|
Thermal Spray Systems : |
| Thermal
Spraying Equipments |
| METAL
SPRAYING UNIT |
|
It consists of
1) Sprayjet-88 Gun
2) Gas control unit
3) Dual gas flow-meter
4) Air control unit
5) Wire dispenser
6) Hose kit
7) Trolley
Net weight : 50 kg.
Gross weight : 150 kg. |
 |
|
| Gas contorl unit |
: |
Multi
stage unti provides control and regulation of high pressure
fuel gas and oxygen supply. It has two gauges-one to indicate
cylinder pressure and other for delivery pressure. |
| Dual gas flow-mete |
: |
Provides an accurate
regulation of flow of oxygen & fuel gas. It detects leak
or restriction in gas supply, eliminates human error in setting
proper flame. |
| Air control unit |
: |
Controls air pressure
and filters air from oil vapour and moisture. An additional
outlet is provided for operator's helmet if needed. |
| Wire dispenser |
: |
It holds metallizing
wire in standard coil and feed it to the gun properly. |
| Hose kit |
: |
Consists of black
hoses for oxygen and air, one red hose for acetylent-all 5
mtr. long. |
| Trolley |
: |
Light weight castored
trolley ousing the fll unit and makes it a mobile tool. It
has shelves for tools and wire coils. |
|
| SPRAYJET-88
GUN |
 |
 |
1. Gas nozzle and air cap
2. Gas head valve and siphon plug
3. Gun handle for manual operation4. On-off lever
5. Gun mounting stud
6. Fuel gas connection |
7. Oxygen connection
8. Air connection
9. Turbine and wire drive unit
10. Wire grip mechanism
11. Non-return wire guide |
|
| SPECIFICATIONS |
| Wire Drive |
: |
Air turbine |
| Wire size |
: |
3.17 mm STandard |
| |
|
1.6 mm Optional |
| |
|
4.75 mm Optional |
| Approx. Spray Rates(kg/hr) |
: |
Steel Zinc |
| using 3.17 mm wire |
: |
5 14 |
| using 4.75 mm wire |
: |
8 28 |
| Approx. Compressed air |
: |
1.8 m3/min |
| Consumption |
: |
at 4.5 kg/cm2. |
| Net weight (Gun only) |
: |
2.65 kg. |
| Shipping Weight |
: |
9.50 kg. |
|
STANDARD
SPRAYJET-88 is supplied complete with one each spare nozzle 3.17
mm, air cap, gas head 'O' ring set, valvelube, gearlube, wire
cutter, lighter, nozzle cleaning kit, tool post attachment, service
tools and instruction manual packed in a decent case.
SPRAYJET-88 HS : It is similar to Standard Sprayjet-88, but
with high speed gear to facilitate fast spraying of aluminium,
zinc and other low melting wires.
LPG CONVERSION KIT : A set of parts are available to use Low
Pressure Gas (in place of acetylene), to cut fuel cost, particularly
with Sprayjet-88 HS. |
FEATURES
OF SPRAYJET-88 METAL SPRAYING GUN
1. it sprays fast and uses upto 3/16" wire. Whatever wire
size you choose, the wire pulling power and high speed combustion
system of Sprayjet-88 assure you high speed rates :- These are
: 8 kg. 25 kg. and 6 kg. per hour for steel, zinc and stainless
respectively using 3/16" wire. The same are 5 kg., 14.0
kg., 5.5 kg. per hour respectively with 1/8" wire.
2. The gas head valve is designed for long service life with
minimum maintenance. Worn or damaged valve parts can be replaced
without lapping or other precise fitting. There is no sliding
metal-to-metal contact and no sticking, jamming or freezing of
gas valve.
3. Wire feed can be stopped while the gun remains alight. This
may be necessary while checking coating thickness or changing
job. A simple, quick action lever operates the wire grip mechanism
to start and stop the wire feed instantaneously.
4. An improved nozzle, having more gas holes provides a uniform
distribution of heat around the metallizing wire for maximum
thermal efficiency and high spraying speeds.
5. The wire nozzle, siphon plug and front wire guide assemble
as a unit which can quickly and easily be removed and replaced
when changing wire size or for servicing.
6. The gun mounting stud is centrally located, making it very
easy to adjust the gun position when it is lathe-mounted.
