HARDFACING BY METAL

SPRAYING
TOP-JET / MASTER-JET

January 2001

The technical characteristics, applications and physical properties cited in this document are
communicated for information only. SNMI does not provide any technical or commercial guarantee. SNMI
reserves the right to modify this document without informing its customers.

SAINT-GOBAIN – CS – SNMI
Courtine Mourre Frais – BP966 – 84093 Avignon cedex 9
Tél : 04 90 85 85 00 – Fax : 04 90 82 94 52
http://www.snmi.com
CONTENTS

GENERALITIES 3

DEFINITION AND PRINCIPLE 3

MATERIAL AND IMPLEMENTATION 3

ADVANTAGES OF THE PROCESS 4

COATING METALS 4

MATERIAL DATA SHEETS 5

ASM 130 (1 et 2) 5

ASM 18/8 6

Tin Bronze 7

Molybdenum 8

ROCDUR 67 9

ROCDUR 6750 10

Alumina 11

Blue Corundum 12

Chromium Oxide 13

Nickel Chrome 14

NIALIDE 15

ANNEXES 16

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DEFINITION AND PRINCIPLE

It should be remembered that metal spraying is the spraying of a metal

or molten oxide on to a part that has been prepared in advance.

Originally, this technique was simply used for repairing worn mechanical
parts by means of spray gun metal spraying.
Today, a large number of new parts are also treated in this way to
improve their resistance to abrasion, friction and so on.

MATERIAL AND IMPEMENTATION

The spray guns used are TOP-JET or MASTER-JET type guns with all
the elements necessary for drive, fusion and spraying of the finishing
metal, in the form of wire, flexible cord or rods.

The parts are prepared by sand blasting so as to create the surface

profile required for cohesion.
The deposits can be of a thickness of several millimeters and are often
machined with tools or a grinding wheel.

ROCDUR 6750 hardfacing with the TOP-JET

In the case of hardening alloys (nickel base), the deposit must be

remelted at 1050 °C. These are called self-fluxing or ROCDURs.

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ADVANTAGES OF THE PROCESS

• Very fast and economical

• All thicknesses available, from a few hundredths to 3 cm

• No high temperature. No deformation or thermal treatment

necessary

• The porosity of the deposit is an oil reservoir which gives the base
material self-lubrication properties

• After grinding, the deposits leave a very attractive finish and the
parts are within the tolerances indicated

• In manufacturing, metal spraying makes it possible to considerably

improve mechanical parts at a low cost by limiting the use of noble
metals. The bulk of the part can thus be made of a more economical
material.

COATING METALS

There is a very wide range of finishing materials. This document provides

a summary of the 11 most frequently used materials in hardfacing.
They include:

METALS OXIDES
- 13 % Chrome Steel - Alumina
- Stainless Steel - Blue Corundum
- Tin Bronze - Chromium Oxide
- Molybdenum

SELF-FLUXING UNDER-LAYER
- ROCDUR - Nickel Chrome
- ROCDUR 6750 - NIALIDE

Metal spraying hardfacing makes it possible to treat all worn or

new mechanical parts that are confronted with friction, abrasion
or corrosion.

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 ASM 130 (n°1 et n°2)
13% Chrome Steel Wire

Repairs of parts worn

out by friction

APPLICATIONS :
- Pump shafts
- Bearing cages
- Valve opening bearings
- Valve rods, cylinder rods
- Faucet shanks
- Sealing rings
- Motor sleeves

Repairing a crankshaft (130 n°2)

Préparation : Sand-blasting + Nialide undercoat (5/100)

STANDARD THICKNESSES
REPAIRS
As sprayed: 1 mm (2 mm max.)
After machining: 0.5 mm

Spray speed (∅3,17) : 4,5 kg/h

Deposit time per m2 (épaisseur 1/10) : 15 min.
FRICTION
Hardness : 180HB (n°1) and 300HB (n°2)
Finishing : Machining (n°1) or grinding (n°2)

