Powders for Hot and Cold Spray Processes
Alloys for Use with CastoDyn速 and TeroDyn速 Thermal Spray Systems
Hot Flame Spraying Eutalloy® RW Process - Two Step Spray & Fuse Function Eutalloy® RW is a 2-step hot flame spraying process. The first step is to «cold» spray a thin, regular layer of «RW» self-fluxing quality powder onto a precleaned, preheated steel substrate using an n oxy-acetylene powder spray system such as the CastoDyn DS 8000 or TeroDyn System 2000. First step: Cold spraying with CastoDyn DS 8000
The second step is then to heat the “RW” powder deposit “red hot” using a flame torch, until a reflective fused surface finish is visible locally. An induction system or an oven can also be used. Strong metallurgical diffusion bonding of the resultant wear resistant coating is thus achieved without melting or dilution with the substrate. The coating thickness may then be further increased by continuing to spray & fuse the powder simultaneously followed by controlled slow cooling to ambient temperatures. Second step: red hot fusion using a flame torch
Advantages Smooth surface for little to no post machining No dilution of the base material Best purity and performance of the coating alloy Homogeneous and pore free coatings High bond strength Good shock resistance
Applications The Eutalloy® RW process is designed to hot flame spray a range of wear resistant powder coatings onto fast rotating or stationary even surfaces. Final «RW» pure precision coatings are characterised by smooth surface finish requiring little or no post machining operations for optimum service performance.
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Hot Flame Spraying Eutalloy® RW Powders
Powder Hot Flame Spraying
Eutalloy Powders - 12xxx Series Designations
Product Type / Max Service Temp.
Properties
Applications
Eutalloy® 12494
Ni-Cr-B-Si-Fe alloy / 1200oF (650oC)
~38 HRc. Similar to 13494. An intermediate hardness alloy with a good combination of hardness and wear resistance coupled with good machining properties. Coatings have unlimited build-up capability and can be machined with carbide tool bits.
Shafts, Gears, Tools, Gauges, Feed Rolls, Molds, Keyways, etc.
Eutalloy® 12496
Ni-Cr-B-Si-Fe alloy / 1020oF (550oC)
~59 HRc. Similar to 13496. Hard, nickel-base alloy with excellent wear properties. Coatings are resistant to abrasion, erosion and adhesive wear. Eutectic 11496 coatings produce a smooth wear scar during use that improves service life. Finish by grinding.
Mandrels, Tappets, Plug Gauges, Molds, Cams, Camshafts, Screws, etc.
Eutalloy® 1207
Ni-Cr-B-Si-Fe alloy / 1020oF (550oC)
35-40 HRc. For exceptionally clean & porosity-free coatings. A nickelbase alloy with excellent wear properties. Coatings are resistant to abrasion, hot-glass erosion and adhesive wear. Finish by grinding.
Mold plungers and baffles…
Eutectic Powders - 13xxx Series Product Type / Max Service Temp.
Designations
Eutectic® 13017
Properties
~59 HRc. Nickel-base fusible powder with additions of copper and Ni-Cr-B-Si-Fe-Cu-Mo molybdenum to provide enhanced resistance to corrosion, friction and alloy / 1200oF (650oC) erosion. Finish by grinding.
Applications
Boat Sleeves, Shafts, Screw Flights, Plug Gauges, Valve trim, etc.
Eutectic® 13494
Ni-Cr-B-Si-Fe alloy / 1200oF (650oC)
~39 HRc. Intermediate hardness coating for use on crack sensitive base metals or when a machinable fused deposit is required. Finish using carbide tool bits.
Camshafts, Diesel Valves, Transmission Shafts, Bearing Sleeves, etc.
Eutectic® 13495
Ni-Cr-B-Si-Fe alloy / 1200oF (650oC)
~48 HRc. Provides an optimal combination of hardness and wear resistance with a reduced tendency for cracking. Finish by grinding.