7. An improved turbine and drive unti ensure a much wider and
more suitable wire speed. It has a stronger wire-pulling power
which can feed even 3/16" steel wire consistently. |
| POWDERJET
- 85 (Powder Flame Spray System) |
| For coating
of hardfacing alloys, ceramics, metals and carbides. |
 |
Powderjet-85 is
a gun that deposits various metals, ceramics, cermets etc.
which are available in powder form. The powder stored in the
hopper at the top of the gun is gravity fed into the nozzle
system where it is melted by oxy-acetylene (or hydrogen) gas
flame & is spray deposited on the substrate surface as
shown in the sketch. |
|
| Special
Features of Powderjet-85 |
 |
1.
Powder Hopper : It is removable without need of any tool.
2. Powder Flow Control Valve : It has a numbered index dial
for precise setting of feed rate of powder.
3. Start-stop Trigger : For easy start-stop of powder flow.
4. Cylinder Valve Core : Single lever valve-easy liggtening
of gun. No needle valve required for gas adjustment. It simultaneously
opens & closed both oxygen & fuel. |
| Powderjet-85
is supplied with complete kit having spark lighter, gas hose
kit, valve lube, spare nozzle, O-rings, tool post fixture,
dark glasses & instruction manual. |
|
Typical Spraying Rates of 85
Gun |
Standard
Accessories |
Supplementary
Accessories |
| Powder |
Spray
RAte Kg/Hr. |
Gas Control Unit :
It consists of two-stage precision regulators for oxygen & acetylene.
Gas Flowmeter :
For regulating flow of gases and preventing backfire.
Vibrator (Optional) :
It helps free flow of fine powders specially metallic |
Cooling Vent
Fusing Torch
Face Shield
Gritblast Gun
Gritblast Cabinet
Gun Manipulator
Lathe Manipulator
Spray Booth
Surface Pyrometer
Extension Nozzle
Lathe Exhaust hood with Dust Collector |
| NI-Cr Self Fluxing
Alloy |
08 |
| Cobalt Based
Self Fluxing Alloy |
08 |
| Ni-AI Alloy |
2.7 |
| Alumina-Titania |
1.2 |
| Chormium Oxide |
1.2 |
|
| POWDERJET-86-II
(Heavy Duty Thermal Powder Spray System) |
 |
For
coating of hardfacing alloys, ceramics, metals and carbides |
|
POWDERJET-86-II
GUN (Fitted with Cooling Wand)
|
POWDERJET-86-II A UNIVERSAL GUN
The Powderjet-86-II Gun is extremely versatile and offers
premium coating for wear resistance, corrosion protection,
thermal and electrical insulation etc., which have long been
the attaindent goal of all the coating processes. The system
can be made fully automatic or programmable.
The heavy duty thermal spraying gun, 86-II is successfully
used with varying spray rates, as high as 25 Kg/hr, which
shortens the spray time on large parts.
The specially designed high performance nozzle, accelerates
spray powders efficiently by feeding the powders directly
into the flame centre of gun & gives the consistent deposition
efficiency for varied spraying.
Standard unit is with Oxy-Acety gases but is also usable
with Oxy-LPG/CNG gases for economy and cleaner environment.
Optionally Oxy-LPG/CNG gases can be used for low melting
powders like plastic powders to save fuel cost.