Packaging : ∅2,3/3,17 wire on 20Kg coil

SPRAYING PARAMETERS (∅ 3.17) ABRASION

Air pressure: 4-4.5 bars

Oxygen pressure: 4 bars (Bearing height 51)
Acetylene pressure: 1.2 bars (Bearing height 66)
Wire speed: 1.5 m/min (Speed 1-fast 3-slow on TOPJET)
CORROSION

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 ASM 18/8
Stainless Steel 307L Wire

Highly resistant coating to friction in a

corrosive environment

APPLICATIONS :
- Pump parts
- Turbine rotors
- Gland rings
- Pump lines
- Pump plungers
- Inking roller jack guides

Repairing inking rollers

Preparation: Sand-blasting + Nialide undercoat (5/100)

STANDARD THICKNESSES
As sprayed: 1 mm (2 mm max.) REPAIRS

After machining: 0.5 mm

Spray speed(∅3,17) : 5 kg/h

Deposit time per m2 (thickness 1/10) : 10 min.
FRICTION
Hardness : 150HB
Finishing : Machining

Packaging : ∅2,3/3,17 wire on 20Kg coil

SPRAYING PARAMETERS (∅ 3.17) ABRASION

Air pressure: 4-4.5 bars

Oxygen pressure: 4 bars (Bearing height 51)
Acetylene pressure: 1.2 bars (Bearing height 66)
Wire speed: 1.5 m/min (Speed 1-fast 3-slow on TOPJET)

CORROSION

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 Tin Bronze
Tin Bronze 88/12 wire

Hardfacing parts that fret against steel

APPLICATIONS :
- Pump wheels
- Drilling screws
- Cast-iron valve covers
- Opercules de vannes en fonte
- Valves and seats
- Cages de roulement

Roller connection

Préparation : Corindonnage

STANDARD THICKNESSES
REPAIRS
As sprayed: 1 mm (3 mm max.)
After machining: 0.5 mm

Spray speed (∅3,17) : 6,8 kg/h

Deposit time per m2 (thickness 1/10) : 10 min.
FRICTION
Hardness : 70HB
Finishing : Tool machining

Packaging : ∅2,3/3,17 wire on 20Kg coil

SPRAYING PARAMETERS (∅ 3.17) ABRASION

Air pressure: 4-4.5 bars

Oxygen pressure: 4 bars (Bearing height 48)
Acetylene pressure: 1.2 bars (Bearing height 65)
Wire speed: 1.8 m/min (Speed 2-fast 3-slow on TOPJET)
CORROSION

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 Molybdenum
Molybdenum Wire

Excellent friction qualities

APPLICATIONS :
- (New) car parts
- Local repair of inking rollers
- Machine-tool guide tracks
- Pump pistons
- Clutch disks
- Bearing cages

Clutch release fork

Preparation : Sand-blasting

STANDARD THICKNESSES
REPARATION
As sprayed: 0.5 mm (2 mm max.)
After machining: 0.3 mm (low thickness possible)

Spray speed (∅3,17) : 2 kg/h

Deposit time per m2 (thickness 1/10) : 35 min.
FROTTEMENT
Hardness : 600-800HB
Finishing : Grinding

Packaging : ∅2,3/3,17 wire on 20kg coil

SPRAYING PARAMETERS (∅ 3.17) ABRASION

Air pressure: 3.8 bars

Oxygen pressure: 4 bars (Bearing height 46)
Acetylene pressure: 1.2 bars (Bearing height 72)
Wire speed: 0.5 m/min (Speed 1-slow motor on TOPJET)
CORROSION

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 ROCDUR 67
Nickel Base Alloy Cord

Versatile Self-Fluxing

APPLICATIONS :
- Feeding screws for abrasive
products
- Glassworks parts (chutes,
blades)
- Internal parts for incinerators
(tubes, blocks)
- Pump pistons

Cylinder undergoing remelt

Preparation : Consult SNMI for further information

STANDARD THICKNESSES
As sprayed : 0,8 mm (3 mm maxi) REPAIRS

After machining : 0,5 mm

Spray speed : 5,3 kg/h

Deposit time per m2 (thickness 1/10) : 15 min.
FRICTION
Finishing: remelt at 1050 °C