Ash Plates, Steam Nozzles, Camshafts, Bearing Fits, etc
Eutectic® 13496
Ni-Cr-B-Si-Fe alloy / 1200oF (650oC)
~58 HRc. Combines high hardness and wear resistance in an easyto-fuse alloy form. Coatings provide a smooth wear surface in service coupled with a low coefficient of friction. ASTM G65 Wear 32 mm3 loss.
Feed Screws, Slurry Pipes, Wear Rings, Steam Nozzles, Brick Dies, Plug Gauges, etc
Eutectic Powders - 23xxx Series Designations
Product Type / Max Service Temp.
Eutectic® 23005
Ni-Cr-B-Si-Fe alloy and tungsten carbide / 1200oF (650oC)
Eutectic® 23045
Ni-Cr-B-Si-Fe alloy / 1200oF (650oC)
Properties
Applications
~58 HRc. Blend of a nickel-base fusible alloy plus 35% Recoating wear pieces of agricultu-ral machines, mixer tungsten carbide particles. Coatings are designed to blades, ceramic press feeder plungers.Resurfacing pump provide resistance to abrasion, erosion and fretting. Finish wear sleeves, steel industry transport rollers by grinding. ASTM G65 Wear 18 mm3 loss. ~58 HRc. Nickel-base fusible alloy that combines high hardness and ease of application. Coatings produce a smooth wear scar in service and exhibit a relatively low coefficient of friction. ASTM G65 Wear 32 mm3 loss.
Plug Gauges, Dies, Wear Rings, etc.
Eutectic® 23065
~58 HRc. Nickel-base fusible powder with alloying additions Ni-Cr-B-Si-Fe-Cu-Mo alloy of copper and molybdenum to give enhanced resistance to / 1200oF (650oC) pitting and corrosion.
Eutectic® 23075
~58 HRc. Blend of a nickel-base fusible alloy plus 40% Ni-Cr-B-Si-Fe alloy tungsten carbide particles. The carbide is sized to give the and tungsten carbide / coating enhanced resistance to solid particle erosion. Finish 1200oF (650oC) by grinding. ASTM G65 Wear 16 mm3 loss.
Brick Dies, Agricultural Knives and Shear Bars, Pump Pistons, Impellers, etc
Eutectic® 23085P
~60 HRc. Blend of a nickel-base fusible alloy plus 50% Ni-Cr-B-Si-Fe alloy tungsten carbide particles. The carbide is sized to give the and tungsten carbide / coating enhanced resistance to solid particle erosion. Finish 1200oF (650oC) by grinding. ASTM G65 Wear 14 mm3 loss.
Brick Dies, Agricultural Knives and Shear Bars, Pump Pistons, Impellers, etc
Eutectic® 53606
Boat Sleeves, Plug Gauges, Valve Trim, etc.
Ni-Cr-Mo-Si-B-Cu alloy ~58 HRc. Excellent wear and corrosion resistance Boiler tubes, shafts and sleeves in waste / 1200 °F (650 °C) to both reducing and oxidizing environments. incineration, chemical, pulp and paper industries.
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Powder Cold Flame Spraying RotoTec®, ProXon® & MetaCeram® Processes - Cold Spraying
Function RotoTec®, ProXon® & MetaCeram® are «cold» processes whereby a new alloy or ceramic is reliably coated onto a cylindrical surface of a metal workpiece or part. The sprayed coatings are applied to the desired thickness at temperatures that do not overly stress, change the base metal properties or create distortion. These «cold» processes mean that the part should not exceed about 302°F (150°C) during coating. These thermal spray powders are categorized into the following processes: ProXon® process where the self-bonding powders are «cold» sprayed in «one-step». RotoTec® & MetaCeram® processes where the powders are sprayed in «two-steps». The first step is to «cold» spray a bond coat to ensure proper bonding with the part. The second step is to «cold» spray a final coating with the required wear resistance properties.