The system is equipped with Reverse Flow Check Valve to ensure
safety of opeartor. |
|
|
POWDERJET-86-II Heavy Duty
Flame Spray System consists of :
Posderjet-86-II Spray Gun
Powder Feeder, PF-700
Gas Flowmeter
Gas Control nit
Air Control Unit
Cooling Wand (Airejet Assy)
Interconnecting Hose Unit (5 mtr.) |
 |
|
| REFERENCE PARAMETERS |
| Gas |
Operating Pressure |
Consumption |
| Oxygen |
2.2 Bar |
2.7 M3/hr |
| DA |
1.0 Bar |
1.7 M3/hr |
| Powders |
Spray Rates |
Deposit Efficiency* |
| Ceramics |
0.9 Kg/hr |
25-75% |
| Metallic |
2.7 Kg/hr |
80-90% |
| Self fluxing |
9.1 Kg/hr |
85-95% |
| *Depends upon powder composition & particle size. |
| Above parameters are only for guidance. |
|
COOLIND WAND
Posderjet-86-II Gun can be fitted with cooling wand to accelerate
velocity of powder particles and cool the substrate. This avoids
overheating of coating and the job. |
 |
POWDER
FEEDER: PF-700
Powder Feeder, works on pressurization & constant volumetric
feed principal. It has a variable AC Drive fitted with digital
RPM display. During operation, the powder is gravity fed
into the slots of the rotating disk through which controlled
quantityt of the powder is pushed into the powder feed hose
by the carrier gas. The power feed rate is directly proportional
to the powder disc RPM which can be controlled by a pot on
the front panel. A safety valve is provided to release high
canister pressure. |
|
|
FEATURES :
Feed Rate from 1 RPM to 28 RPM
Disc RPM Display
Remote or Local Powder Feed Control selectable
High Pressure Safety Valve
Sensol less vector control technology for accurate RPM Control
Canister Capacity : 700 Cm3
Optional Model : PF-3350 (capacity : 3350 Cm3) |
| AUTOMATIC
CONTROL PANEL; AP-2200 (OPTIONAL) |
Automatic
Control Panel; AP-2200 to give a new speed to your production.
The user can remotely Start/Stop the gun as well as control
the powder feed rate. The PLC controls the Start & Stop
sequences as well as monitors the flame and the pressures
of various gases. The panel is compact and robust for rough
and tough operation. The PLC displays the status and any
fault in the system.
Complete with S.S. Tube fittings & tubings and can be
hanged on wall as well as mounted on a stant. Manually each
parameter can be set for initial setting using different
gases.
Power Supply : 230 VAC/1P/3Amps
Dimensions (mm) : 600 (L) x 350 (W) x 750 (H) (Excluding
Stand)
Weight (Kg) : 55 Kg. (nett) (Excluding Stand) |
 |
|
THERMAL
SPRAY POWDERS
NICKEL ALUMINIUM POWDERS
A) MEC-1037 (Ni-AL 95/5)
Nickel aluminium composite that reacts exothermically during
spraying. General purpose bond coat, produces dense & self
bonding coating. Good resistance to thermal shock & oxidation.
hardness : 75Rb
B) MEC-1087 (Ni-AI-MO 90/5/5)
Nickel-aluminium-molybdenum composite, for general purpose,
medium hard coating for hard bearing and wear resistant application.
Coating is tough & can withstand impact. Hardness : 75Rb
NICKEL BASE SELF FLUXING ALLOY
A) MEC-1260 (Ni-Cr-Fe-B)
Nickel based self fluxing alloy, produces hard, dense and porefree
coaing that is fusible, good resistance to corrosion & wear
by abrasive grains, hard surface, particle erosion, fretting & cavitation,
easy to fuse and will not crack even in thick build up. Hardness
: 60Rc
CERAMIC POWDERS
A) MEC-1011 (AL203-TiO2 97/3)
Alumina-Titania (97/3) powder for good wear resistance to abrasion & erosnion.
It can be used in many environments including most acids & alkalies.
hardness : 50Rc
B) MEC-1070 (AL2O3-TiO2 60/40)
Contains 60% aluminium oxide & balance titanium oxide for
highly abrasion resistant coating with good corrosion resistance.
It can be used for thread guide to resist abrasive fibres. Hardness
: 60Rc
C) MEC-1025 (Cr2O3)
Pure chroumium oxide powder, suitable for wear due to abrasion,
corrosion, oxidation, fretting or erosion resistance coating.