Packaging : ∅ 4.75 cord on 10 kg spool

ABRASION
SPRAYING PARAMETERS

Air pressure: 4 bars

Oxygen pressure: 4 bars (Bearing height 70)
Acetylene pressure: 1.2 bars (Bearing height 85)
Wire speed: 1 m/min (Speed 1-fast 2-slow on TOPJET)
CORROSION

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 ROCDUR 6750
50/50 Nickel/Carbide Base Alloy Cord

Self-fluxing anti-abrasion

APPLICATIONS :
- Extrusion screws
- Scrapers
- Feeding screws for abrasive
products
- Friction zones in mixers
- Internal parts of incinerators
(tubes, blocks)

Beetroot screw press (∅ 750 L6000)

Preparation : Consult SNMI for further information

STANDARD THICKNESSES
REPAIRS
As sprayed : 0,8 mm (3 mm maxi)
After machining: 0,5 mm

Spray speed : 3 kg/h

Deposit time per m2 (thickness 1/10) : 35 min.
FRICTION
Hardness : 57HRc (Matrix Ni) and 2000HV (Carbides)
Finishing : Remelt at 1050°C

Packaging : ∅4,75 cord on 10kg spool

SPRAYING PARAMETERS ABRASION

Air pressure: 3 bars

Oxygen pressure: 4 bars (Bearing height 39)
Acetylene pressure: 1.2 bars (Bearing height 52)
Wire speed: 1 m/min (Speed 1-fast 2-slow on TOPJET)
CORROSION

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 Alumina
Aluminum Oxide Cord

Characteristics similar to
plasma coatings

APPLICATIONS :
- Thermal insulation for furnace
parts
- Moldes parts (crucibles)
- (Textile) heating cylinders
- Electrical insulation (inductors)
- Wear sleeves

Electrical insulation of an inductor (∅1000)

Preparation : Sand-blasting + undercoat (5/100)

STANDARD THICKNESSES
REPAIRS
As sprayed : 0,5-0,8 mm (3 mm maxi)
After machining : 0,3-0,5 mm

Spray speed : 1,1 kg/h

Deposit time per m2 (épaisseur 1/10) : 20 min.
FRICTION
Hardness : 1100HV
Finishing : Grinding

Packaging : ∅4,75 cord on 3,7kg spool

SPRAYING PARAMETERS ABRASION

Air pressure: 4 bars

Oxygen pressure: 4 bars (Bearing height 70)
Acetylene pressure: 1.2 bars (Bearing height 84)
Wire speed: 0.5 m/min (Speed 1-slow motor on TOPJET)
CORROSION

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 BLUE CORUNDUM
Alumina/Titanium 97/3 Cord

Versatile wear-resistant coating

APPLICATIONS :
- Pump pistons
- Mixers
- Tank coatings
- Shaft journals
- Parts for the ceramics industry

Hélice de malaxeur

Preparation : Sand-blasting + Nialide underlayer (5/100)

STANDARD THICKNESSES
REPAIRS
As sprayed : 0,5-0,8 mm (3 mm maxi)
After machining : 0,3-0,5 mm

Spray speed : 1,2 kg/h

Deposit time per m2 (épaisseur 1/10) : 20 min.
FRICTION
Hardness : 1020HV
Finishing : grinding

Packaging : ∅4,75 flexible cord on 3,2kg spool

SPRAYING PARAMETERS (∅ 3.17) ABRASION

Air pressure: 4 bars

Oxygen pressure: 4 bars (Bearing height 70)
Acetylene pressure: 1.2 bars (Bearing height 84)
Wire speed: 0.5 m/min (Speed 1-slow motor on TOPJET)
CORROSION

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 Chromium Oxide
Chromium Oxide ROKIDE Rod

Better Wear Resistance than

with Plasma Coatings

APPLICATIONS :
- Gasket surface
- Hydraulic jack rams
- Wear rings
- Wire-drawing capstan
- Extractor fans

