History and Development of Thermal Spraying Engineering...

Volume 20, Number 4 Fourth Quarter 2013

Publ ished by The Internat ional Thermal Spray Assoc iat ionA S t a n d i n g C omm i t t e e o f T h e Am e r i c a n We l d i n g S o c i e t y

SPRAYTIME Fourth Quarter 2013

Continued on page 11.Continued on page 4.

History and Development of Modern Thermal Spray Guns

By James BrowningPrior to the 1950s, metallizing was done using spray gun

devices with compressed air as the accelerants of theparticles. Both flame-spray and twin wire-arc methods werepatented in the early 1900s by Mr. Shoop. The break camein the 1950s with the development of the detonation gunby Union Carbide. The D-Gun speeds the particles to impactvelocities several times those previously available.

Merle Thorpe, while a graduate student at Dartmouth’sThayer School of Engineering, worked on a government-sponsored program studying the combustion of small solidfuel particles with air. He won a national student researchpaper competition held at MIT and sponsored by the ASME;the title “Lateral Blow-Off of Bunsen Flames”. Some yearslater he returned to New Hampshire, and in 1958, he joinedthree of us in founding Thermal Dynamics Corporation. Thermal Dynamics was interested in electric arc heating

devices for producing supersonic jet streams. Metco, whowas aware of our work, invited us to Westbury to discuss animportant problem that had developed.Soon after arriving in Westbury we were in Rae Axline’s

office with Herb Ingham. Their problem was a drop in saleslevels of their flame-spray products – particularly, thespraying of tungsten-carbide. The cause of the drop was theD-Gun’s ability to spray improved coatings of that material.After a long period of discussing this matter, all four of usagreed “Let’s try plasma as the spraying medium”.

The arrangement set up a Research and Developmentprogram sponsored by Metco, but carried out at ThermalDynamics under the leadership of Merle Thorpe. Merledeveloped and patented the device1. In our contract withMetco, they (Metco) would have sole rights (resulting from

Thermal Spraying Engineering CoatingsUsing Silver

RFI Screening Limited, specialist surface treatmentengineers, has opted for Metallisation MK61 Flamesprayequipment to thermal spray a 40 ton generator rotor withfine silver.

The generator rotor, which is a combination of electrical,mechanical and manufacturing components, is regularlyexposed to hard mechanical stress and high temperatures,while being subjected to electrical voltage and current.Over time this stress can lead to breakdown, costly repairand maintenance and possibly inconvenient downtime. Tomaximize the lifetime of the generator rotor, RFI Screeningwas contracted to thermal spray it, using the flamesprayequipment.Prior to thermal spraying the generator rotor, the surface

was grit blasted, to Standard SA 2.5, to clean and preparethe shaft. The shaft was also pre-heated by induction to

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Published byInternational Thermal Spray Association

A Standing Committeeof the American Welding Society

Mission: To be the flagship thermalspray industry newsletter providingcompany, event, people, product, research,and membership news of interest toindustrial leaders, engineers, researchers,scholars, policy-makers, and the publicthermal spray community.

Kathy M. Dusa Managing Editor

Jason Falzon Editor

Joe Stricker Technical Editor

SPRAYTIME (ISSN 1532-9585) is a quarterlypublication of the International ThermalSpray Association.

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I N DU S T RY N EWSAdvertisers Listing ..............................................................................31American Roller Celebrates 75 Years........................................................21ASM TSS Journal of Thermal Spray Technology Abstract..............................25ASM International New Alloy Center Database Release ..............................12Calendar of Events ..............................................................................26Cold Spray Enables Welding of Crack-Sensitive Alloys ................................22Fabtech Canada ..................................................................................32Fabtech Mexico 2014, Mexico City ..........................................................27Farr Gold Series Dust Collectors ..............................................................14Free DIN Standards Poster ....................................................................25Free GTS/Linde Thermal Spray Process Poster............................................25H.C. Starck and Masan Group Establish Tungsten Ventures ..........................19History and Development of Modern Thermal Spray Guns ............................1International Thermal Spray Association ............................................16-18ITSC 2014, Barcelona, Spain ..................................................................23NACE 2014 Bring On The Heat, ..............................................................30Offshore Wind Energy: Life Cycle Cost Reduction Through Thermal Spray ......28SVC Society of Vacuum Coaters TechCon2014, Chicago ..............................24TurboExpo 2014, Dusseldorf, Germany ....................................................29Watson Coatings Laboratory Accreditation ..............................................21

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4 SPRAYTIME Fourth Quarter 2013

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History continued from page 1.the program) within the metallizing field. Thermal wouldhave sole rights for applications outside metallizing. Ajointly-owned corporation, PlasmFlame, was established toformalize this arrangement. It became evident that theThorpe gun was useful, as developed, for uses in additionto metallizing. And then, Sputnik went up! The rush was on for materials

and re-entry testing equipment. It was found that only twocompanies were marketing the new plasma equipmentwhich proved qualified for this high-temperature test work.“BOOM”, Plasmadyne and Thermal sales soared. Each soldgeneral-purpose plasma guns which could also spray metalsand ceramics. A possible conflict with Metco arose for us,but it was easily solved. Thermal could include metallizingas a use of general purpose equipment up to the timeMetco commenced marketing their own equipment. Thermalwould then drop out of the metallizing field for equipmentoperating under the Thorpe patent. (In fact, Thermal neverdeveloped a gun specifically designed for spray use.)Thermal sold several plasma systems operating at 1mw, orabove with the highest powered installation using 7mw toStanford University for studies in magnetohydrodynamics(MHD). (It should be mentioned that Thermal’s designs ofsuch high-powered arc guns relied heavily on the pastMetco program. This is also true regarding our plasmacutting spray guns.) We learned later that Union Carbidehad built a 20 mw unit – presumably for MHD studies.

Increased Plasma Spray Power LevelsYears after leaving Thermal Dynamics, Richard Whitfield

and I began work on a 200 kw plasma spray gun designedto extend HVOF type spraying to much higher jet velocitiesand temperatures. We settled on purchasing 200 kwThermal Dynamics metal cutting system using theirinexpensive power supplies, controls, and the like. Themajor change was attaching the spray gun in place of thecutting torch. The system ran fine with an estimated12,000°F peak temperature and a jet velocity of about9,000 ft/sec. We sold several of these systems. An offerfrom a Japanese firm for exclusive world-wide rights to thecontrolling patents was too favorable to turn down. Wewent on working, I believe on high-pressure HVOF designs.The Japanese firm that continued making these units ran

into real estate speculation difficulties and, to make endsmeet, sold their exclusive patent rights and designs to anestablished thermal spray firm in the United States. Thepower level had been increased to 250 kw. The UnitedStates firm made and sold five complete systems to anaircraft engine manufacturer for the main purpose ofspraying ceramics on gas turbine engine parts. To myknowledge, the new manufacturer discontinued making thisoutstanding equipment.High Pressure HVOF Spray Apparatus

The early HVOF spray guns operated at inlet oxygenpressures below 100 psig. Over a several year period, thepressure rose to 200 psig for the J-Gun which DickWhitfield and I commenced selling in the middle 1980s.This gun, after extensive improvements by TAFA, who hadtaken over its manufacture, has been very successful overthe past many years providing a superior gun, the JP-5000.Much of this success has been due to its ability to impactun-melted particles against the work piece at velocities sogreat that the heat-of-impact produced fusion coatings.Events in HVIF spraying (High Velocity Impact Fusion)happen so rapidly that oxidation levels are nearly zero.Metco, at a later date, commenced the sale of HVIF unitscapable of operating at over 300 psi.

The operating pressure increases led to much highercoating quality. Pondering this fact, the HVOF operatingoxygen pressures were raised to 1,000 psi. Again, majorimprovements resulted in coating quality (see figures 2 and3). Boundary lines between contact particles in thecoatings are difficult to detect. No decarburization of thetungsten carbide is evident. The accelerating jettemperature is so low due to the high expansion level, thatthese adverse effects were minimized. The results of the 1,000 psig operation were so good that

a 4,000 psi liquid oxygen pump was purchased with itswater-heated high strength evaporator. Before using thisreally high pressure apparatus, I presented the 1,000 psiresults at a meeting in Quincy, MA. The audience (at least