Coating will be dense and can be used on pump seal areas3
ground rolls & wear rings. Hardness : 60Rc |
| Wide
Range of Applications : |
 |
Engine
Valves, Stems, Glass Moulds, Pulverizing Equipment Parts, Wire
Drawing Capstans, Pump Plunger, Gas Turbing Parts, Metal Pouring
Troughs Spout, Crusher Rolls, Heat Treating Rolls, Oil Well
Pump, Flame Brooms, Nozles, Lapping Plates, Textile Cones,
Thread Guide, Wear Rings, Casting Inserts, Exhaust Fan, Impellers,
Bearing Shafts, Pump Sleeves, Conveyor Screws, Plug Gauges,
Textile Spindles, Extrusion Rams, Seal Rings, Cutting Lances,
Galvanizing Kettles & many more. |
|
| HIPOJET-2700
(High Velocity Oxy-Fuel Spray System) |
 |
 |
| AIR COOLED HIPOJET-2700
GUN |
WATER COOLED
HIPOJET-2700 GUN |
|
| HIPOJET-2700
SYSTEMS |
|
HIPOJET-2700 AUTOMATIC HVOF SPRAY SYSTEM
HIPOJET-2700 MANUAL HVOF SPRAY SYSTEM |
SYSTEM
FEATURES |
AUTOMATIC |
MANUAL |
Ideal
for medium to large shops with high-volume surfacing
needs and increased quality control requirement.
Fully-automatic operation for highly occurate and repeatable
HVOF coatings.
PLC based controller with Rotameter.
Compatible with both Air Cooled Hipojet-2700 Gun and a
high performance Water Colled (Hybrid) Hipojet-2700 Gun.
Built-in monitoring and alarms system with automatic shutdown
for safe operation.
Interfaces with workpiece handling equipment, gun manipulators,
exhaust system and accessories.
Convertible to 6P-II.** |
Ideal for
small & medium shops with occasional surfacing needs.
Precision components designed for reliable & repeateble
coatings incorporation high safety standards.
Rotameter gas metering system.
Compatible with both Air Cooled Hipojet-2700 Gun and a
high performance Water Cooled (Hybrid) Hipojet-2700 Gun.
Customize your system with gun and part manipulation equipment
ideal for your spray applications.
User friendly mobile Unit.
Convertible to DJ-2700 as well as 6P-II.** |
|
| SPECIFICATIONS |
| |
AUTOMATIC |
MANUAL |
| GUN |
HIPOJET-2700-A |
HIPOJET-2700-M |
| Weight |
1.7 kg. (3.74 lb) |
1.85 kg. (4.07
lb) |
| Gases |
Oxygen, LPG / Propane
/ Natural Gas, Air |
Oxygen, LPG / Propane
/ Natural Gas, Air |
| CONTROL PANEL |
AP-2100 |
MP-2100 |
| Dimensions |
970 x 600 x 260
mm |
870 x 500 x 140
mm |
| Weight |
45 kg (99.2 lb) |
39 Kg (85.9 lb) |
| Electricity |
220 V / 1 P / 50/60
Hz |
220 V / 1 p /50/60
Hz |
| |
110
V / 1 P / 60 Hz (Optional) |
110
V / 1 P/ 60 Hz (OPtional) |
| POWDER FEEDER |
PF-3350-HP |
PF-700 |
| Capacity |
3350 CC |
700 CC (3350 CC
Optional) |
| Weight |
40 Kg (88 Ib) |
32 Kg (70.4 Ib) |
| Electricity |
220 V / 1 P / 50/60
Hz |
220 V / 1 p /50/60
Hz |
| |
110
V / 1 P / 60 Hz (Optional) |
110
V / 1 P/ 60 Hz (OPtional) |
|
| REFERENCE
PARAMETERS |
| Gas |
Flow (LPM) |
Operating Pressure |
|
Powder |
Spray Rate |
Deposit Efficiency |
| Oxygen |
250-350 |
10.0 Kg/Cm2 |
|
WC-12Co |
38 gm/min (5.01 lb/hour) |
70 % |
| LPG / Propane |
60 - 80 |
07.0 Kg/Cm2 |
|
WC-17Co |
38 gm/min (5.01 lb/hr) |
60 % |
| Air |
600 - 700 |
07.0 Kg/Cm2 |
|
WC-10Co-4Cr |
38 gm/min (5.01 lb/hr) |
70 % |
| |
|
Cr3C2-NiCr |
25 gm/min (3.30 lb/ hr) |
58 % |
|
|
 |
STANDARD SYSTEM