Technical data Flame temp.: 5792°F (3200 °C) Particle velocity: up to 112mph
Rotor repair with RotoTec® «cold» spray process for lowest heat input
Advantages
Applications
Low heat input to the base metal minimizes distortion, warping and changes in the base metal. «Cold» is key to simplicity, efficiency, speed and reliability. Wide range of powders can be sprayed. Spraying equipment is inexpensive. Easy to handle. The low level of noise and fumes during spraying facilitates setting up a new low cost spraying facility.
«Cold» powder flame sprayed coatings have a very broad field of applications. Both metals and ceramics are sprayed for different application needs. In particular, parts suitable for coating consist of those which can be rotated and require repair due to wear on surfaces which are cylindrical in shape. This represents a wide range of applications, consisting of shafts, journals, rolls and bearings on areas such as bearing seats, press fits, seal and packing zones.
Deposition rate: 0.27 to 1.66 g/s Coating material: Alloys and ceramics in powder form Coating density: 85 - 95% Noise level: 70 - 80 dB(A) These «cold» thermal spray powders are applied with a flame powder spray system, such as the oxy-acetylene CastoDyn DS 8000 and TeroDyn System 2000. The powder is fed with help of injector effect or a carrier gas (nitrogen, argon or air) into a gas flame (often acetylene/oxygen). The flame heats the powder particles and propels the droplets towards the substrate forming a dense coating with good bonding properties. Due to the moderate transfer of heat to the powder particles and to the workpiece, the base metal stays relatively cool.
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Powder Powder spray stream
Oxygen
Acetylene Compressed Air
Cold Flame Spraying
Powder Cold Flame Spraying
Proxon Powders - 21xxx Series Designations
Product Type / Max Service Temp.
Properties
Applications
Proxon® 21021
Ni-Al-Mo alloy / 1000oF (540oC).
~75 HRb. Nickel-aluminum-molybdenum powder designed to produce a medium hard, wear resistant bearing surface. Finish by machining with carbide tool bits.
Impellers, Pump Shafts, Wear Rings
~80 HRb. Modified version of ProXon 21021 with Ni-Al-Mo-Cr-B-Si alloy additions of chromium, boron and silicon to enhance / 1200oF (650oC). machinability and service temperature. Machine using carbide tool bits.
Pump and Motor Shafts, Bearing Fits, Seal Surfaces, etc.
Proxon® 21022
~90 HRb. An iron-base composite powder with additions of nickel, aluminum and molybdenum Proxon® 21023 offering excellent bonding and machining characteristics. ~90 HRb. Nickel chromium alloy powder offering Ni-Cr-Al-Fe-Mo alloy / excellent resistance to oxidation and corrosion at Proxon® 21031 1600oF (870oC). elevated temperature. Machine using carbide tool bits. ~30 HRc. Nickel-base alloy offering the best Ni-Mo-Fe-Ti-Sicombination of resistance to oxidation and Proxon® 21032S W alloy / 1200oF corrosion. Coatings have excellent anti-galling (650oC). properties. Finish by machining. Fe-Ni-Al-Mo alloy / 1500oF (815oC).
Proxon® 21041
Proxon® 21071
Ni-Cr-Al-Fe-Mo-BSi alloy / 1200oF (650oC).
~32 HRc. Self-bonding, nickel-chromium alloy with additions of boron and silicon to provide enhanced resistance to abrasion and erosion. Finish by grinding.
~60 HRb. Self-bonding, aluminum bronze alloy for Cu-Al-Fe alloy / 700oF use in soft-bearing applications. Coatings are easily (370oC). machined to a fine finish using carbide tool bits.
Heat Treat Fixtures, Machine Element Repair, Bearing Fits, etc.
Heat Treat Fixtures, Motor Shafts, Boiler Tubes and Pump Impellers, etc.
Impellers, Pump Shafts, Wear Rings, Print Rolls, Seal Surfaces, etc.