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in my interpretation of statements made) would neveraccept the use of such high oxygen pressures. The devicewas not marketable. Why go on with this work? I nevermade use of the liquid oxygen apparatus. (To this day, mybelief is that HVOF spraying could in many cases competewith fusion welding and “printing” in applications forforming structures.) HVAF – Its Success and Sudden DemiseThe high-velocity air-fuel thermal spray equipment was

designed after several years of experience gained usingmuch larger air-fuel burners in other applications. Adramatic use of a high-output air-fuel unit was successfullyused to drill a hole 1,100 feet deep in the Conway, NHGranite for the purpose of measuring the temperaturegradient in this formation containing radio-active Thorium.(The gradient found – 30°C per kilometer of depth.) The

flame-drill was provided with 1,200 scfm of compressed airat 900 psig! The hole produced averaged 10 inches indiameter – the drilling rate a bit over 100 ft/hr!The exclamation points above were purposely included to

dramatize how much less complex the air-fuel unitsdesigned for thermal spray would be. Their design utilizedregenerative air-flow cooling of the combustion devicewhich operated at about 120 psig at the compressed airinlet, with flows up to 150 scfm.These HVAF units had several advantages over their HVOF

competitors. First, costs for similar heating levels aregreatly reduced to those for oxygen. Secondly, the peakcombustion temperature, prior to expansion to theatmosphere, is about 3,400°F versus over 5,000°F for pureoxygen. Expansion to atmospheric pressure produces a jettemperature below that of stainless steel’s melting point ofabout 2,700°F. No melting of stainless particles beingsprayed was the result. In fact, the phenomenon of “impactfusion” was discovered when test-spraying using early HVAFdesigns. The high-velocity particles forming the exitingplume were barely visible with a much brighter circularglow evident on the work piece surface. For discussions ofHVAF operation, see references (2), (3) and (5). ProfessorHorst Richter, co-author of (2) has recently retired from theThayer School of Engineering. His advice in ways to reduceoxidation in coatings is to provide peak combustiontemperatures near, or below, the dissociation temperaturesof such flame species as CO, OH, and O which are intenselyoxidizing. This advice has been followed in HVOF cases byburners using additions of non-combustibles such asnitrogen or, even, small flows of water.The demise of HVAF in this country is a sad and tragic

story. The most recent marketer of HVAF equipment hadsold a European-made HVOF systems which is comprised ofa console containing both oxygen and fuel flowinstrumentation with a safety bulkhead separating the tworeactants. The customer, without the knowledge of themarketing firm, had drilled hole(s) through the bulkhead.The technician sent to start-up the device was, tragically,killed by the ignition of the pre-mixed reactants. Themarketer was so overwhelmed by this event that itterminated activities in thermal spray equipment sales,including HVAF which had not been involved.Why Not Use HVOF Advantages For Spraying Wire?

We can. With the aim of eliminating water cooling ofHVOF equipment, it was found that a strong oxygen vortexflow along the bore wall could stretch the hot flame wellalong the bore’s length before over-heating the the barrel.For maximum bore lengths, the fuel is injected axially intothe low pressure vortex “eye” passing centrally along thebore’s axis. This effect was studied carefully and it wasfound that the exiting supersonic jet does a beautiful jobusing wire introduced into the jet just beyond the boreexit. The advantages of spraying with uncooled HVOF isthat the penalty of a heat loss of up to 25% when watercooling is required, is avoided. Simplicity of construction isremarkable – only one, or two, small pieces of copperrequired, and, for most designs, total weights under one

Figure 2. Photomicrograph of powder-sprayed Stainless Steelusing 1,000 psig oxygen pressure using a water-cooled spraygun with 18 in long nozzle length.

Figure 3. The spray gun of Fig (2) used to spray tungsten-carbide/cobalt powder using 1,000 psig Oxygen.

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pound even for units consuming up to 3,000 scfh ofoxygen. United States patent No. 7,628,606,issued in2009, covered the design of such systems, both for heatingand propulsion purposes. The single claim of the patentlimits the L/D ratio of the bore to a minimum of 6. (L is thebore length, D its minimum inner diameter.) Theexperimental work on this vortex application dates back 6years to before 2008 (See fig. 1 for a typical wire-madecoating.) Short length guns, at that time, were of littleinterest.

With the growing interest of HVOF coating on the innerwalls of small diameter pipes and automotive cylinders, therestriction requiring relatively long nozzles began to beseen as a problem under ‘606. A continuing researchprogram to lower the L/D ratio to under 2 had provensuccessful. United States Patent No. 8,455,056 issued inJune 2013 reduced this minimum useful ratio to under 3.Patent ‘056 simply moves the fuel entry holes into the boreaway from the stagnant “eye” to the vortex high-velocitygases immediately surrounding the “eye”. What produced adiffusion flame under ‘606 became a pre-mixed flame under‘056. The older patent technology produced the highestpossible jet velocities. ‘056 has a lower velocityj, but ahigher temperature, and an “L” about half as long for thesame bore diameter.

At this writing, a new patent application is underexamination. It reverses the fuel and oxygen flow positionswith the fuel flowing adjacent to the bore wall — theoxygen along the bore axis. It was determined that L/Dratios as low as 2 are possible. This third step in thegeometry of the flows of reactants allows burner borelengths as short as ¾ in. for small bore diameters.

A recent improvement in short burner lengths utilizesvortex flow of each of the reactants into the bore. Themixing of these reactants is so rapid that the bore lengthfor a 3/8 in. ID bore is only 5/8 in. The L/D ratio is about1.7. This allows a burner length of only ¾ in. Such smalllength burners, arranged to impact their supersonic jetsradially against the inner wall, show promise of being ableto produce coatings in pipes down to 2 in. diameter. In closing this section, a major advantage found for HVOF

wire spraying is the ability to use large wire or roddiameters. Spray gun V 1/8 sprays rods up to 5/16 in.diameter. The increased area of the rod surface exposed toflame-jet heating allows for better hear transfer. Nearlystraight rods are required with less than ¼ in. castdeflection per foot of rod length. Alternatively, up to threewires, twisted together to form a straight length, may beused to an advantage. The smaller the wire diameter, thegreater the surface area-to-mass becomes. For Those Desiring “Cold Spray”, HVOF-PoweredEquipmentUsing vortex-stabilized units, as described above, cold-

spray, warm-spray, and hot-spray, each producingimpact-fusion, are possible. It is not the same though.Outside water cooling is necessary with nozzle lengths upto 16 in. long using ½ in. bores. The principle is simple.The first couple of inches after the reactants have beenintroduced into the bore, may be un-cooled. When theflame within the bore is fully stabilized, a small flow ofquench water is introduced. Allowing time for a sufficientamount of evaporation of this water to begin limiting thejet stream temperature within the bore — about 6 inches

History continued from page 5.

Figure 1. Photomicrograph of a typical HVOF wire-sprayedcoating of a 316 Stainless Steel using a non-water cooled gun.

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—, then add the powder. Adjust the quench water flow sothat the powder being accelerated never melts. It has morethan 8 in., or so, to travel to the exit. Arrange the totalbore length to produce impact fusion of the lowest meltingpoint of the metals required; while reducing the quenchwater exiting the bore to about zero. In some cases a smallamount of liquid water may be an advantage —particularly, when it is fully vaporized by the jet a smalldistance beyond the exit. Maximum flows of quench waterused is about 30 gallons per hour, using a ½ in. diameterbore.Recently, powder has been used in both the ‘606 style

burner and the double-vortex short spray gun. Theinjection-point is about 1/8 in. prior to the bore exit(similar to plasma spraying). The coatings included suchmaterials as aluminum, Ni-Al, chrome-carbide, tungsten-carbide/cobalt, and Ni-Cu. The coatings look excellent. Theheated particle plumes within the accelerating jets werebarely visible in a lighted-room. It is possible that open-air, high-velocity jets are better for accelerating particlesthan for heating them. It may be that these coatings wereproduced by “impact fusion” (but, just a guess). Figure 4 isa view of a possible arrangement of such a double-vortexset-up.The Substitution of Thin Metal Strips in Place of WiresThe advantage of this is the nearly doubling of the heat

transfer area of the heat-exposed metal surface of a stripover that of wire weighing the same per unit of length.(See Figure 6 of reference (4) on page 8.) Although higherspray rates and finer spray particles are obtained, I don’tbelieve any manufacturer, or user, would chose to use it.See Figures (5), (6), and (7) on page 8. The question is, “Isthe high spray rate shown in (6) too much for the job?” (Itis about 30 lb/hr.) If so, just reduce it by the correctamount.A more detailed sketch is shown of this enlarged zone to

about 6 in. beyond the spray gun exits of Figures 5, 6, and7. In this view, shown in Figure (8), a visual depiction isattempted. The spray guns illustrated are 1 in. long with a1 in. diameter. The added length of the support may beeliminated by connecting the tubes delivering thereactants radially to the spray guns within the boundariesof their 1 in. lengths. Other Applications of Burner Types Discussed To NowImportant uses for this technology other than thermal-

spray exists. Rock drilling has been discussed anddemonstrated. In spallable-rock drilling, solid chips areseparated from the rock mass by stresses set-up using theintense temperature gradient imposed at the surface wherethe flame-jet impinges. The best types of rock are,basically, quite hard. Included are sandstone, granite,dolomite, dolomitic marble, some basalts, and taconite.Drilling to deep depths is complicated by having to providean upward assist for chip removal. Holes to about one milein depth may escape this complication. Included uses, to amile in depth, include general heating purposes. For theConcord, New Hampshire Granite the rock temperature atthe one-mile depth adds a near-surface temperature of

Figure 4. Sketch of apparatus using a 2V 3/8-3/4 spray gunto powder-spray inside diameters of pipes and automotivecylinders. Combustion-bore 3/8 in. diameter with 5/8 in.length. L/D = 1.7.

Become a Member of theInternational Thermal Spray AssociationYour company should join the International Thermal

Spray Association (ITSA) now! ITSA is now a StandingCommittee of the American Welding Society expandingthe benefits of company benefits. As a company-mem-ber professional industrial association, our mission isdedicated to expanding the use of thermal spraytechnologies for the benefit of industry and society.ITSA members invite your company to join us in thisendeavor. See pages 16-19.

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History continued from page 7.55°F to that of the temperature-gradient produced 80°F,for a total of 135°F. Holes of less depth (up to about 600ft) are used for heat-pump installations. Water wells, ofcourse, require random depths. Returning to the hightemperature-gradient granites, depths to two miles can

produce temperatures of around 200°F— capable ofproducing electrical energy (geo-thermal heating).Other uses include abrasive blasting, heat-treating, steam

cleaning, and the like.

