Metalspray engages growth in Agricultural applications.

The necessity for cutting/slashing and ploughing means that the components used are subject to very abrasive and corrosive conditions.

Metal/thermal spray coatings and hard facing can provide the solution for wear and corrosion resistance as well as extended life and increased performance.

The necessity for the irrigation of planted crops requires pumps that will withstand the hardness and ph values of the water and fertilizers. The metal spray process can apply ceramics to pump seal areas to repair and protect OEM components.

Agricultural: Knives and blades, Threshing components, Ground engaging machinery

Agriculture, forestry: barking blades & tools, wear parts for farming tools, feeding screws for fertilizers, feeding screws for wood barks,

Sugar cane: sugar cane crusher, sugar cane cutters,

The metalspray and hard facing processes use various forms of equipment that employs wire, powder and cord to deliver the required solutions.

Every problem of abrasion does not involve the same solution and requires a careful study of each application according to:

  • type and size of the abrasive material,
  • abrasion rate, temperature, impact occurrence…
  • geometry,size and the weld ability of the part,

Agri1      Agri2

Tuf-Cote® “rope like” hardfacing electrodes to improve ABRASION & EROSION resistance.

TUF-COTE is brazed using an oxygen-acetylene torch It can be weld on mild steel, low carbon steel, low alloyed steel, stainless steel, lamellar grey cast iron, spheroid cast iron. It can also be brazed on certain alloys of manganese steel with precautions. TUF-COTE® is weld-able on itself, making local repair or recycling of parts possible.

The Powder welding process utilises a Oxy Acetylene flame is ideal for the deposition of smooth , thin, well bonded layers on a wide range of substrates, including cast iron. The Hardfacing takes place at lower temperatures, which minimises oxidation and distortion of the workpiece and enables easy surfacing of edges.

Agri3        Agri4  Powder Welding

 

Oxy Acetylene Flame spraying followed by Fusing as a two stage process where after spraying the coating is fused with an oxyacetylene burner or for mass production by using induction heating or in a vacuum furnace allows the coating to be Metallurgically bonded, extremely hard, corrosion resistant and resistant to impact and chipping. The  powders used for Spray and Fuse Hardfacing are typically compositions of Ni, Cr, Co, Bo, Fe, W and WC in varying blends

The application of Chrome Oxide ceramic powder or cord allows various pump parts to be either repaired or have their life expectancy increased with a very hard wearing coating.

Agri5                  Agri6                Agri7

Mechanical Seals                                         Pump Impellor                                       Pump Shafts

Pumps can also be coated with Monel®, Inconel®, Stainless Steels by Flamespray and Arcspray methods

Agri8       Arcspraying

Arcspray employs two wires (hence a common term for the process is Twin Wire Arc Spray), are fed into the pistol and electrically charged, one positive and one negative. The wires are forced together and form an electric arc, melting the wire. Compressed air, passing through a nozzle, atomises the molten metal and sprays it onto the work piece.

With Australia looking to be the Market garden of the world the Metalspray and Hardfacing processes will be playing a large part in its success.

 

Metalspray coating for Animal transport vehicles

The Metalspray process has many applications that are carried out Worldwide. One of its major applications is the application of anti –corrosion coatings. The material applied maybe Zinc (as used in the Galvanising process), Aluminium or alloys of these materials.

The application of the coating is generally by Arcspray (sometimes referred to as twin wire arc spray) is a process that uses an electric arc to melt wires.  The molten metal is then atomised with compressed air to create a spray stream that applies the coating onto the surface being sprayed.

transport11   transport12-png

 

As well as providing anti –corrosion protection the coating can be applied with a coarse coating to provide anti-slip properties particularly useful on vehicle tail lifts and ramps on commercial vehicles and trailers.

An application where the Metalspray process has a significant advantage over Paint and Galvanising is in Animal transport vehicles and trailers. Not only does the surface have to be able to withstand wear from the animal hooves etc. that may contain erosive soil but also the chemical effect of their urine and excrement. The use of Zinc in this application works within a pH range of 6 to 10. The urinary pH range for the cow, sheep, goat, and horse is ∼7.9 ± 0.5. For the pig, this range may extend to 6.5 ± 1.5, for cats and dogs 6.0 ± 1.0, and for humans 6.5 ± 1.5 (1). The diet of the animal is the major determinant of urinary pH levels.

How does Metalspray compare with Painting?

  • Materials are of consistent quality and purity, no mixing required before application
  • Materials have an infinite shelf life if stored correctly
  • Fewer process steps required. This allows simpler quality control and fewer opportunities for error.
  • Sprayed components require no protracted curing or drying times giving superior utilisation to floor space
  • Sprayed Zinc, Aluminium and their Alloys give effective corrosion resistance and protection immediately
  • Sprayed metals are more robust than paints and can withstand rougher usage
  • Even if the sprayed layer is damaged the sacrificial action prevents corrosion.
  • Metals can be sprayed in a wider range of climatic conditions (temperature and humidity) than paints
  • The materials used since the early 1900’s have not changed they are still in existence today, whereas many paint systems have been superseded many times over.

How does Metalspray compare with Galvanising?

  • Low heat input during spraying eliminates the risk of component distortion
  • There is no limit to the size of component to be treated
  • Components can be treated on site and therefore no transport or waiting issues and giving you the opportunity to Up Sell to your customer.
  • Metalspraying is used to restore corrosion protection on damaged areas of welded galvanised steel and International Standards exist covering this
  • Coating thickness can be varied from area to area to provide extra protection in critical areas
  • The Metalspray process is not limited to Zinc as Aluminium, Steels, Bronzes etc. can also be applied for a variety of applications
  • No re-work required from Galvanising dross
  • The Metalspray coating is porous and therefore the perfect surface to accept paint (that’s if required as it is not necessary). No need to pre –etch etc.
  • “AS/NZS 2312 Guide to the protection of iron and steel against exterior atmospheric corrosion” is the Australian Standard based on the International ISO standard that provides guidance for architects, engineers, builders the surface coating industry and users of protective services in general, on coating system for the protection of iron and steel against exterior atmospheric corrosion.

As indicated above the Metalsprayed coating is porous and therefore in this application the use of a  paint sealer would be required, which as shown in AS/NZS 2312 would further enhance the lifecycle of the coating.