Railway Coach Axles

Many hundreds of passenger coach axles have been treated by with an arc sprayed copper deposit forming a brush path. No undercutting is carried out and the copper deposit is sprayed through a metal stencil held a short distance away from the axle onto a gritblast surface. After spraying the copper deposit is machined. The method of testing the coating is by rolling to compact the copper. During testing a failure rate of 50% occurred with axles previously sprayed with a molybdenum bond coat and subsequently built up with copper using Flame Spray Equipment. Using Electric Arc Equipment, the success rate is now 100%.

Mill Roll Journals

A badly worn hot mill strand roll reclaimed with 25mm (1”) deposit of S2 Steel. The heavy wear that rolls of this type are continually subject to is ample testimony to the strength of the arc spray deposit and its wear resisting properties. Rolls of this type are now sprayed with S2 as part of the original manufacture in order to obtain the longer service life that the arc spray deposit provides.

Paper Mill cylinder

A large engineering component was metal sprayed over its entire length by Metalliseringsverket A/S of Oslo, Norway. The component, a massive cylinder, has been surfaced with an acid resistant stainless steel as it is destined for use in a North American Paper Mill and the paper making process involves the use of toxic chemicals, 1.524M (5ft) in diameter and 10.97M (36ft) in length, the cylinder weighs 18 tons and was fabricated in Norway. The surface was prepared by rough cutting to a depth of 500microns (0.20”) followed by gritblasting. A mixed bond coating of aluminium bronze and carbon steel was then applied followed by an intermediate deposit of S2, a further layer of a mixed deposit of S2 and stainless steel was then applied. The final coating of approximately one ton of stainless steel was then sprayed. The work was carried out using two Metallisation Arcspray Pistols in toolpost mountings and a total of one and a half tons of wire was deposited. Flamespray and Plasmaspray techniques can also be used.

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