Figure 5. A ½ in. wide by 0.025 in. steel strip being sprayedby a V 1/8-3/4 burner using 500 scfh of Oxygen with a sprayrate of about 20 lb/hr.

Figure 6. The wire strip of Fig. (5) being sprayed from anearly vertical path into the jet from a 2V 3/8-3/4 spray gunat a spray rate of about 30 lb/hr using about 2,000 scfh ofOxygen.

Figure 7. A 1 in. wide by 1/8 in. thick zinc strip using the V1/8-3/4 burner — spray rate, “very high”.

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Random Views and CommentsEarly in this report four “experts” in the metallizing

business produced a plasma spray application theory whichsoon was to be proven quite wrong. Plasma-jettemperatures are so high that tungsten-carbide particlesare badly decarburized reducing wear life to nearly 50% ofthose for the D-Gun. Luckily, plasma has worked well fornearly everything else. (Perhaps the D-Gun is really the firstto produce impact fusion, and possibly even before theRussians.)I wish to thank Professor Heinrich Kreye, Universität Der

Bundeswear Hamburg, for the important help he hasgiven me. He has been responsible for most of the pho-tographic examination of the many different wirecoatings. In particular, I learned that 8% content ofoxygen in molybdenum is optimum. He, very generously,gave me a large amount of the slippery metal (to put onthebottom of my ski s). I never did. I later learned theprice of the wire — nearly $100 per pound.Figure 7 shows a strip of zinc, measuring 1 in. wide by

1/8 in. thick, being sprayed by the V 1/8-3/4 double-vortex device. This use of the HVOF process has an

Figure 8. Sketch showing photographically hidden zones of Fig. (5).

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INDUSTRY

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History continued from page 9.important advantage over zinc arc-melting spray processes.The arc actually vaporizes up to 10% of the zinc beingsprayed. This vapor cools rapidly and oxidizes in thesurrounding atmosphere resulting in clouds of white dustcomposed of nano-sized, dangerous-to-breathe, particles.No such clouds result using HVOF.

In my opinion, both thermal spray users and theirsuppliers of the equipment are responsible for the slowprogress being made using the many new processes thatcould advance the quality of modern coatings. Higherimpact velocities are needed. Jet heating must be correctto maximize the properties of the impacting particles. I canunderstand the decisions of both parties. The users do notwant to take a chance using new technology when presentcoatings are acceptable to their customers. Themanufacturers do not wish to jeopardize the continuingsale of its presently well-operating products. Foreign-made equipment has not been discussed. I know

very little about them.These double-vortex units do a superb job spraying

molybdenum wire — better than the single vortex,probably due to the exit jet’s higher temperature.

A good question for thermal spray users to ask theirequipment manufacturers is, “Why don’t you provide uswith equipment that makes the best-possible coatings?”A good question for equipment manufacturers of thermal

spray apparatus is, “If we provide equipment capable ofproducing optimum coatings requiring 500 psig inletoxygen pressure, will you use it?”In closing, I must quote the following from Section 5 of

Reference 5, “The HVOF-sprayed Wc-Co-Cr coatings showeda wear rate that was an order of magnitude higher thanthat of the HVAF Wc-Co-Cr coatings”.

REFERENCES:(1) United States Patent No. 2,960,594 issued in 1960 toMerle L. Thorpe and assigned to the Plasma FlameCorporation.(2) M.L. Thorpe and H.J. Richter, “A Pragmatic andComparison of HVOF Processes”, 1992, Hobart TAFATechnologies, Inc., Concord, NH(3) T.C. Hanson and G.S. Settles, “Particle Temperature andVelocity Effects on the Porosity and Oxidation of an HVOFCorrosion-Control Coating”, ASM TSS Journal of ThermalSpray Technology, SEP 2003, p. 403.(4) United States Patent No. 4,788,402.(5) L. Jacobs, M.M. Hyland, and M. DeBonte, “Study of theInfluence of Microstructural Properties on the Sliding-WearBehavior of HVOF and HVAF Sprayed WC-Cermet Coatings”,ASM TSS Journal of Thermal Spray Technology, MAR 1999. For more information, contact author Jim Browning via

phone at 603.448.4729.


Where is your advertisment? From classifiedto business-card size to full page sizes, we can workwith your format. Please visit www.spraytime.org forrate information, email the SPRAYTIME publishing officevia [email protected] or contact Editor KathyDusa at 440.357-5400, [email protected].

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Where is your article? We encourage you tosend articles, news, announcements and information to

[email protected].

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prevent coating shrinkage issues and enhance the adhesionof the thermal spray. The generator rotor was then sprayedwith a 25 micron coating of Molybdenum, which is abonding material, to optimize the adhesion of the top coatof silver. A final coating of silver was then added to achievethe specified outside diameter on the shaft. Silver ischosen due to its high levels of conductivity compared toother materials such as steel and even copper. In a typicalapplication, a coating 250 microns thick of silver would besprayed.The flamespray system was chosen instead of arcspray due

to the higher efficiency that can be achieved with a morecontrollable application process. The flamespray systemwith small diameter wire will also produce a fine, closestructured coating that will maximise the conductivity ofthe applied silver, which is the main purpose of thecoating.

The Metallisation MK61 is an oxygen-acetylene fuelledflamespray system, primarily for spraying engineeringcoatings of steels, bronzes, copper and molybdenum. Thelightweight, robust pistol offers the possibility to reclaimdamaged parts for small to medium sized applications, as ithas a continous nozzle set up, ideal for engineeringcoatings. Molybdenum can also be sprayed with the MK61as a soft bond coat through to a very hard, wear resistantcoating. The MK61 is also ideal for use with RFI Screening’s mobile

thermal spraying unit, as, although the pistol is light-weight, it is robust, sturdy and well balanced making itvery easy to handle. Requiring only gases and compressedair, it also lends itself to site applications where 3-phaseelectricity may not be available. It comes with a variety ofhose lengths to suit a wide range of applications wheredifficult access may be an issue.RFI Screening was established in 1982. At its industrial

site in Ware in Hertfordshire it has five blast rooms, fivecabinets to cover most blasting processes, as well as itsmobile blasting and thermal spraying unit. RFI Screening’sexpertise in applying surface treatments to a wide range offerrous and non-ferrous substrates has resulted in thecompany doing projects overseas, as well as in the UK. Themost recent thermal spraying job was completed in SaudiArabia on a Saudi Naval vessel. Steve Noble, Owner of RFI Screening, says: “We choose

Metallisation equipment because the company is verycustomer focused and were very professional in theirdealings with us. We were also thrilled with the quality ofthe service and speed of delivery of the equipment. Theequipment is reliable, easy to use and complements ourservices perfectly. I would happily recommendMetallisation to any company looking for good quality

Thermal Spraying Silver continued from page 1.

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Fax No. +44 (0)1384 237 196 www.metallisation.com

M

16:32

Thermal Spraying Silver continued from page 11.equipment and excellent knowledge and understanding ofthermal spraying.”

Metallisation provides thermal spraying equipment,consumables and expert advice to industries around theworld and has been doing so since 1922. Its equipment hasbeen designed for a wide range of uses, from universalcorrosion protection of steel fabrications, to engineeringcoating applications, such as the one described in thisfeature. Engineering application include work within theautomotive, aerospace, oil and gas and manufacturingindustries. For more information please contact Stuart Milton, Sales

Director, +44 (0) 1384 252 464 or visitwww.metallisation.com

See advertisment page 13.

ASM International Announces New Releaseof ASM Alloy Center Database

ASM International is pleased to announce a major newrelease of the ASM Alloy Center Database™, providing fullysearchable, online access to authoritative materials data.

Content includes worldwide equivalencies for alloys,mechanical, physical and chemical property data, andcorrosion characteristics in various environments. Accessall new alloy data sheets, stress-strain curves, creep curves,time-temperature curves and other engineering graphs forthousands of significant alloy designations.“The Alloy Center Database has been a trusted source of

engineering data for metals and alloys for more than adecade,” said Scott D. Henry, Senior Manager of ContentDevelopment and Publishing for ASM International. “Thislatest update increases the value of this dataset andenables additional useful functionality for users.”

This important release features the below key contentupdates and software enhancements:

• Data Sheets & Diagrams • Alloy Finder • Materials Property Data • Coatings Data • Corrosion Performance Data • Database Software

Individual, small multi-user and enterprise wide licensesare available.

For more information, contact Denise Sirochman viaphone 440.338.5409

Do you know of online thermal spray films?Send information to [email protected] for

sharing in future issues of SPRAYTIME.

Where is your employee news???Send to [email protected]

One Nation . . . Possibilities!

Call (888) 665-5525

Nation Coating is North America’s leader in the development and use of application-specific thermal spray coatings. We specialize in innovative, high-performance solutions for aerospace, military, powergen, automotive, petrochem, pulp and paper, printing, and industrial applications.

Advanced Met Lab for R&D and testingDedicated spray booth for client and academic testingFAA Repair – AS9100:2009 Rev C – NADCAP

Sister Company ofStronghold Coatings

A Veteran-owned Business

Nowin Our

Year ofService

NATIONCOATINGSYSTEMS

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Mass Flow Control SystemsMetallisation’s Plasma, HVOF and automated fl ame spray systems all have mass fl ow control for ease of operation and optimum repeatability. The systems are PLC controlled with a familiar Windows interfaced touch screen that users fi nd easy to operate. All of Metallisation’s systems are high quality, compact and easy to use.