Steering knuckle

Preparation : Sand-blasting + underlayer

STANDARD THICKNESSES
REPAIRS
As sprayed: 0,5 mm (0,6 mm maxi)
After machining : 0,3 mm

Spray speed : 0,3 kg/h

Deposit time per m2 (thicknesses 1/10) : 3 h.
FRICTION
Hardness : 1200HV
Finishing : Rectification

Packaging : ∅4,75 and L608 rods in package of 10

SPRAYING PARAMETERS ABRASION

Air pressure: 4 bars

Oxygen pressure: 4 bars (Bearing height 70)
Acetylene pressure: 1.5 bars (Bearing height 85)
Wire speed: 0.15 m/min (MASTERJET necessary)*
* TOPJET : Chromium Oxide is available in ∅ 3.17 cord CORROSION

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 Nickel Chrome
80/20 Nickel Chrome Wire

UNDER LAYER

APPLICATIONS :
- Under layer for
Alumina
Blue Corundum
Chromium Oxide
- Good resistance to
temperature corrosion up to
800-850°C
- Excellent on copper base
alloys
Mag. ×100

Preparation : sand-blasting

STANDARD THICKNESSES REPAIRS

As sprayed : 5/100 à 1/10

Spray speed : 4 kg/h

Deposit time per m2 (thickness 0,1mm) : 15 min.
FRICTION
Hardness : 280HB
Finishing : Machining possible

Packaging : ∅2,3/3,17 wire on 20kg coil

SPRAYING PARAMETERS ABRASION

Air pressure: 4-4.5 bars

Oxygen pressure: 4 bars (Bearing height 51)
Acetylene pressure: 1.2 bars (Bearing height 66)
Wire speed: 1.1 m/min (Speed 1-fast 2-slow on TOPJET)
CORROSION

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 NIALIDE
95/5 Nickel Aluminum Cord

Excellent underlayer

APPLICATIONS :
- underlayer for
Steel
Alumina
Blue corundum
Chromium Oxide
- Low temperature

Mag. ×100

Preparation : Sand-blasting recommended

STANDARD THICKNESSES
REPARATION
As sprayed : 5/100 à 1/10

Spray speed : 2 kg/h

Deposit time per m2 (thickness 0,1mm) : 30 min.
FROTTEMENT
Hardness : 250HV
Finishing : Machining possible

Packaging : ∅3,17/4,75 cord on 6,5kg spool

SPRAYING PARAMETERS ABRASION

Air pressure: 4-4.5 bars

Oxygen pressure: 4 bars (Bearing height 70)
Acetylene pressure: 1.5 bars (Bearing height 85)
Wire speed: 0.6 m/min (Speed 1-slow motor on TOPJET)
CORROSION

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ANNEX 1 : PREPARATION

Proper preparation prior to metal spraying assumes that the metallic

surface is clean, that is to say, a uniform gray-white, with no traces of
scale or rust.

The adherence of metallic coverings also requires sufficient roughness,

that is to say a surface microgeometry that allows mechanical cohesion
between the sprayed metal and the base metal.

The simplest definition of this roughness is that of Ra, which is the

average of level differences between the tip of the peaks and the bottom
of the valleys.

For standard metal spraying, there should be Ra = 10-12 µm.

To improve the cohesion of certain coats (oxides), or to produce thick

hardfacing (>5/10 for steel), it is advisable to use an intermediate coat
between the substrate and the coating. The thickness of this undercoat
varies from 5/100 to 2/10, depending on the application.

ANNEX 2: GAS FLOW

The following tables show the estimated gas flow as a function of the
spraying parameters.

OXYGEN
Bearing height P=4 bars
39 1,75 m3/h
46-48 2,15 m3/h
51 2,30 m3/h
70 3,50 m3/h

ACETYLENE
Bearing height P=1,2 bars P=1,5 bars
52 0,80 m3/h -
65-66 1,05 m3/h -
72 1,20 m3/h -

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