Wear Rings, Seal Surfaces, Bearing Fits, etc.
Compressor pistons, trunnions and pulleys, etc
Proxon Powders - 19xxx Series Designations
Product Type / Max Service Temp.
Properties
Applications
Proxon® 19121
Ni-Al-Mo alloy / 1000oF (540oC).
~75 HRb. Nickel alloy one-step powder designed for use with the RotoTec 1A Torch. Coatings produce a medium hard, wear resistant bearing surface. Finish by machining with carbide tool bits.
Impellers, Pump Shafts, Wear Rings
Proxon® 19122
Ni-Al-Mo-Cr-B-Si alloy / 1200oF (650oC).
~80 HRb. Modified version of ProXon 19121. The additions of chromium, boron and silicon give improved machinability and increased service temperature capability. Finish by machining.
Pump and Motor Shafts, Bearing Fits, Seal Surfaces, etc.
Proxon® 19132
~30 HRc. Self-bonding, nickel-base alloy powder Ni-Mo-Fe-Ti-Si-W alloy developed for use with the RotoTec 1A Torch. / 1200oF (650oC). Coatings provide a unique combination of resistance to corrosion and abrasion. Finish by machining.
Impellers, Pump Shafts, Wear Rings, Seal Surfaces, Recovery Boilers, etc
Proxon® 19132S
~30 HRc. A slightly coarser version of ProXon 19132 Ni-Mo-Fe-Ti-Si-W alloy designed for use with the RotoTec 1A, DS 8000, and o o / 1200 F (650 C). TeroDyn 2000 Systems.
Impellers, Pump Shafts, Wear Rings, Seal Surfaces, Recovery Boilers, etc
Proxon® 19171
Cu-Al-Fe alloy / 700oF (370oC).
~60 HRb. Self-bonding, aluminum bronze alloy for soft bearing applications. Coatings are easily machined with carbide tool bits
Reclamation of copper base metal parts, etc
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Cold Flame Spraying Metaceram Powders - 25xxx Series Designations
Product Type / Max Service Temp.
Properties
Applications
Metaceram® 25010
Al2O3 / 3000oF (1650oC).
~50 HRc. Aluminum oxide powder produces a hard, dense, wear resistant coating suitable for use at elevated temperatures. Excellent electrical insulating properties. Finish by grinding.
Slag troughs, Pump Seals, Impellers, etc
Metaceram® 25020
Al2O3 + 3% TiO2 / 2000oF (1100oC).
~55 HRc. Aluminum oxide-titanium dioxides blend with excellent resistance to heat, cavitation, and liquid metal erosion. Finish by grinding
Piston Rods, Rocker Arms, Pump Sleeves, Thread Guides, Piston Rods, etc.
Metaceram® 25030
Al2O3 + 13% TiO2 / 1000oF (540oC).
~60 HRc. Aluminum oxide-titanium dioxide blend that produces coatings which have a slightly lower resistance to abrasion than 25010 but produce a better grind finish.
Piston Rods, Rocker Arms, Pump Sleeves, Thread guides, Piston Rods, etc.
~57 HRc. Titanium dioxide coatings offer the best finish capability and provide excellent resistance to mild cavitation. Good abrasion resistance.
Pump Sleeves, Impellers, Propeller Shaft Bearings, Thread Guides, etc.
Metaceram® 25040 TiO2 / 1000oF (540oC). Metaceram® 25050
Cr2O3 / 1000oF (540oC).
~65 HRc. Chromium oxide coatings offer the best resistance to hard particle abrasion and are resistant to most acids and alkali solutions when properly sealed.
Buffing Fixtures, Wear Rings, Plungers, Pump Seals, Cylinder Liners, etc,
Metaceram® 25060
Al2O3 + 40% TiO2 / 1000oF (540oC).