METJET 4L - Liquid Fuel HVOF system

MK74-PC - Powder Flame Spray system

Plasma PS50M-PC - 50kW Plasma Spray system

Manual Spray SystemsMetallisation’s manual systems are suitable for engineering coatings where a combination of manual and tool post mounted spraying is required. Our range includes oxy-acetylene fl ame spray systems and a full range of hand held or automated arc spray systems from 250A to 1,500A.

Excellent Customer ServiceMetallisation’s customer service is second to none, including an exceptional after sales service. With a network of distributors around the globe, and a team of fully qualifi ed and highly experienced service engineers, customers can rely on the highest standard of care, wherever they are in the world.

Metallisation Limited Peartree Lane, Dudley, West Midlands DY2 0XH EnglandTel No. +44 (0)1384 252 464 Fax No. +44 (0)1384 237 196 www.metallisation.com

MK66E-PC - Wire Flame Spray system

Global Engineering Coating Equipment

PCC - Pistol Control Console Our proven mass fl ow control system that can be confi gured to operate a range of plasma or HVOF pistols, powder feeders and power supplies commonly used in the industry. The system can operate liquid fuel or gas fuel HVOF pistols and plasma pistols up to 80kW.

operate a range of plasma or HVOF pistols, powder feeders and power

liquid fuel or gas fuel HVOF pistols

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INDUSTRY

NEWS

Farr Gold Series® Dust Collectors Spark Improvements for Electronic

Component ManufacturerVishay Components India Pvt. Ltd. (Pune, India) is one of

the largest manufacturers of semiconductors and passivecomponents in the world, with several plants spread acrossthe Americas, Europe and Asia. In India, Vishay has beenmanufacturing these electronic components with aproduction set-up that included thermal spray boothsserved by dust collectors containing horizontally-mountedfilter cartridges.

Vishay used two of these collectors imported from Europefor their two thermal spray booths for spraying zinc andaluminum, and a locally supplied dust collector for theirepoxy coating application. Vishay was concerned with twomain issues: dust spreading in their thermal spray andepoxy coating booths; and higher emission levels, whichthe old dust collectors were not able to handle to Vishay’ssatisfaction. To address these concerns, they approachedCamfil India for a possible solution.Camfil India and Camfil APC Malaysia cooperated in this

project to provide the customer with sales, marketing andtechnical support. After a series of surveys andpresentations, Vishay placed an order for two Farr GoldSeries® GS32 dust collectors for the thermal spray booths.Each collector handles system airflow of 7500 m3/hr and is

equipped with 32 high efficiency filter cartridges. Vishaysimultaneously ordered a smaller Gold Series GS6 collectorcontaining six cartridges for the epoxy coating machines.All units were equipped with explosion vents andmechanical isolator dampers. Manufactured at Camfil APC’sheadquarters plant in Jonesboro, Arkansas, they reachedthe customer in January 2013.In addition to the new dust collectors, Camfil provided a

design plan for replacing all the existing ductwork. Thedust collectors were installed and commissioned in June2013 under Camfil APC Malaysia’s supervision.Notable improvements documented by Vishay include:• They have nearly eliminated the spread of dust in

booths due to suction velocities being almost doubled.The results are cleaner booths and rooms – and happieremployees.

• Electrical energy costs are lower due to energy-efficient10 HP motors for blowers, instead of 20 HP motors usedin the previous dust collectors.

• The new dust collectors operate at a very low noiselevel compared to the previous equipment.

The Farr Gold Series dust collector is popular for a rangeof thermal spray applications because of several designfeatures that contribute to greater reliability and reducedmaintenance. A high entry cross flow inlet eliminatesupward can velocities that can hold fine powder up in thefilters, reducing re-entrainment of the fine particles.

Vertically arranged filters shed all the metalparticulate, unlike horizontally mountedfilters which allow the metal to build on topof the filter. The high efficiency filterscapture 99.99% of particulates at 0.5µ orlarger. Special treated filter media and anopen-pleat media design contribute tolower pressure drop operation and longfilter service life.For more information, contact Camfil APC

at (800) 479-6801 or (870) 933-8048;email [email protected], webwww.camfilapc.com.

Both GS32 dust collectors are in place after replacing two horizontalfilter-mount collectors at Vishay Components.

Tungsten CarbidesChromium CarbidesMetal Powders

Pure Metal PowdersSpecial Order

1901 Ellis School RoadBaytown, Texas 77521

Lineage Alloys offers a comprehensive range of thermal spray powdersto the industry.

Please visit our website www.lineagealloysllc.com to view ourproducts, services and special order capabilities.Lineage Alloys technical staff are ready to discuss your thermal spray

powder requirements and determine how we can best meet your needs.For information, contact us at 281.426.5535, fax: 281.426.7484,

email: [email protected]

Gold Series GS6 dust collector for epoxy coating fumes/dust captureapplication.

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www.praxairsurfacetechnologies.com

Copyright © 2012 Praxair S.T. Technology, Inc. All rights reserved.Praxair, the Flowing Airstream design, the TAFA logo and the FLAME design are trademarks of Praxair S.T. Technologies, Inc. TAFA Incorporated is a wholly owned subsidiary of Praxair Surface Technologies.

Thermal spray coating equipment and consumables from Praxair

What: Why: Services:

installations and training, calibrations and repairs

Half a century of leadership

-brand coating equipment

Thermal spray powder and wire Replacement parts HP/HVOF �, arc spray, plasma systems and more

INDUSTRY

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Become a Member of The International ThermalSpray Association

Your company should join theInternational Thermal SprayAssociation (ITSA) now! As acompany-member, professional

industrial association, our mission is dedicated toexpanding the use of thermal spray technologies for thebenefit of industry and society. ITSA members invite and welcome your company to join

us in this endeavor.New - All ITSA company members are now also

Supporting Members of the American Welding Societywhich includes five individual AWS memberships.Whether you are a job shop, a captive in-house facility,

an equipment or materials supplier, an educational campus,or a surface engineering consultant, ITSA membership willbe of value to your organization.As an ITSA member, your company has excellent marketing

exposure by being listed centerfold in our SPRAYTIMEnewsletter and many other benefits.Visit www.thermalspray.org.


NEW “Supporting Societies” MembershipThe International Thermal Spray Association now

has a “Supporting Societies” membership categoryto establish communication with otherassociations/societies involved in thermal spray andsurface engineering activities worldwide. See the Supporting Societies listing on page 17. This is ideal for membership exchange between

organizations. Contact Kathy Dusa at theheadquarters office email to [email protected]

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J OB S HO P M EMB E R C OMPAN I E SAccuwright Industries, Inc. - Gilbert, AZ, USA

www.accuwright.com 480.892.9595Mr. David Wright, [email protected]

Atlas Machine & Supply, Inc. - Louisville, KY USAwww.atlasmachine.com 502.584.7262Mr. Richie Gimmel, [email protected]

Bender US - Vernon, CA USAwww.benderus.com 323.232.2371Mr. Doug Martin, [email protected]

Byron Products - Fairfield, OH USAwww.byronproducts.com 513.870.9111Mr. Keith King, [email protected]

Cascadura Industrial S.A. - Sorocaba SP Brazilwww.cascadura.com.br 55.15.3332.9622Mr. Ricardo Leoni, [email protected]

Castolin Eutectic - Lausanne, Switzerlandwww.castolin.com 0041.21.694.1132Ms. Christina Swan, [email protected]

Cincinnati Thermal Spray, Inc. - Cincinnati, OH USAwww.cts-inc.net 513.793.0670Ms. Cindy Abbott, [email protected]

Curtiss-Wright Surface Technologies - East Windsor, CT USAwww.metalimprovement.com 860.623.9901Mr. Peter Ruggiero, [email protected]

Ellison Surface Technologies, Inc. - Mason, OH USAwww.ellisonsurfacetech.com 513.770.4928Mr. Eric Dolby, [email protected]

Exline, Inc. - Salina, KS USAwww.exline-inc.com 785.825.4683Mr. Doug Porter, [email protected]

F.W. Gartner Thermal Spraying - Houston, TX USA www.fwgts.com 713.225.0010Mr. Jason Falzon, [email protected]

Ferrothermal Spray Coating - Monterrey N.L. Mexicowww.drexel.com.mx 52.818.331.0816Mr. Renato Drexel, [email protected]

Hayden Corporation - West Springfield, MA USAwww.haydencorp.com 413.734.4981Mr. Dan Hayden, [email protected]

Nation Coating Systems - Franklin, OH USAwww.nationcoatingsystems.com 937.746.7632Mr. Larry Grimenstein, [email protected]

New England Plasma Development Corp. - Putnam, CTwww.neplasma.com 860.928.6561Ms. Maureen M. Olshewski, [email protected]

Plasma Coatings - Union Grove, WI USAwww.plasmacoatings.com 262.878.2445Mr. Daniel Cahalane, [email protected]

Plasma Technology, Inc. - Torrance, CA USAwww.ptise.com 310.320.3373Mr. Robert D. Dowell, [email protected]

St. Louis Metallizing Company - St. Louis, MO USAwww.stlmetallizing.com 314.531.5253Mr. Michael Murphy, [email protected]

Sharkskin Coatings and Surface Technologies - Canadawww.sharkskincoatingsltd.com - 519.627.0060Ms. Shari Webber, [email protected]

Spraymetal, Inc. - Houston, TX USAwww.schumachercoinc.com 713.924.4200Mr. Andrew Schumacher, [email protected]

