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High Velocity Oxy-Fuel (HVOF) Solutions: Sulzer Metco
High Velocity Oxy-Fuel (HVOF) Solutions: Sulzer Metco
Introduction
A Continuing Tradition of Excellence
In 1988, Sulzer Metco introduced its first HVOF coating solutions with a new line of spray equipment and materials.
Designed to meet the need of our customers for tougher, more wear and corrosion resistant surfaces, our Diamond
Jet™ equipment and Diamalloy™ materials quickly achieved market success as the innovative answer sought by many
industries.
We never stopped innovating. Today, Sulzer Metco offers our customers unparalleled freedom of choice with gas and
liquid fuel HVOF solutions that perform beyond their expectations.
Optimum Materials…
Innovative Technology…
Perfect Coatings…
It’s the performance and value package you’ve been looking for!
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Applications
We Meet the Challenges of the Most Demanding Applications
With Sulzer Metco’s HVOF solutions, increased performance and improved economics are not mutually exclusive
concepts. Our surface engineering experts can help you to:
Printing and Paper/Pulp Equipment Print roll covers, inking rolls, calendar and press roll covers
Petrochemical Pump components, gate valves, ball valves, valve seats, exhaust stacks,
sucker rods, hydraulic rods, conveyor screws
Glass Manufacture Glass-mould plungers
Metal Processing Steel mill guides and rolls, wire-drawing capstans, forming dies, sheet
metal cutters
General Industry Pump housings, impellors and shafts, plastic extruders, cam follow-
ers, wear rings, machine bedways, press fits, restoration of machinery
components
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Characteristics
Advanced HVOF Technology for Superior Coating Characteristics
High Density
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Process
Proven to Produce Reproducible Surfaces to Exacting Requirements
The HVOF process efficiently combusts oxygen and a The powder particles flatten plastically upon impact with
gaseous or liquid fuel to produce high kinetic energy with the substrate; cooling and solidifying to form the coating.
controlled heat input. The coating material, in powder
form, is introduced into and uniformly heated by the hot High particle velocities, uniform heating and low dwell
gas stream to a molten or semi-molten condition. The time combine to produce coatings that are very dense
flame and powder are accelerated by a converging / di- and tightly bonded to the substrate. Coating chemistries
verging nozzle (air cap) to produce supersonic gas and are more predictable and coatings have fine, homoge-
particle velocities, which propel the powder particles to- neous microstructures.
ward the substrate to be coated.
Ignition
Kerosene
Oxygen
Cooling Water Substrate
Flexibility
Flexible Process Choices Result in Surfaces Engineered for Specific Applications
At Sulzer Metco, we know our customers have unique needs and application goals, so we offer the widest range of
process choices to ensure we meet your exact expectations.
• Choice of Coating Materials. Choose from a wide variety of coating materials including pure metals, metallic
alloys, metallic blends, carbides and self-fluxing materials, tailored to gas or liquid fuel systems.
• Fuels. Gas-fueled systems can use hydrogen, ethylene, propane, propylene or natural gas. Liquid-fueled sys-
tems can use Jet-A or kerosene. Choose the fuel process that is suitable to your production requirements,
economics and coating quality needed.
• System Options. Choose the system configuration that fits your budget and production requirements, with a
choice of standard and customized part manipulators and gun manipulators.
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Which is right for your application? Your choice of a gas fuel or liquid fuel system will depend on many factors that
can include:
• Configuration / geometry of the part to be coated • Desired finished surface roughness
• Substrate composition • Desired coating internal stresses
• Coating material to be applied • Number of parts to be coated
• Desired coating thickness • Size of coated area
• Applicable customer coating specifications • Utilities to be used (process media, air, water, etc.)
• Desired as-sprayed surface roughness
Let us help you decide on the technology that’s right for you. Only Sulzer Metco has the experience you need for
both gas fuel and liquid fuel HVOF technologies. Using our broad portfolio of HVOF coating materials, our Coating
Solution Center specialists can develop your surface solution using the best HVOF process technology for your ap-
plication. Our System integration experts will design an HVOF system that is exactly suited to your production and
budget requirements. It’s the Sulzer Metco difference!
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Key Components. Key elements are required for all Handling Equipment. In all but the most simple of man-
HVOF spray systems. These include the coating mate- ual spray systems, handling equipment precisely con-
rial to be applied, a powder feeder to deliver the coating trols the movement of the spray gun and workpiece, and
material to the spray gun, the HVOF spray gun that will the position of the gun relative to the workpiece.
heat the coating material and propel it to the workpiece,
and a control system that accurately controls the gas
flows required for HVOF combustion. Peripheral Equipment. Most HVOF spray installations
require a cooling water system for the spray gun and it
is often necessary to have cooling air to control the tem-
perature of the workpiece. In addition, a soundproof
cabin and an air filtration and exhaust system protect
both personnel and the environment.
Peripheral Components
Handling Components
Key Components
Workpiece
Manipulator
Material
Gun
Manipulator Spray
Controller
HVOF
Spray Gun Spray
Cabin
Powder
Feeder
Water
Chiller Handling
Controller
Filter
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Materials
Every Successful Application Starts with the Right Material Choice
Sulzer Metco’s portfolio of HVOF coating materials is de- Do you already own a system with an HVOF gun not pro-
signed to achieve optimum results, with each product duced by Sulzer Metco? You can still benefit from a Sul-
sized and formulated for the selected HVOF process. zer Metco HVOF material solution! Many of our HVOF
Our specialists will consult with you to determine the ide- products are available in a variety of particle sizes opti-
al candidate for your application from our diverse line of mized for popular HVOF spray guns.
material chemistries.
