turned on a lathe and are suitable for severe operating conditions, with indicative application intervals in the order of 200/300°C.
high-adhesion coatings
NiTi and NiAl alloys are used when it is necessary to obtain high adhesion, also for ceramic coverings and thin coatings. The molten particles, superheated by the exothermic reaction, they form microscopic welding spots on the substrate.
Anti-wear coatings and special applications
wear-resistant coating
Hard steels are used, like the martensitic ones at Cr, for surfaces subject to wear. Depending on the application, it is possible to integrate elements such as Co and Cr to improve the behavior of the coating and its durability.
Atmosfere corrosive
Where wear and corrosion act simultaneously, Standard materials may not guarantee sufficient durability. In these cases, carbide-cored wires or high-performance compositions are used, capable of increasing the resistance of the fill.
Coating reconstruction
Mild steels and high-alloy steels are used to rebuild generator drive shafts, paper cylinders, seats and gaskets. Bronzes and tin-based alloys are also suitable for repairs to naval engine liners.
High temperature
For vaporizers, tubes for vapor transport, Coal boilers and incinerators are used NiCr and FeCr cored wire coatings with high chromium content, chosen for their resistance to oxidation, corrosion and erosion at high temperatures.
Effect of alloying elements
Effect of Chromium Metal
Metallic chromium forms an oxide film on the surface of the coating even in the presence of low oxygen gases. A thick layer of chromium oxide significantly improves the durability of the component in corrosive atmospheres.
Effect of Boron and Silicon
Silicon and boron lower the melting point of some iron and nickel alloys, reducing the viscosity of the atomized particles. This favors denser deposits, a better laying of the coating and a decrease in porosity.
Cored wires
To obtain longer life on components such as boilers, rollers and parts subject to high stress, Carbon-cored wires are used, chrome, aluminum, carbides or specific combinations capable of increasing wear, adhesion and corrosion resistance.
| Type flux cored wire | Application |
|---|---|
| Fe C Mn Si | High wear resistance in dry atmosphere |
| Fe Cr B Si | Wear-resistant coating, good resistance to corrosion, high adherence |
| Fe Cr B Si + W C Co Cr | Excellent resistance to high temperature corrosion, high adherence |
| Fe Cr Si | Resistance to wear and corrosion at high temperatures up to 900°C, high adherence |
| Ni Cr 50/50 | High temperature corrosion resistance up to 900°C |
| Ni B Si + WC | High wear resistance, good corrosion resistance |
| Ni Cr B Si | High resistance to corrosion in humid atmospheres, good resistance to wear |
List of Colimet metal wires
| Type | HB hardness | Diameter (mm) | Material / Analyses |
|---|---|---|---|
| 20L | 190-200 | 1,6 | Low C |
| 30L | 210-230 | 1,6 | Low C |
| 55L | 300-320 | 1,6 | 1,3% C |
| 60L | 300-340 | 1,6-2 | Inox |
| 62L | 240-266 | 1,6 | Inox |
| 65L | 380-440 | 1,6 | High C |
| 80L | 220 | 1,6-2 | Inox 18/8 |
| 85L | 250-270 | 1,6 | Inox 18/8 |
| 95L | 280 | 1,6 | 18/11/2 |
| 70L | 160-200 | 1,6 | Monel |
| CuL | - | 1,6 | Pure Rame |
| 100L | 480 | 1,6 | Pure Molybdenum |
| 98L | - | 1,6 | Nichel-Chrome |
| RniL | 160 | 1,6 | Pure nickel |
| NiAl / L | 230 | 1,6 | Nichel-Al |
| PBz / L | - | 1,6 | Lega PBz |
| Al / L | 20-40 | 1,6-2-2,5 | to the pure |
| Sn / L | - | 2-2,5 | Sn puro |
| AlMg5 / L | - | 2,5 | Orientation Al-Mg |
| LMSn / L | - | 2,5 | Orientation |
| Ms / L | - | 1,6 | Orientation Cu-Zn |
| AlBz9Mn / L | 160-180 | 1,6 | Super Orientation |
| Orientation Cu-Zn | - | 1,6 | Cu 68% - Zn 32% e ALTR tenor |
| Filo Zn | - | Everyone | Zn puro |
| Filo Zn / Al | - | - | Location Zn 85% - To the 15% |
| Filo Zn / Sn | - | - | Location Zn 80% - Sn 20% |
| Gross Ella di Zn | - | - | Zn puro |
Technical solutions for every industrial need
Colimet provides materials, experience and technical skills to identify the most suitable coating depending on the support, the operating environment and the required performance.
Request information