Superior Shot Peening, Inc. - Houston, TX USAwww.superiorshotpeening.com 281.449.6559Ms. Mollie Blasingame, [email protected] Group - Daytona Beach, FL USAwww.taratechnologies.com 386.253.0628Ms. Amy Davis, [email protected]

United Surface Technologies - Altona, Melbourne Australia61.393.98.5925Mr. Keith Moore, [email protected]

S U P P L I E R M EMB E R C OMPAN I E SAdvanced Material Services - West Chester, OH USA

513.907.8510Mr. Jim Ryan, [email protected]

AMETEK, Inc. - Eighty-Four, PA USAwww.ametekmetals.com 724-225-8400 Ms. Cindy Freeby, [email protected]

Ardleigh Minerals, Inc. - Beachwood, OH 44122 USAwww.ardleigh.net 216.464.2300Mr. Ernie Petrey, [email protected]

Bay State Surface Technologies, Inc. - Auburn, MA USAwww.baystatesurfacetech.com 508.832.5035Mr. Jay Kapur, [email protected]

Camfil APC - Jonesboro, AR USAwww.farrapc.com 800.479.6801Mr. Dale Gilbert, [email protected]

Carpenter Powder Products - Pittsburgh, PA USAwww.carpenterpowder.com 412.257.5102Mr. Chip Arata, [email protected]

Centerline Windsor Limited - Windsor, ON Canadawww.supersonicspray.com 519.734.8464Mr. Julio Villafuerte, [email protected]

Donaldson Torit - Minneapolis, MN USAwww.donaldsontorit.com 800.365.1331Ms. Lori Lehner, [email protected]

Flame Spray Technologies, Inc. - Grand Rapids, MI USAwww.fst.nl 616.988.2622Mr. Terry Wilmert, [email protected]

ITSA Mission StatementThe In te rna t iona l The rma l Sp rayAssociat ion, a Standing Committee ofthe Amer ican Welding Society, i s aprofess iona l indust r ia l o rganizat iondedicated to expanding the use ofthermal spray technologies for thebenef i t of industry and society.

INTERNATIONAL

THERMAL

SPRAY

ASSOCIATION

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Visit us at www.thermalspray.org

Fujimi Inc. - Arlington Heights, IL USAwww.fujimico.com 847.398.6544Mr. Michael Akiyoshi, [email protected]

Genie Products, Inc. - Rosman, NC USAwww.genieproducts.com 828.862.4772Mr. Richard Grey, [email protected]

Global Tungsten and Powders Corp - Towanda, PA USAwww.globaltungsten.com 570.268.5393Mr. Paul Sedor, [email protected]

Globe Metal, Inc. - Sainte-Catherine, QC Canadawww.globemetal.com 450.645.9397Mr. Adam Rubin, [email protected]

Green Belting Industries LTD - Mississauga, ON, Canadawww.greenbelting.com 905.564.6712Mr. Tim Connelly, [email protected]

H.C. Starck North American Trading LLC - Newton, MA USAwww.hcstarck.com 617.407.9960 Ms. Ana Duminie, [email protected]

HAI Advanced Material Specialists - Placentia, CA USAwww.hardfacealloys.com 877.411.8971Mr. Daren Gansert, [email protected]

Haynes International - Mountain Home, NC USAwww.haynesintl.com 765.456.6094Mr. Richard Hoskinson, [email protected]

Kennametal Stellite Company, Inc. - Goshen, IN USAwww.stellite.com 574.534.8631Mr. David A. Lee, [email protected]

Linde Gas USA LLC - Murray Hill, NJ USAwww.us.linde-gas.com 908.771.1353Dr. Joe Berkmanns, [email protected]

Lineage Alloys - Baytown, TX USAwww.lineagealloys.com 281.426.5535Mr. Gordon Jones, [email protected]

MesoCoat, Inc. - Euclid, OH USAwww.mesocoat.com 216.453.0866Mr. Anupam Ghildyal, [email protected]

Metallisation LimitedDudley West Midlands, United Kingdomwww.metallisation.com +44.1384.2524646Dr. Terry Lester, [email protected]

North American Höganäs - Hollsopple, PA USAwww.hoganas.com 814.361.6875Mr. Andy Hoffman, [email protected]

PM Recovery, Inc. - Harrison, NY USAwww.pmrecovery.com 860.536.5396Mr. Paul Sartor, [email protected]

Polymet Corporation - Cincinnati, OH USA www.polymet.us 513.874.3586Mr. Bob Unger, [email protected]

Praxair Surface Technologies - Concord, NH USAwww.praxair.com/thermalspray 603.224.9585Mr. Richard Thorpe, [email protected]

Progressive Surface - Grand Rapids, MI USAwww.ptihome.com 800.968.0871Mr. Bill Barker, [email protected]

Saint-Gobain Ceramic Materials - Worcester, MA USAwww.coatingsolutions.saint-gobain.com 508.795.2351Mr. Howard Wallar, [email protected]

Sulzer Metco (US) Inc. - Westbury, NY USAwww.sulzermetco.com 516.334.1300Ms. Mae Wang, [email protected]

Thermach, Inc. - Appleton, WI USAwww.thermach.com 920.779.4299Mr. David Lewisen, [email protected]

Thermion, Inc. - Silverdale, WA USAwww.thermioninc.com 360.692.6469Mr. Dean Hooks, [email protected]

ASSOCIATE MEMBER ORGANIZATIONSAdvanced Materials and Technology Services, Inc.

Simi Valley, CA USA www.adv-mts.com - 805.433.5251Dr. Robert Gansert, [email protected]

ASM Thermal Spray Society - Materials Park, OH USA http://tss.asminternational.org 440.338.5151Randall S. Barnes, [email protected]

State University of New York at Stony BrookStony Brook, NY USAwww.ctsr-sunysb.org 631.632.8480Prof. Sanjay Sampath, [email protected]

S U P POR T I N G M EMB E R S O C I E T I E SDVS, The German Welding Society

www.die-verbindungs-spezialisten.deMr. Jens Jerzembeck, [email protected]

GTS e.V., The Association of Thermal Sprayerswww.gts-ev.de +49.89.31001.5203Mr. Werner Kroemmer, [email protected]

IMM, Institute of Materials Malaysiawww.iomm.org.my 603.5882.3584Mr. Johar Juhari, [email protected]

JTSS, Japan Thermal Spray Society+81.6.6722.0096 www.jtss.or.jpMr. Nick Yumiba, [email protected]

MPIF, Metal Powder Industries Federationwww.mpif.org 609.452.7700Mr. James R. Dale, [email protected]

TSCC - Thermal Spraying Committee of China Surface Engineering Association

www.chinathermalspray.org +86.10.64882554Prof. Huang Xiaoou, [email protected]

INTERNATIONAL

THERMAL

SPRAY

ASSOCIATION


I T SA H e a d q u a r t e r sPost Office Box 1638, Painesville, OH 44077 USAvoice/cell: 440.357.5400 • fax: [email protected] • www.thermalspray.org

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The International Thermal Spray Association is closelyinterwoven with the history of thermal spray developmentin this hemisphere. Founded in 1948, and once known asMetallizing Service Contractors, the association has beenclosely tied to most major advances in thermal spraytechnology, equipment and materials, industry events,

education, standards andmarket development.

A company-memberassociation, ITSA invites allinterested companies to talkwith our officers, andcompany representatives tobetter understand memberbenefits. A complete list ofITSA member companies andtheir representatives can befound at www.thermal-spray.org

ITSA Mission StatementT h e I n t e r n a t i o n a l T h e rm a l S p r a y

A s s o c i a t i o n , a S t a n d i n g C omm i t t e e o fT h e Am e r i c a n We l d i n g S o c i e t y, i s ap r o f e s s i o n a l i n d u s t r i a l o r g a n i z a t i o nd e d i c a t e d t o e x p a n d i n g t h e u s e o ft h e rm a l s p r a y t e c h n o l o g i e s f o r t h eb e n e f i t o f i n d u s t r y a n d s o c i e t y.

OfficersChairman: Jason Falzon, FW Gartner Thermal SprayingVice-Chairman: Bill Mosier, Polymet CorporationCorporate Secretary: Kathy DusaExecutive Committee (above officers plus the following)Richard Grey, Genie Products, Inc.Larry Grimenstein, Nation Coating SystemsDan Hayden, Hayden CorporationDavid Wright, Accuwright Industries, Inc.

ITSA Scholarship OpportunitiesThe International Thermal Spray Association offers annual

Graduate Scholarships. Since 1992, the ITSA scholarshipprogram has contributed to the growth of the thermal spraycommunity, especially in the development of newtechnologists and engineers. ITSA is very proud of thiseducation partnership and encourages all eligibleparticipants to apply. Please visit www.thermalspray.org forcriteria information and a printable application form.

ITSA Thermal Spray Histor ica l Col lect ionIn April 2000, the International Thermal Spray

Association announced the establishment of a ThermalSpray Historical Collection which is now on display at theState University of New York at Stony Brook in the ThermalSpray Research Center, USA. Growing in size and value, there are now over 30 different

spray guns and miscellaneous equipment, a variety of spraygun manuals, hundreds of photographs, and several historicthermal spray publications and reference books. Future plans include a virtual tour of the collection on the

ITSA website for the entire global community to visit.This is a worldwide industry collection and we welcome

donations from the entire thermal spray community.