~57 HRc. Aluminum oxide - titanium oxide blend that is less technique sensitive to apply and easier to finish than 25010 or 25030. Excellent finishes are possible via grinding and lapping.
Piston Rods, Buffing Fixtures, Thread Guides, Pump Sleeves, etc
~55 HRc. MetaCeram 25088 is suitable for use as a ZrO2 + (Al2O3 + SiO2 + thermal barrier coating, to resist wetting by molten metals TiO2) / 1800oF (980oC). or to resist hard particle abrasion.
Heat Treat Fixtures, Pouring Troughs, Ingot Molds, Tuyères, etc
Metaceram® 25088
Eutectic Powders - 29xxx Series Designations
Ultrabond® 50000
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Product Type / Max Service Temp.
Properties
Nickel-base alloy used as a bond coating for two-step Ni-Al-Mo alloy / 1000oF 29XXX Series Powders and selected Specialized Application (540oC) Powders. Apply to a thickness in the 0.004-0.008 in. range.
Applications
Bond coat for all two step cold powders.
Eutectic® 29011
Fe-Cr-Ni-Mo-Si alloy / 1000oF (540oC)
~85 HRb. Low carbon, 300 Series austenitic stainless steel alloy offering excellent resistance to a wide range of corrosive media. Finish by machining.
Valve Trim, Pistons, Pump Shafts, Machine Element Repair.
Eutectic® 29012
Fe-Cr-Ni alloy / 1200oF (650oC)
~30 HRc. A high chromium, martensitic stainless steel offering excellent metal-to-metal wear characteristics. Finish by grinding.
Pistons, Rolls, Sleeves, Cylinder Liners
Eutectic® 29021
Ni-Cr-Si-Fe-B alloy / 800oF (430oC)
~32 HRc. A hard, grindable final coat formulated to reduce bearing-seat wear due to severe friction. Finish by grinding
Valve Trim, Pistons, Pump Shafts, Machine Element Repair, etc.
Eutectic® 29029
Ni-Al-Mo alloy / 1000oF (540oC)
Similar to UltraBond 50000. A nickel-base alloy used as a bond coat for two-step 25XXX and 29XXX series powders. Bonds to most metals except pure copper. Apply to a thickness in the 0.004-0.008 in. range.
Bond coat for all two step cold powders.
Eutectic® 29061
Cu-Al-Fe alloy / 700oF (370oC)
~70 HRb. Aluminum bronze coating with good resistance to fretting wear. Coatings are most often used for bearing applications. Finish by machining with carbide tool bits.
Pump Shafts, Impellers, Seals, Guides, etc
Eutectic® 29077
~92 HRb. Low carbon steel powder used primarily as a Fe-C-Ni-Mo alloy / 800oF cushion layer or for heavy build-ups, particularly when cost is (430oC) a prime concern. Finish by machining with carbide tool bits.
Machine Element Repair of Steel Parts,etc.
Eutectic® 29079
~90 HRb. Aluminum bronze alloy with additions of nickel to Cu-Al-Ni-Fe alloy / 700oF increase hardness and to enhance bearing properties. Use in (370oC) place of 29061 when a harder bronze coating is required.
Bearing Surfaces, Piston Guides, Shafts, etc
Eutectic® 29096
Ni-Cr-Fe-Si alloy / 1200oF (650oC)
~82 HRb. Corrosion resistant, machinable nickel-base alloy coating used in the reclamation of steel and nickel alloy parts. Finish by machining.
Motor Shafts, Journals, Sleeves
Eutectic® 29123
Ni-Cr-B-Si-Fe alloy and tungsten carbide / 1200oF (650oC)
~50 HRc. Blend of 75% WC/Co and nickel-base alloy powders. Coatings provide excellent resistance to abrasion and erosion. Do not grind. Use in the as-sprayed condition.
Fan Blades, Grain Chutes, Gripping Rolls
Cold Flame Spraying
Powder Cold Flame Spraying
Eutectic Powders - LT Two-Step Series Designations
Product Type / Max Service Temp.