Hipojet-2700-A OR Hipojet-2700 M HVOF Gun
Control Panel; AP-2100 OR MP-2100
Powder Feeder; PF-3350-HP OR PF-700
Gas Regulator for Oxygen & LPG; GR-2100
Air Control Unit; FR-210
Hose Unit for Oxy, Fuel & Air (7.5 mtr length)
Portable Trolley; TR-2100
Set of Recommended Spares for Hipojet-2700 Gun
OPTIONAL ACCESSORIES
LPG Vaporizer; VP-2100
water Jam Box; HY-2100
Extension Kit for internal spray (length 1', 2', 3')
Water Cooled Jacket (Hybrid); HY-2100
Gas Manifold for Oxygen clylinders (6, 10 or 20#)
Air Blast Unit (for cooling substrate); AJ-2100
Extra length of Hose (upto 30 mtr)
Extra length of Powder Feed Tube (upto 30 mtr)
|
|
| Applications |
   
    |
| ARCJET-95/400
TWIN WIRE ARC SPRAY SYSTEM |
 |
The MEC Arc Spray System is teh heavy duty
state of the art Twin Wire Arc Spray System for industrial
applications. It can spray all types of wires and is suitable
for manual as well as robotic arc spray applications. |
|
| SPRAY RATE |
 |
| Material |
Spray
rate at 400 A (75% duty/cycle) Kg/hr. |
Coverage with 100 mocrons thickness
kg/m |
M/hr. |
zinc & Alloys*
Tin Zinc*
Aluminium*
Ai Bronze
Copper
Carbon
Stainless Steel |
30.0
50.0
08.1
12.3
15.0
12.5
13.5 |
1.22
1.20
0.31
1.10
1.10
0.90
0.98 |
24.6
41.5
26.1
11.6
13.6
13.8
13.8 |
Wire size is 1.6 mm unless mentioned otherwise.
*These figures are for 2 mm wire size. |
| *ABOVE FIGURES
ARE FOR GUIDANCE ONLY |
|
| HIJET-9600
SYSTEM |
| HIGH
VELOCITY COMPUSTION WIRE SPRAY SYSTEM |
HIJET-9600
SYSTEM CONSIST OF THE FOLLOWING:
HIJET-9600 Oxygen-Propane / LPG Flame Gun with
Motorised wire Feed System
Air Control Unit
Gas Control Unit
Gas Flow Meter
Interconnecting Cables and High Pressure Hoses
Wire Reel Stand |
 |
|
| COATING CHARACTERISTICS |
| HARDNESS (ASTM-E384-89) |
MOLYBDENUM
STAINLESS AISI 420 |
- UPTO 1000 VHN
-500
VHN |
| DEPOSIT EFFICIENCY |
MOLYBDENUM
STAINLESS AISI 420 |
-70% -ABOVE 80% |
| BOND STRENGTH
(ASTM-C633-79) |
MOLYBDENUM
STAINLESS AISI 420 |
-30MPa 25 MPa |
| POROSITY |
2-5% |
|
| THICKNESS |
0.025 MM TO>3MM
(Depending upon Material sprayed) |
|
| SURFACE ROUGHNESS |
AS SPRAYED
GROUND
LAPPED |
-2.0-4.0 Microns Ra
-<1.0 Microns Ra
-<0.1 Microns Ra |
|
| TILTING
TURNTABLE |
SPECIFICATION
Baser Plate Diameter : 800 mm
Max rmp : 300
Tilting Angle : 0 to 270 Deg.
Capacity : 1000 Kgs.
MEC Tilting turn table is suitable for job mounting and rotation.
The turn table can be integrated with the robotic spray cell. |
 |
|
| POWDER
FEEDER; PF-700 |
 |
SPECIFICATION
Powder Container 45 Cubic Inches
Size 8: x 4" x 4"
Powder Wheel rmp 5 to 15 stepless
Electric Supply 115V AC 60 1Ph
220V AC 50 1Ph
Powder Hose Length 10 Feet
Net Weight 70 lbs
Gross Weight 77 lbs |
|
| EXTEND
YOUR SPRAY CAPABILITY |
 |
Sprayjet
Extensions are available in lngths 30 cm, 45 cm & 60 cm.
Minimum ID of 30 mm can be sprayed with ease. |
|
 |
 |
| High velocity
Wire Spray Extension are used for coating minimum ID of 70
mm. Various lengths are avilable. |
HVOF Powder Spray
Extension for high quality coatings |
|
  |
MEC supplies wide
range of thermal spray consummables like, metallic, alloyed and
cored wires, metallic, ceramic & cermet powders, masking compound
and various sealers. |