ITSA SPRAYTIME NewsletterSince 1992, the International Thermal Spray Association

has been publishing the SPRAYTIME newsletter for thethermal spray industry. The mission is to be the flagshipthermal spray industry newsletter providing company,event, people, product, research, and membership news ofinterest to industrial leaders, engineers, researchers,scholars, policy-makers, and the public thermal spray

Become a Member of The International Thermal Spray Association

Your company should join the International Thermal SprayAssociation (ITSA) now! As a company-member,professional industrial association, our mission isdedicated to expanding the use of thermal spraytechnologies for the benefit of industry and society. ITSA members invite and welcome your company to join

us in this endeavor.New - All ITSA company members are now also

Supporting Members of the American Welding Societywhich includes five individual AWS memberships.Whether you are a job shop, a captive in-house facility,

an equipment or materials supplier, an educational campus,or a surface engineering consultant, ITSA membership willbe of value to your organization.

One valuable member asset is our annual membershipmeetings where the networking is priceless! Our meetingsprovide a mutually rewarding experience for all attendees -both business and personal. Our one-day technicalprogram and half-day business meeting balanced by socialactivities provide numerous opportunities to discuss theneeds and practices of thermal spray equipment andprocesses with one another.

As an ITSA member, your company has excellentmarketing exposure by being listed centerfold in theSPRAYTIME newsletter.ITSA member companies are also highlighted in the ITSA

booth at several trade shows throughout the year(International Thermal Spray Conference ITSC, FabtechThermal Spray Pavilion and Conference, FAbtech Canada,Power-Gen, Society of Vacuum Coaters (SVC),TurboMachinery, NACE and TurboExpo).For more information, contact Kathy Dusa 440.357.5400

or visit the membership section at www.thermalspray.org.

Chairman Falzon

INTERNATIONAL

THERMAL

SPRAY

ASSOCIATION


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INDUSTRY

NEWS



Masan Group and H.C.Starck to Establish

Tungsten Chemical Joint VentureH.C. Starck, a leading worldwide manufacturer of

technology metals and one of the biggest companies in theglobal tungsten industry, and Nui Phao Mining Company(Nui Phao), a subsidiary of one of Vietnams largest privatesector business groups, Masan Group Corporation (HOSE:MSN, Masan Group), have announced the signing ofdefinitive agreements to establish a joint venture for theproduction of value-added tungsten chemicals in Vietnam.

Nui Phao and H.C. Starck will own 51% and 49%respectively of the joint venture, which will process all ofNui Phaos tungsten concentrate into higher value-addtungsten chemicals, including ammonium paratungstate(APT) and blue tungsten oxide (BTO). The joint venturecompany will have an installed capacity of 6,500 tonstungsten trioxide per annum. H.C. Starck will manage thejoint venture and has committed to buy a significant shareof the production for its own internal use. The company willalso support marketing of the remaining product throughthe joint venture.

Andreas Meier, President and CEO of H.C. Starck said,Masan has developed a world-class mining operation andthe Nui Phao mine will be a stable source of material forthe joint venture. For H.C. Starck this joint venturestrengthens our leading position as a global tungstenproducer and increases our manufacturing footprint in Asia.Based on the secured supply of tungsten concentrate andour recycling capabilities, we can provide our customerslong-term supply security independent from regulatoryrestrictions and we expect less price volatility for themineral.

H.C. Starck has significant experience in the tungstenprocessing business, which is a niche and technologicallyintensive industry, and will therefore be responsible for theindustrial management of the joint venture. Dominic Heaton, CEO of Masan Resources, a subsidiary of

Masan Group and the parent company of Nui Phao,commented, H.C Starck has world-class expertise in theprocessing of tungsten chemicals and oxides. With H.C.Starcks specialized know-how and technology, Masan Groupis able to contribute to Vietnams objective of becomingmore of a manufacturer of value-added products. Madhur Maini, CEO of Masan Group, said: H.C Starck is the

technology leader in the production of several high-technology metals. The partnership with H.C. Starck, one ofthe worlds largest tungsten players, will help Masancapture more of the tungsten value chain and is a

Continued on page 28.

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Join the ASM Thermal Spray SocietyOnline Community Forum

ASM TSS members welcome visitors to register andaccess the new searchable forum, as well as explore the

new online community.To subscribe, visit http://tss.asminternational.org,choose networking and forum for instructions.

INDUSTRY

NEWS

American Roller Celebrates 75 Years in Business

American Roller Company proudly announces its 75thAnniversary, the launch of a new website, and a newlocation. Founded in Chicago, IL in 1938, American Rollerhas built an industry-wide reputation for quality,responsive service, innovation, dependability and superiorvalue, and has consistently earned the confidence oforiginal equipment manufacturers and end-users in a widevariety of markets.

Over the years, asmanufacturing hasevolved, struggled, anddissipated, AmericanRoller has managed tonot only stay relevant,but to expand. During2012, American RollerCompany opened a newlocation in Houston,

TX. The Houston facility aids in the capacity to produce,manufacture, and most importantly exceed customers'needs, requirements, and expectations. It provides theopportunity to utilize technological advances, in turn,allowing them the capabilities to produce products withextremely tight tolerances. Additionally, 2013 plans includethe opening another new facility in Shanghai, China.

In conjunction with the anniversary, American Rollerwould also like to announce the launch of a brand newwebsite at www.americanroller.com. This new site allowsease of navigation while gaining knowledge on all thatAmerican Roller has to offer. While browsing throughproducts and services, learn how the company can helpincrease productivity. Find plant locations, fill out arequest for quote, and read about current news within thecompany.American Roller Company (www.americanroller.com), with

its Plasma Coatings Division (www.plasmacoatings.com),has manufacturing facilities throughout the United Statesand international licensees around the world. AmericanRoller currently manufactures a full range of syntheticrubber, polyurethane, ceramic and metal matrix coatings,hard coats, nylon, heated rollers, steel and composite coresand shafts, bowed rollers, and chilled rollers for theconverting, metals processing, business machine, graphicarts, pulp and paper and non-woven markets. Founded in1938, American Roller is committed to providing its valuedcustomers ever-improving roller performance.For more information, visit www.americanroller.com and

www.plasmacoatings.com

Watson Coatings LaboratoryAnnounces A2LA Accreditation

The Watson Coatings Laboratory, a division of WatsonGrinding and Manufacturing announces its A2LAAccreditation ISO 17025:2005.A2LA Accreditation ISO 17025:2005 is used by testing and

calibration laboratories that produce testing andcalibration results. The standard is specific in requirementsfor competence. Accreditation is a formal recognition of ademonstration of that competence. A prerequisite for alaboratory to become accredited is to have a documentedquality management system. Laboratories use A2LAAccreditation ISO 17025:2005 to implement a qualitysystem aimed at improving their ability to consistentlyproduce valid results.In recognition of the successful completion of the A2LA

evaluation process, accreditation is granted to thislaboratory to perform the following tests on metal powdersand thermal spray coatings:• Metal Powders - apparent density, flow rate, sieve

analysis• Hardness - Knoop & Vickers, Rockwell (B and C)• Thermal Spray Coatings - adhesion, area percentage

porosity, metallographic preparation, bondlinecontamination, coating thickness.

All QSLP test methods are in-house procedures.Watson Grinding and Manufacturing is a full-scale

machine shop, offering specialty carbide and ceramicthermal spray coatings via HVOF and Plasma application.Manufacturing and servicing a wide variety of parts,including shafts, valves, rotating and pump components,the company specializes in turning, milling, coating andgrinding exotic alloys, hard metals and large parts.

Strategic investments and technical innovations haveconsistently enhanced Watson Grinding’s capabilities. Theaddition of a robotic thermal spray facility and an on-sitemetallurgical laboratory in recent years have made WatsonGrinding a leader in the precise application of thermalspray coatings, dramatically extending the service life ofparts in highly corrosive or wear intensive environments.Machined parts are used in a variety of severe serviceprocesses and in various applications. The Watson CoatingsLaboratory is a division of Watson Grinding andManufacturing in Houston, TX.For more information, visit www.watsongrinding.com

Scholarship OpportunitiesSince 1991, the International Thermal

Spray Association Scholarship Programhas contributed to the growth of thethermal spray community. ITSA offers up to

three Graduate Scholarships of $2,000.00 each.Applications accepted April 15 through July 15 ONLY.Visit www.thermalspray.org scholarship area for details.