Properties
Applications
AluTec® 29210
Al-Si alloy / 500oF (260oC)
~85 HRb. Aluminum-12% silicon alloy powder widely used to repair worn aluminum or magnesium parts. Finish by machining
Shafts, Casings, Pumps, Blower Housings
~40 HRH. Pure zinc powder used to protect iron & steel structures and fabrications from rusting and corrosion. Excellent for repairing ruptured galvanized coatings.
Bridges, Castings, Christmas-tree pipe assemblies, tubing, etc
CorResist® 29230 Zn alloy / 500oF (260oC)
BabTec® 29240
Sn-Sb-Cu alloy
Excellent behavior under friction.Low melting temperature.
Antifriction alloys. Resurfacing bearings. The best adhesion is obtained by prepara-tory tinning using 157 PA
Eutectic® 1960
Zn 99% / 787oF (420oC)
~40 HRH. Elemental zinc powder used to provide galvanic protection for iron and steel parts. Do not use at service temperatures above 140 °F. Use as-sprayed; do not finish.
Steel Structures, Hand Rails
Eutectic® 1961
Al 99% / 1220oF (660oC)
~30 HRH. Elemental aluminum powder used to provide galvanic protection for iron and steel parts. Coatings are generally used in the as-sprayed condition.
Steam Piping, Valve Bodies, I-Beams
Eutectic® 5018
Combination of light weight, high strength and resistance to environmental factors make this thermoplastic ideal Reduced friction wear applications, barrier coatings including Nylon 11 white / 250oF material for industrial, municipal, commercial and industrial particulate erosion resistance, pipe flanges, brackish water (120oC) applications. Powder coatings have broad corrosion pumps, etc… resistance and excellent low-friction properties.
Eutectic® 5094
Combination of light weight, high strength and resistance to environmental factors make this thermoplastic ideal Reduced friction wear applications, barrier coatings including o Nylon 11 gray / 250 F material for industrial, municipal, commercial and industrial particulate erosion resistance, pipe flanges, brackish water o (120 C) applications. Powder coatings have broad corrosion pumps, etc… resistance and excellent low-friction properties. suitable for use with Terodyn 3000 only.
Hot and Cold Spray Equipment CastoDyn DS 8000 CastoDyn DS 8000 is an advanced modular oxy-acetylene thermal spray system, designed to spray a wide range of alloys C and a other materials for many different applications, from anti-abrasion coatings to thermal shielding. The CDS 8000 can be b integrated into automated installations for large-scale mass-production applications. For F «hot» thermal spraying of Eutalloy® RW powders For F «cold» thermal spraying of RotoTec® and Proxon® alloy powders For F «cold» thermal spraying of MetaCeram alloy powders
TeroDyn System 2000 The TeroDyn System 2000 produces a very stable and thermally efficient flame that delivers up to 110,000 BTU/hr.* This high energy level makes it possible to produce superior quality coatings while spraying at very high deposition rates. Unique, high performance nozzles produce hot, concentrated spray patterns for exceptional deposit and target efficiency - minimizing waste from overspray. The TD System 2000 can be used with acetylene, propylene, MAPP, propane and hydrogen, depending on the powder being deposited. Liquid fuels are advantageous because they’re safer and often more economical than acetylene. Propylene can often provide higher deposition rates due to its increased BTU output.
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Statement of Liability: Due to variations inherent in specific applications, the technical information contained herein, including any information as to suggested product applications or results, is presented without representation or warranty, expressed or implied. Without limitation, there are no warranties of merchantability or of fitness for a particular purpose. Each process and application must be fully evaluated by the user in all respects, including suitability, compliance with applicable law and non-infringement of the rights of others, and Eutectic Corporation and its affiliates shall have no liability in respect thereof. H&C 1-15 © 2008, Eutectic Corporation, ® Reg. T.M., Printed in the U.S.A.