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Product designations marked with an x indicate the availability of a variety of particle size ranges optimally sized for different HVOF spray guns.
* Inconel is a registered trademark of International Nickel; Rene is a registered trademark of GE.
** Product sized for HVOF supplied upon request.
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Spray Systems
Ensure the Success of Your Application with the Right System
Only Sulzer Metco has an equipment portfolio designed to meet your unique needs. Shown here are just a few ex-
amples of system configurations. Let our team of experts support you in designing your perfect system.
1
6
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Spray Systems
Ensure the Success of Your Application with the Right System
5
6
1
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Spray Systems
Ensure the Success of Your Application with the Right System
3b
4
3a
1
3c
2a
2b
1 EvoCoat™-LF controller
2a* WokaJet™-410-S liquid fuel HVOF gun, or
2b* WokaStar™-610-S liquid fuel HVOF gun
3a Powder feeder Twin-140-H, or
3b Powder feeder 5MPE-HP, or
3c Powder feeder 9MPE-DJ
4 Water chiller Climet RC-LF
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Spray Systems
Ensure the Success of Your Application with the Right System
5b
5a
1
2
3a 3b 3c
Sulzer Metco MultiCoat™ Advanced HVOF Gas fuel / Liquid fuel Spray System
• The most advanced system platform on the market!
• Ideal for medium to large shops with many different surfacing needs, R&D facilities, and moderate to high-volume
production needs
• Configurable for multiple spray processes including gas fuel HVOF, liquid fuel HVOF, plasma, combustion powder
and wire spray – all of which can be controlled from a single controller
• Fully-automatic operation for highly accurate and repeatable coatings
• Twin-Brain design with PC-based operator console and Programmable Logic Control (PLC) based controller with
mass-flow control gas metering system
• User friendly, color touch-screen programming with storage for 1000 spray recipes
• Advanced diagnostics, monitoring and control with multi-level alarm system and automatic shutdown for safe
operation
• Digital data bus interface to workpiece handling equipment, gun manipulators, exhaust system and accessories
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Flexible Choices
HVOF Spray Guns, Powder Feeders, Handling Equipment
Gas fuel
Liquid fuel
5MPE-HP 9MP-DJ
* used with automatic models; can be used with hand-held water cooled DJ gun if ** WokaJet™-410 and WokaStar™-610 with hydrogen ignition
ordered with an optional hydrogen ignition kit, available on a special order basis.
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Services
Sulzer Metco Essential Services for On-Going Success
Training
Let our staff professionally train your personnel on the
safe operation and maintenance of your thermal spray
systems.
Field Service
Qualified, factory-trained field service technicians will
keep your systems in peak operating condition. Our field
services include flexible maintenance contracts, emer-
gency breakdown repairs and troubleshooting help.
Traceability
Fully traceable calibrations, including gas flows and pres-
sures, ensure the accuracy and repeatability of your
spray facilities.
Simplified sourcing
Simplify your purchasing decisions with Sulzer Metco
quality consumable parts and materials for competitive
HVOF spray guns.
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HVOF
HVOF Advanced Technology Solutions and Services
Sulzer Metco is a global leader in surface engineering solutions and services offering:
• A broad range of thermal spray, thin film and other advanced surface
technology equipment
• Integrated systems and materials
• Specialized coating and surface enhancement services
• Manufactured components for the turbine, automotive
and other industries
• Customer support services
Sulzer Metco (US) Inc. Sulzer Metco Europe GmbH Sulzer Metco AG (Switzerland) Sulzer Metco (Japan) Ltd.
Headquarters - Americas Headquarters - Europe Wohlen, Switzerland Headquarters - Japan
Westbury NY, U.S.A. Kelsterbach, Germany Phone: +41 56 618 81 81 Tokyo, Japan
Phone: +1 516 334 1300 Phone: +49 6142 6033 0 Phone: +81 3 5920 3302
+1 888 262 8544 Sulzer Metco WOKA GmbH
Sp.z.o.o. Oddzial w Polsce Barchfeld, Germany Sulzer Metco (Singapore) Pte. Ltd.
West Coast Distribution Poznan, Poland Phone: +49 36961 861 0 Headquarters - Asia/Pacific
Brea CA, U.S.A. Phone: +48 61 847 44 20 P. R. Singapore
Phone: +1 800 826 3826 Sulzer Metco (UK) Ltd. Phone: +65 6708 7000
Succursale en France Cwmbran, Gwent, U.K.
Sales Latin America Bron, France Phone: +44 1633 488090 Sulzer Metco Surface Technology
Doral FL, U.S.A. Phone: +33 4 72 81 60 80 (Shanghai) Co. Ltd.
Phone: +1 305 477 2525 Sulzer Metco (Russia) LLC Shanghai, P. R. China
Sucursal en España Moscow, Russian Federation Phone: +86 21 6708 7000
Sulzer Metco (Canada) Inc. Madrid, Spain Phone: +7 495 554 61 46
Ft. Saskatchewan AB, Phone: +34 91 570 33 49 Sulzer Metco (Australia) Pty. Ltd.
Canada Padstow, NSW, Australia
Phone: +1 780 992 5100 Branch Benelux Phone: +61 2 9796 2011
Standdaarbuiten,
Sulzer Brazil S.A. Netherlands
Jundiai, Brazil Phone: +31 165 880 405
Phone: +55 11 4589 2478
Filiale Italiana
Cusago (MI), Italy
Phone: +39 02 903 9241
Filial Norden
Stockholm, Sweden
Phone: +46 8 680 7580
www.sulzer.com • info@sulzermetco.com
Information is subject to change without prior notice