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INDUSTRY

NEWS

Cold Spray Enables Weldingof Crack-Sensitive Alloys

Case StudyAuthors: V. Juechter, T. Mitchell, T. Marrocco, and M. Nunn

Susceptibility to cracking is well known issue when powerbeam welding 6xxx series aluminium alloys. To preventcracking the weld metal composition is often modified byaddition of 4xxx series filler in wires or foil form. Whenwelding complex assemblies conventional fillers may bedifficult to introduce due to limited access. The cold spraytechnique offers the opportunity to coat all kinds ofirregular shapes with a buttering layer prior to welding.TWI has successfully investigated this new way of addingfiller material to overcome weld cracking issues.Principles and ProcessesThe cold spray process is used for coating applications

where lower thermal spray temperatures are beneficial. Themain advantages over conventional thermal sprayinginclude: the powder remains in the solid phase, lowersubstrate surface temperatures, less oxidation of thepowder and the substrate material, no metallurgicaltransformations and reduced residual stress formation. Thepowder is accelerated and impact on the surface wheredeformation, local heating and a bond occur. By repeatingthis process a near dense layer of increasing thickness isbuilt.Introduction of a cold sprayed layer may be the solution

for many welding challenges. In the case of electron beam(EB) welds only thin layers of filler material are needed tomodify the composition of the weld pool as the weld isnarrow. Electron beam welding locally melts the material atthe interface of two parts, forming a high integrity,normally autogenous, joint after solidification. EB weldingtakes place in a clean vacuum environment, can work fromlong stand-off distances and with a wide range of materialsand thicknesses. The process produces a relatively narrowsingle pass weld and is often chosen where thermal damageexcess distortion must be avoided. The process is ideal formany aluminium alloy applications such as complicated

heat exchanger assemblies.Proof of FeasibilityAluminium alloys 6061 and 6082 are representatives of

materials which are crack sensitive when EB welded without

the addition of appropriate filler material. The use ofaluminium alloy 4047, introduced into the weld as wire orfoil, can eliminate liquation cracking in these alloys due tothe high silicon content. Where assemblies are complicatedit may not be viable to introduce 4047 filler as a foil orwire. Deposition of a buttering layer by cold spray has beensuccessfully demonstrated by TWI. Welded circular patchtest coupons were used to test for crack susceptibility. Thewelds were evaluated by radiography and metallography toshow that the approach was practical to apply, to ascertainthe overall quality achieved and to check for cracking.ResultsThe cold spray process easily deposits layers of sufficient

thickness to act as a buttering layer; the bond strength isadequate to allow subsequent pre-weld machining ifrequired to ensure a good fit between parts. Welds madewithout filler material exhibited cracks, and the 6061 alloyappeared to be more crack sensitive than the 6082 alloywhen EB welded. By adding filler material, using the coldspray process, the crack sensitivity decreased. The hardnessprofile of the welds was very promising, as nearly nohardness reduction was evident. Comparison of welds madewith more conventional foil fillers showed similar results. ConclusionThe feasibility of using a cold sprayed buttering layer to

locally alloy weld metal and enable EB welding of cracksensitive aluminium alloys has been shown. Besides verypromising hardness results, the cold spray process alsoopens opportunities for viable application onto complexgeometries and is suitably robustness to allow handlingand machining, where required, before welding. Theprocess may be adopted for other materials and weldingprocesses (such as laser welding) to prevent cracking, or tochange mechanical or metallographic properties of the weldzone. This new technique of adding alloying filler materialinto welds shows significant promise.

For further information, visit websitehttp://www.twi.co.uk/technologies/welding-coating-and-material-processing/surface-and-coating/cold-spraying/or contact TWI Head Office, Phone: +44 (0)1223 899000Fax: +44 (0)1223 892588 or email Catherine Condie MCIPRAWeldI, Senior Project Leader, Marketing/PR [email protected]

Crack in EB weldedaluminim alloy 6061Crack-free EB weld in6082 alloy made usingcold sprayed butteringlayer. (weld metal,right; parent material,left)

Crack-free EB weldin 6082 alloy madeusing cold sprayedbuttering layer.

Crack-free EBweld in alloy6061 alloy madeusing foil fillermaterial.






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INDUSTRY

NEWS

International Thermal Spray

Conference & Exposition

ITSC 2014 21-23 May 2014 Barcelona, Spain

No Fiction: Thermal Spray the Key Technology in Modern Life!

www.itsc2014.com

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CLOSING DATE FOR APPLICATIONS:

15 NOVEMBER 2013

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FOR MORE INFORMATION: [email protected] . 505-856-7188 . WWW.SVC.ORG

OCTOBER 1, 2013

MAY 3–8

MAY 6–7

MAY 5–8

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ADVANCED COATINGS FOR TRANSPORTATION

57TH ANNUAL TECHNICAL CONFERENCE, HYATT REGENCY CHICAGO, ILLINOIS, USA

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INDUSTRY

NEWS

Become a Member of theInternational Thermal Spray AssociationYour company should join the International Thermal

Spray Association (ITSA) now! ITSA is now a StandingCommittee of the American Welding Society expandingthe benefits of company benefits. As a company-mem-ber professional industrial association, our mission isdedicated to expanding the use of thermal spraytechnologies for the benefit of industry and society.ITSA members invite your company to join us in thisendeavor. See pages 16-18.

Journal of Thermal Spray Technology®A publication of the ASM Thermal Spray Society

Determination of Thermal Spray Coating Property withCurvature Measurements

Gopal Dwivedi, Toshio Nakamura, and Sanjay SampathReal-time curvature measurement of a coating-substrate

system during deposition has facilitated the monitoring ofcoating stresses and provided additional insights into thermalspray deposition mechanisms. However, the non-equilibriumstate of coating formation along with harsh spray boothenvironment introduces complexity not only in data interpreta-tion but also in the coating properties estimation. In thispaper, a new procedure is proposed to estimate the elasticmodulus of thermal sprayed ceramic coatings using in situ cur-vature and temperature measurements. In order to correlatethe measurable parameters to coating elastic modulus, a sys-tematic study is conducted to develop a suitable methodology.First, various finite element model analyses are carried out toformulate suitable relations between the measurements andelastic modulus. Subsequently, experiments are conducted tovalidate the procedure to estimate coating moduli. The resultsare compared with more accurate measurements obtained frompost-deposition characterization technique under lowtemperature thermal cycles. The comparison suggest that themoduli estimated using the proposed procedure are in goodagreements with those obtained from the post-depositiontechnique. Further, the nonlinear response of coatings are eval-uated from the estimated moduli during deposition and cooldown, which offer additional information on the characteristicsof thermal spray coatings.

Read the entire article in the December 2013 IssueVisit www.asminternational./tss

Editor: Christian Moreau • Lead Editor: Basil MarpleEditor Emeritus: Christopher C. Berndt

Associate Editors:

Free Poster From Linde and the GTS (Association of

Thermal Sprayers) illustrates the differentthermal spray processes (suitable for

framing). Send request for poster via emailto [email protected]

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Free DIN Standards Poster GTS – the Association of Thermal Sprayers – has pro-

duced this spectacular new poster of “ThermalSpraying: Standards and Technical Bulletins”.

The poster identifies DIN Standards for ThermalSpraying and the DVS Technical Bulletins. The

standards/bulletinnames are inGerman and inEnglish.

The posterprovides contactinformation forobtaining thecomplete versionStandards andBulletins.The International

Thermal SprayAssociation isproud to be one ofthe sponsors ofthis project.

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CALENDAR OF EVENTS2014

MARCH 20149-13 San Antonio, TX USA Corrosion 2014 - visitwww.nace.org12-13 Houston, TX USA 6th Annual LAM Laser AdditiveManufacturing Workshop and Conference- visitwww.lia.org/conferences/lam/conference17-19 Cape Town, South Africa Power-Gen Africa - visitwww.powergenafrica.com18-20 Toronto, Canada Fabtech Canada - visitwww.fabtechcanada.com

APRIL 201410-12 New Delhi, India FABTECH India and Weld India -visit http://www.fabtechexpo.com/fabtech-india23-26 Tokyo, Japan Japan Int’l Welding Show - visitwww.weldingshow.jp/english24-26 Savannah, GA USA Int’l Thermal Spray AssociationAnnual Membership Meeting - contact Kathy [email protected]

MAY 20145-7 New Delhi, India Power-Gen India and Central Asiawith Renewable Energy World India, HydroVision India andDistribuTECH India - visit www.power-genindia.com.5-8 Chicago, IL USA 57th SVC Annual Technical Conference- visit www.svc.org5-8 Indianapolis, IN USA 2014 Iron and Steel TechnologyExpo - visit www.aistech.org6-8 Hartford, CT USA MFG4 Manufacturing 4 The FutureAerospace, Defense, Medical, Micro - visit mfg4event.com6-8 Mexico City, Mexico FABTECH Mexico - visitwww.fabtechmexico.com18-21 Orlando, FL USA 2014 World Congress on PowderMetallurgy and Particulate Materials - visit www.mpif.org21-23 Barcelona, Spain Int’l Thermal Spray ConferenceITSC 2014 - visit www.itsc2014.com

JUNE 201416-19 Orlando, FL USA AeroMat - visit www.asminterna-tional.org16-20 Dusseldorf, Germany ASME TurboExpo - visitwww.turboexpo.org17-19 Houston, TX USA NACE Bring On the Heat 2014 -visit www.nace.org17-19 Bremen, Germany WindForce 2014visit www.zinc.org25-27 San Diego, CA USA Mega Rust 2014Naval Corrosion Conference - visitnavalengineers.org/MegaRust2014

SEPTEMBER 201415-19 Garmisch-Partenkirchen, Germany14th Int’l Conference and Exhibition onPlasma Surface Engineering - visit www.pse-conferences.net/pse2014.html18-22 Orlando, FL USA PM2014 WorldCongress - visit www.mpif.org

22-25 Houston, TX USA 43rd TurboMachinery and 30thPump Symposia - visit turbolab.tamu.edu.

OCTOBER 20148-9 Hartford, CT USA Aerospace Coatings Conference andExposition - visit [email protected] Medellín, Colombia LATINCORR 2014 IX LatinAmerican Congress of Corrosion – visitwww.latincorr2014.org

NOVEMBER 201411-13 Atlanta, GA USA FABTECH with a Thermal SprayPavilion and Conference - visit www.fabtechexpo.com

2015FEBRUARY 2015

TBD Doha, Qatar Middle East TurboMachinery SymposiumMETS 2015 - visit middleeastturbo.tamu.edu

APRIL 201525-30 Santa Clara, CA USA 58th SVC Annual TechnicalConference - visit www.svc.org26-29 Helsingør, Denmark JOM-18 18th Int’l Conferenceon Joining Materials - contact [email protected]

Is Your Event Listed? Send not ice tosprayt [email protected]

CALENDAR

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C a r e e r O p p o r t u n i t i e s a t C i n c i n n a t i T h e rm a l S p r a yFrom engineering robotics to developing new technological processes

to be used around the world, you will find a field in which to excel atCTS. With facilities across the nation, we pride ourselves in our mostimportant asset, our employees.

