Podmoskovnaya company "Plakart" introduces the domestic market is one of the most promising methods for surface treatment — thermal spraying. With it, be coated with micro-and nano-structure, which should save the material from corrosion and high temperatures.
For example, thermal spraying is used in the energy and aviation (for protection of gas turbine engines and landing gear aircraft), construction (for protection of bridges and steel structures of buildings). This technology can be sprayed metals, alloys, ceramics and cermets.
This year’s "Plakart" supported "RUSNANO" is going to open new sites in St. Petersburg, Nizhny Novgorod, Cherepovets, reports NTV (Download the video).
CJSC "Plakart" offers advanced technology surface treatment methods of thermal spraying and coating deposition of nanostructured materials.
We develop technologies, supply equipment and materials, perform works by spraying, welding and processing of functional coatings, including nanostructured. We emphasize that we do not offer nanoscale coatings — are still in demand in microelectronics more than in engineering. Nanostructured coating in a thickness of tens to hundreds of microns have properties superior wear resistance, corrosion resistance, low coefficient of friction with respect to not only the base material but also to conventional coatings.
The surfaces of parts and products are subject to corrosive media, and other details. Lock or change it with a coating, we can significantly increase the life of the product. We is sprayed and the deposited coatings of metals, alloys, metal-ceramic and ceramic to metal, ceramic, plastic parts. Due to the fact that the deposition surface of the sprayed product is not heated over 120 ° C, the application of gas-thermal coating does not cause thermal leash and does not change the structure of the steel. Plasma and laser welding can provide a metallurgical bond with the base coat to allow the use of deposited coating under strong shock and shear loads.
Methods of spraying and welding, invented in the early XX century, got a new life and widespread due to the emergence in the late twentieth century, a new generation of robotic systems, high-speed deposition, plasma welding, laser welding, as well as the use of nanotechnology. Coatings obtained using said technologies have low porosity absent or small mixing with the substrate, corrosion resistance and high wear resistance.
Here are some examples of the successful application of coatings of practice:
Replacement chrome plated. Solid chrome plating, widespread as a method of protecting surfaces from wear products, has been actively displaced worldwide technology of thermal spraying. The reasons are as dangerous electroplating processes for the Environment (hexavalent chromium is a potent and fast-acting carcinogen) and low economic efficiency of electroplating with small-and medium series production (to which the global industry is increasingly seeking). High-speed coating of carbide coatings can provide better protection detail than chrome plating, as well as cost effective to restore worn-out chrome. Among the most popular items we can mention: the stem hydraulics, valves and compressors, high pressure pumps, pistons, calender rolls, the details of the drilling equipment. The effective replacement for spraying methods and also chemical-thermal processing.
Covering the working bodies of valves
Cladding units. Chemical, petrochemical and refinery deal with aggressive media, and many machines lay bimetallic clad walls of blood vessels and vehicles. Unfortunately, traditional methods of production bimetal require highly skilled and very expensive welding work, and the welds after they remain the most vulnerable point. Spray Corrosion resistant metal (the same as in the plating) is performed after assembling the machine in the factory or on-site installation and ensures protection of the whole surface of the device, including welds. Our coatings are working in absorbers, electric dehydrators, the isomerization units "Sulfrin", etc, protect about hydrogen sulfide, acid and alkali corrosion. Selection of materials that are similar in electrochemical potential, the use of multi-layer coatings underfilm avoid corrosion.
Anti-corrosion coating of metal. Aluminum and zinc metal coatings (coatings as well as their alloys) are the most reliable and technologically advanced of all coatings, high-quality implementation of which is technologically feasible at the installation of steel structures. Full-scale tests conducted by the U.S. Department of Transportation on the bridge Matiz for 20 years, showed that of the 47 tested, only coatings thermally sprayed zinc and aluminum were less than 3% of it in 20 years of operation in the marine atmosphere. Plating coatings are widely used to prevent corrosion in oil and gas offshore (platforms, submersible equipment), port and water treatment plants, reservoirs and tanks, high-voltage poles.
Improving the competitiveness of the equipment, import substitution. Foreign companies are often able to reduce the cost of products, their material and energy while providing the specified service life characteristics through the application of functional coatings. Thermal spraying, plasma and laser welding are common in Europe, Japan and the United States by an order greater than in Russia and continue to develop. The use of coatings can: change the material of construction for a cheaper, reduce the thickness of the anti-friction coating to facilitate product design by eliminating the allowance for corrosion and wear, increase the guaranteed turnaround. Among the examples of the successful implementation of our technology import: ESP submersible pumps, pump plunger hydraulic fracturing, turbine blades, contact feet of electrical networks, the details of the woodworking and furniture industry.
Reconditioning of parts. Modern manufacturers are increasingly committed to delivering beyond repair parts and equipment. In the decay of the CMEA and the Soviet Union, many manufacturers have stopped production of parts. At the same time, highly skilled engineers — graduates of Soviet and Russian universities can significantly reduce maintenance costs by restoring the geometry of the individual parts. Application of a sputtering technology can not only keep the geometry and crystalline structure of the items, but also (if necessary) to increase the wear resistance, corrosion and friction properties sprayed surface by coating. We have successfully restore protection of electric motors, shafts, rods, pistons, knife gate valves and seats, optional equipment.
Ceramic coatings. Due to the low thermal and electrical conductivity, inertness to most chemically aggressive environments, as well as high hardness and wear resistance, the ceramic coatings are increasingly used in modern engineering. We put ceramic coating on the hot section parts, gas turbine engines, equipment operating in hostile environments, provide protection from sensors Waterjet wear, etc.
The coatings with special properties. As the largest company in Eastern Europe in the field of thermal spraying, we look turn to a non-standard tasks: conducting research and development in the field of engineering surfaces, spraying and welding, the development of new types of coatings (optical, wear, low friction coating cloth, plastic, graphite, etc.).
Our certified by ISO-9000 production are located in the Moscow region, Perm and Tyumen, mobile teams produce work across Russia — on-site equipment. We exclusively supply to the market of CIS powders for sprayi
ng Hoganas, wear plates, casting, powder electrodes and wires Vautid, equipment for spraying and GTV Kermetico, equipment for welding KSK, laboratory equipment. Over two decades of work we have delivered more than 20 turnkey spray systems, completed work for hundreds of clients, from the shop floor to the production of plastic plants of OAO "Gazprom" and Railways.
With our technology you can improve the competitiveness of products, significantly reduce the cost of repairs and maintenance of equipment, increase the rate of its useful life, reducing downtime and increase its energy efficiency, resource conservation and implement the program of import substitution.