Spray & Fuse - training
02-25-2007, 11:31 AM,
#1
Spray & Fuse - training
Hi, I have joined this wonderful forum just today. I would like to know if any one can offer any practical training on 'FUSION' of plasma coated powders. In fact, I have to fuse - in a bogie furnace, preferably - a roll on 400 mm dia & 6000 mm L. The coating thk is 1.5 mm. Can any body help? suggest? Done any where in the world? Procedure? I have done similar job but with a small length - 2100 mm, successfully. But, for such a long job - well, how to avoid distortion at 1100 deg C is the major problem!

Thanks in advance.

Regards,

Sumant
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02-27-2007, 03:47 PM,
#2
RE: Spray & Fuse - training
Hi Sumant

Sign0016 to the Surface Engineering Forum.

I don't think furnace fusing is going to be a practical option here, unless you don't mind a big banana shaped roll. A continuous progressive localised fusing process along the rotating roll will probably be the only viable option. The traditional flame fusing techniques used on much smaller components will struggle or not work, without using a very much more ?beefed-up? specialised torch heating system. Induction heating or the more recent high intensity infra-red lamp heating would be better suited.

For fused coatings on rolls of this size PTA (plasma transferred arc) or other arc welding hard facing processes would normally be the recommended processes. HVOF coatings may be worthy of consideration, depending on the component's intended service.
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03-22-2007, 01:18 AM, (This post was last modified: 03-22-2007, 01:40 AM by Gordon.)
#3
RE: Spray & Fuse - training
Gordon Wrote:Hi Sumant

Sign0016 to the Surface Engineering Forum.

I don't think furnace fusing is going to be a practical option here, unless you don't mind a big banana shaped roll. A continuous progressive localised fusing process along the rotating roll will probably be the only viable option. The traditional flame fusing techniques used on much smaller components will struggle or not work, without using a very much more ?beefed-up? specialised torch heating system. Induction heating or the more recent high intensity infra-red lamp heating would be better suited.

For fused coatings on rolls of this size PTA (plasma transferred arc) or other arc welding hard facing processes would normally be the recommended processes. HVOF coatings may be worthy of consideration, depending on the component's intended service.

I agree in principle with Gordon, expect that the fusing hardly can be made with outside rays (except of laser, which is a completely different story). To achieve a proper fusing one has to be sure that at least some microns of the base material reaches the fusing temperature.
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04-07-2007, 05:48 AM,
#4
RE: Spray & Fuse - training
sumant Wrote:Hi, I have joined this wonderful forum just today. I would like to know if any one can offer any practical training on 'FUSION' of plasma coated powders. In fact, I have to fuse - in a bogie furnace, preferably - a roll on 400 mm dia & 6000 mm L. The coating thk is 1.5 mm. Can any body help? suggest? Done any where in the world? Procedure? I have done similar job but with a small length - 2100 mm, successfully. But, for such a long job - well, how to avoid distortion at 1100 deg C is the major problem!

Thanks in advance.

Regards,

Sumant
Reply
04-07-2007, 05:58 AM,
#5
RE: Spray & Fuse - training
Hi Sumant.u need to design your own process control for this particular spray & fuse job.is this job one off ?.Try doing this job vertically.What is your experience in Thermal Spray.
RGDS,
HK
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06-15-2007, 07:23 AM,
#6
RE: Spray & Fuse - training
HK Leong Wrote:Hi Sumant.u need to design your own process control for this particular spray & fuse job.is this job one off ?.Try doing this job vertically.What is your experience in Thermal Spray.
RGDS,
HK

Hallo Sumant,
Some years back I had visited one of the leading steel maker.
They were having a totally dedicated set up for this application.
The fusing was carried out using high capacity flame torches.
Thanks
Vijay Deshpande
Reply
06-25-2007, 03:02 PM,
#7
RE: Spray & Fuse - training
bhellman Wrote:
Gordon Wrote:Hi Sumant

Sign0016 to the Surface Engineering Forum.

I don't think furnace fusing is going to be a practical option here, unless you don't mind a big banana shaped roll. A continuous progressive localised fusing process along the rotating roll will probably be the only viable option. The traditional flame fusing techniques used on much smaller components will struggle or not work, without using a very much more ?beefed-up? specialised torch heating system. Induction heating or the more recent high intensity infra-red lamp heating would be better suited.

For fused coatings on rolls of this size PTA (plasma transferred arc) or other arc welding hard facing processes would normally be the recommended processes. HVOF coatings may be worthy of consideration, depending on the component's intended service.

I agree in principle with Gordon, expect that the fusing hardly can be made with outside rays (except of laser, which is a completely different story). To achieve a proper fusing one has to be sure that at least some microns of the base material reaches the fusing temperature.

Though I don't think high intensity infra-red lamp heating would necessarily be a viable option at this time for this particular application. I do think it has a lot of promise in this field in the future. With present claims of high-power densities of 3.5 kW/cm2 with a single lamp it is very different from the typical lamps used for drying and curing paint! Please review this article by following link high intensity infra-red lamp heating I would be interested in any comments.
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