• Product Engineer – Texas Facility• Thermal Spray Operators – Texas, North Carolina, and Ohio Facilities• Project Engineer – Ohio Facility• Quality Engineer – Ohio Facility• Operations Manager – New Jersey Facility• Quality Manager – North Carolina Facility• Support Operators – North Carolina and Ohio Facilities

For specific details on these listings and other opportunities at CTS,





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Mayo 6 AL 8, 2014Centro Banamex, Mexico, D.F.

May 6th-8th, 2014· 11,000 Visitantes

· 15,000 m etros cuad rados

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Sea parte del evento industrialmás importante de México

Más información:More information:In Mexico:

Marcela [email protected]: 52+(81) 8191 0444

Come and be part of the most importantindustrial show in Mexico

In USA:

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testament to the quality of Nui Phaos tungsten deposit andprocessing plant.

H.C. Starck is a leading global manufacturer fortechnology metals. Besides being one of the largest globaltungsten companies in the world, it also holds top marketpositions with its tantalum, molybdenum, niobium, andrhenium products. All of these metals require advancedtechnology and know-how to process. Nui Phao, the tungsten concentrate supplier of the joint

venture, has developed one of the largest known tungstendeposits outside of China with an expected mine life ofmore than 15 years. The construction of the tungstenchemical plant that will be part of the joint venture is inprogress. The first stage of the tungsten chemical plantstarted in August, with further stages expected to becompleted in 2014. Tungsten is one of the hardest metals and has the highest

melting point. As a strategic resource, it is used in a varietyof applications requiring high strength. APT and BTO areintermediary chemicals used for the production of highspeed cutting and drilling tools which are in high demandfrom growing industries such as mining and mechanicalengineering, medical technology, and the automotive andenergy industries. APT is also used for catalyst productionin the chemical industry. The European Union identifiedtungsten as one of the critical raw materials that have highstrategic value and yet for which there are only limitednatural resources. The establishment of the joint venture and closing of the

definitive agreements are subject to customary corporateand regulatory approvals. About H.C. Starck

The H.C. Starck Group is a leading global supplier oftechnology metals and advanced ceramics, and servesgrowing industries such as the electronics, chemicals,automotive, medical technology, aerospace, energytechnology, and environmental technology industries, aswell as engineering companies and tool manufacturers,from its own 14 manufacturing facilities located in Europe,America, and Asia. In 2012, the company employedapproximately 3,000 employees in the United States,Canada, Great Britain, Germany, China, Japan, andThailand.For more information, visit www.hcstarck.com/press.

About Mason Group CorporationMasan Group is one of Vietnams largest private sector

companies with a market capitalization of over US$3 bil-lion, focusing on consumption and resources sectors.Masan is committed to executing shareholder value,through building market-leading businesses with aprofessional management team and global partners. For more information, visit www.masangroup.com.

About Masan Resources CorporationA subsidiary of Masan Group, Masan Resources Corporation

(Masan Resources) is the owner of Nui Phao MiningCompany Limited, the developer of the Nui Phao project inThai Nguyen province, located to the north of Hanoi. NuiPhao owns one of the largest tungsten mines in the world.In steady-state operations, the mine will also be one of thelargest single point producers of bismuth and acid-gradefluorspar in the world. Mining will be by open-pit methodswith overall production unit costs projected to be in thelowest cost quartile relative to the world's current tungstenproducers. The mine started production in March 2013. TheNui Phao mine is expected to accelerate Masan Resources'vision to become Vietnam's largest private sector resourcecompany.

INDUSTRY

NEWS

H.C. Starck continued from page 19.

Where is your advertisement? You couldreach 7000+ readers in the thermal spraycommunity.

SPRAYTIME readers are engineers, researchers,industrial leaders, scholars, policy-makers,designers and the public thermal spraycoatings community.

This is a 1/4 page advertisment waiting foryour company logo and product graphics.

This is a 1/10th page advertisementwaiting for your message highlighting yourgoods and services.

Visit www.spraytime.org for a publicationschedule and advertising rates.

Contact Kathy Dusa via 440.357.5400 [email protected] for moreinformation.

Offshore Wind Energy: Life Cycle Cost Reduction ThroughThermal Sprayed Zinc Coatings

Offshore wind energy structures are exposed to the mostsevere climate conditions experienced by engineeredstructures. Additionally access is often difficult, makingmaintenance efforts a sizeable challenge. The cost forcorrecting failure in offshore protection systems is 75 to100 times higher per m² than onshore, having the potentialof placing the long-term economic viability of the entireproject at risk. Therefore a highly protective coating systemis required that provides a 25 year service life with minimalmaintenance.

The magnitude of costs for maintenance of offshorecorrosion protection is often not sufficiently known todecision makers in the wind energy industry. What isplanned on paper often looks completely different offshore,in the rough open sea. The lack of experience is notsurprising because the industry is young and the extensiveexperience with oil and gas can often not be translateddirectly. Consequently, the existing standards and norms for

Continued on page 31.

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A D V E R T I S E R S L I S TYour SPRAYTIME newsletter is provided to you at no charge by our advertisers.

We encourage you to thank these advertisers by visiting, contacting, and referring theirproducts and services at every opportunity.Camfil Farr APC........................2DeWal Industries, Inc. ..............6ERW, Inc.................................8Fabtech Canada .......................32Fabtech Mexico........................27Flame Spray Technologies..........9Genie Products, Inc. .................11

Green Belting Industries ...........4ITSC 2014 ...............................23Lineage Alloys .........................14Metallisation ...........................13Metallizing Equipment Co. .........20NACE Bring On The Heat ...........30Nation Coating Systems ............12

Polymet Corporation .................3Praxair Surface Technologies......15Progressive Surface ..................19Society of Vacuum Coaters ........24Sulzer Metco ...........................32Thermach, Inc. ........................10TurboExpo...............................29

30-minute presentations on topics including:• Corrosion protection for offshore wind energy

installations: expectations versus reality• Different corrosion protection systems and their life-

cycle cost analysis• Thermal zinc spraying: information about the process

and experience from operators (lessons learned)• Combination thermal spray-paint systems to achieve 25

year lives with routine maintenance• Standardizations of norms and specifications for

corrosion protection systems as basis for warranty andmodularization including cost saving potential. IZA invites interested parties to participate in the

seminar organization.For further information, please contact Dr. Frank

Goodwin, Director Technology and Market Development,International Zinc Association phone: +1 919 287 18 78,email [email protected],

This article is a follow up on earlier in SPRAYTIMEpublished articles related to the “Thermal Spray Program forMarine Structures”.About IZAThe International Zinc Association (IZA) is a non-profit

organization founded in 1991. IZA is dedicated exclusivelyto the interests of zinc and its users and helps sustain thelong-term global demand for zinc and its markets bypromoting key end uses as corrosion protection for steel,die casting, brass, oxide and sheet; and the essentiality ofzinc in human health and crop nutrition. IZA’s mainprograms are Sustainability and Environment, Technologyand Market Development and Communications.For further information, visit http://www.zinc.org

INDUSTRY

NEWS

Offshore Wind Energy continued from page 28.offshore corrosion protection are not tailor-made for thisindustry and do not satisfactorily meet the specificrequirements allowing for a 25 year service life withoutextensive maintenance. If this 25 year lifetime cannot beachieved, the cost of corrosion maintenance alone will add$0.0137 USD (1 Euro cent) per KWh, for every KWh ofelectricity produced over the entire life of the offshorewind energy structure.

To highlight the significant cost savings of usingcorrosion protection systems of sprayed zinc alloys theInternational Zinc Association (IZA) has developed a lifecycle cost comparator for the wind industry and willorganize a seminar on corrosion protection for offshorewind structures: CorrWind: a life cycle cost comparator for the windenergy industry The Excel-based cost model CorrWind, designed by IZA,

calculates the life cycle costs for different existingcorrosion protection systems such as thermally sprayedZn15Al including organic coatings (as duplex systems),thermally sprayed Zn coatings and pure organic coatings.

Users can determine the sensitivity of life cycle costresults to input factors like labour and materials costs,rates of inflation over the expected service life of thestructure, financial discount rate and the relationship ofinitial and maintenance costs to the cost per KWh of thewind energy unit, including the capacity factor of typicalwind power units. The results of the comparison show thatthe use of thermal spraying in combination with properlyselected and applied zinc-based paint systems provides thelowest-cost combination of first cost and periodicmaintenance costs during the expected 25 year service life.CorrWind provides the wind industry with an advisory tool

for reducing costs; supports an increase in transparency ofanalysis; and provides data for developing corrosionprotection standards, tailor-made for the wind energyindustry.

CorrWind will be accessible on the IZA websitewww.zinc.org as of November 2013 and will be highlightedas part of a poster presentation during EWEA Offshore inFrankfurt, Germany, on 20th of November 2013 from 5:30through 7:00 p.m. Windforce 2014, 17-19 June 2014, Bremen, Germany

As part of the conference program IZA will organize amorning session on corrosion protection comprising seven

25871_Q42013.qxp_Layout 1 2/14/14 1:10 PM

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History and Development of Thermal Spraying Engineering...

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