Maintain fan efficiency for longer periods. Reduce energy and maintenance costs. Smooth surface for maximum wear resistance. Extremely wear-resistant coating available on high strength steels. SpeciďŹ c solutions developed for OEMs.
C ASTO L AB S ERVICES
Protective coatings for industrial fans
Protective coatings for industrial fans
Industrial fans Large fans are commonly used to provide significant quantities of air needed for operating industrial processes. Coal and lignite fired power plants, cement, metal or woodchip manufacturing are just a few examples of industries that require homogeneous and reliable airflows. When particles are present in the air stream, they relentlessly wearout the fan surfaces. This wear is present both when they are very fine, for example when conveying fumes, as well as when large particulate matter such as wood chips are transported. Impeller blades are the worst attacked components and, once they are worn-out, the resulting geometrical alteration can lead to dramatic drops in efficiency. Furthermore, balancing problems may appear which will affect ancillary equipment service life. As a result, operational conditions are changed; energy and maintenance costs increase and unplanned plant downtimes may be needed.
Worn-out blades leading to efficiency decrease and higher operation costs
Wear experience After more than 20 years of experience gained in repairing and replacing fan parts, we have built a thorough knowledge of erosive wear phenomena that occur rapidly on rotating machines. This know-how allowed us to develop dedicated solutions for fans such as our XuperWave welding pattern. Worn-out impeller
Worn-out blade
Castolin solutions
XuperWave pattern and wear training for Castolin engineers
For improving equipment service life and, consequently, allowing a more regular process with lower energy consumption, a full range of solutions are available: 
Pre-fabricated bi-metallic plates are made by depositing a highly wear-resistant alloy on top of a standard construction steel plate using either welding or powder fusing technologies. They are utilized as liners or, when mechanical stress is low, even as structural parts. They are regularly used for manufacturing large centrifugal fans and also casings.
Coating rich of erosionresistant carbides
Airfoil blades made with powder bi-metallic plates
Blades and impeller protection made with welded bi-metallic plates
Stronger, with Castolin Eutectic www.castolin.com www.eutectic.com
Complete casing made with welded bi-metallic plates
VentiTec coatings have been specifically developed for extremely demanding cases. They are typically used by Original Equipment Manufacturers (OEMs), that need: - Extreme erosion resistance We provide nickel-based coatings with up to 60% of tungsten carbides as well as NanoAlloy® iron-based coatings. - High strength steel substrates Difficult to weld steels such as 1.8928 (S690QL) an 1.8988 (S690QL1) can be protected without dramatic drop of mechanical properties.
Rich tungsten carbides coating
- Good flatness and smooth coating surface Particular attention is given during the coating process to limit deformation and keep the overlay surface smooth which eventually leads to an easier part assembly and limits wear rate. Manufacturing parameters are also optimized for having a good interface between coating and the steel substrate (low dilution).
Smooth surface of nickel-based coating with high content of tungsten carbides.
Controlled interface between coating and substrate.
- Optimization of surface wear-resistance In order to optimize the overall fan wear resistance, various alloys can be applied in different zones. Thus, the most critical positions will have extremely resistant coatings, while the less exposed to wear will be coated with an alloy that offers a sufficient resistance. As a result, the wear-resistance is optimized while the cost is kept to the minimum. Blade coated with highly resistant NanoAlloy® and chromium carbide alloy.
Blade coated with two highly resistant powder alloys rich of tungsten carbides.
- Precise parts Due to the high content of carbides in our VentiTec coatings, cutting and forming parts require experience and correct machines. Consequently, we provide to our customers ready-to-assemble parts. - Engineering Since our VentiTec customers have very specific requests such as, for instance, the part geometry tolerances or mantaining the steel strength properties after coating, we manage this range with engineer driven projects. Our engineering department provides assistance to our customers for developing the optimum cost-effective solutions.
Blade bent at the correct radius
Airfoil leading edge protection ready to be installed
Engineering department
Stronger,with withCastolin CastolinEutectic Eutectic Stronger, www.castolin.com www.castolin.com www.eutectic.com www.eutectic.com
3
Arc-spray wear-resistant coatings are applied on thin parts or lightweight fans that are working in a airflow which is not too heavily charged with particles, but still require a cost-efficient protective layer. Erosion and corrosion solutions are available for complex geometries such as airfoil blades that can easily be coated in our workshops as well as directly on-site when equipment needs to be repaired.
Wear resistant coating made with arc-spray
Axial fan manually protected in our workshop
Axial blade protected with robot in our workshop
Airfoil blades protected on-site
CastoLab® Services Depending on customer needs, tests are regularly done to develop the optimum solution in CastoLab® Services workshops. Ready to be used parts are produced, cut and formed in our facilities while arc-spray coatings can either be made in our spraying booths or directly at your site.
Part production site
Manual finishing
Axial fan leaving CastoLab®
Axial fans protected at customer site
With our international presence, we are always close our customers for helping them to improve their equipment service life and to reduce their costs. Do not hesitate to contact your sales representative to get more information about our fan protective solutions.
CastoLab Services® worldwide presence
Stronger, with Castolin Eutectic www.castolin.com www.eutectic.com