Low dilution, low thickness coatings thanks to PTA-PHE

Saint-Gobain Coating Solutions Ceramic materials Low dilution, low thickness coatings thanks to PTA-PHE 15 th ITSS XUZHOU October 23-25, 2012 Patrice FOURNIER

Contents SG Introduction PTA-PHE Description Materials & Coating morphology Benchmarking vs others PTA-PHE coating features Benefits Applications Conclusion 121024 PF 2

Chapter 1 Low dilution, low thickness coatings thanks to PTA-PHE Saint-Gobain introduction

Speciality Grain & Powder division - Coating Solutions Manufacturing Sales offices R&D locations Saint-Gobain, a global presence GLOBAL PRESENCE www.coatingsolutions.saint-gobain.com Worcester - MA, USA Tel: 1-800-243-0028 Fax: 1-508-795-2380 Shanghai, China Tel: 86-21-6361-6100 Fax: 86-21-6361-7790 São Paulo, Brasil Tel: 55 31 9243 0175 Tel: 5511 2246-7986 Taipei, Taiwan Tel: 886-2-2503-4201 Fax: 886-2-2503-4202 Porz, Germany Tel: 49-2203-956465 Fax: 49-2203-956421 Osaka, JAPAN Tel: 81-6-6569-3511 Fax: 81-6-6569-3515 Avignon, France Tel: 33-4-9085-8500 Fax: 33-4-9082-9452 Seoul, Korea Tel: 82-2-3706-9042 Fax: 82-2-3706-9574 Worcester - MA, USA Weathfield, NY Avignon, FR DengFeng, CN Northampton - MA, USA Huntsfield, AL Cavaillon - FR Randan, CN Northborow, USA Shanghaï, CN 121024 PF 4

Products CCAV : 6 product lines Thermal spray Flexicords and flame spray guns ROKIDE rod spraying ProPlasma Spray systems Thermal Spray powders TUFCOTE hardfacing ropes PTA-PHE : Plasma Transferred Arc welding & cladding equipment 121024 PF 5

Our speciality : WE MANUFACTURE & WE SELL equipments & consumables for spraying & hardfacing - Flame spray - Plasma spray & TSP - Spray flexicords - Brazing flexicords - PTA torches 121024 PF 6

Chapter 2 Low dilution, low thickness coatings thanks to PTA-PHE PTA-PHE Description

PTA-PHE 2 in 1 equipment PTA HARDFACING 2 to 5mm thick PTA Hardware PTA welding parameters Low speed motion PHE HARDFACING 0,4 to 2mm thick PHE Hardware PHE welding parameters High speed motion 121024 PF 8

PTA-PHE + FANUC 6 axis robot 121024 PF 9

PTA-PHE ABB 6 axis robot 121024 PF 10

PTA-PHE + oscillation system + Arc Voltage Control 121024 PF 11

PTA 6PHE + 5 axis motion system 121024 PF 12

Chapter 3 Materials - Powder Main materials Deposit morphology

PTA Chart of the Major Powders Material Standard Hardness Corrosion Hot corrosion Abrasion wear Friction wear High temperature Application Corec 1 ST1 52-56 HRC R R RR RRR R Hot wear, corrosion Corec 6 ST6 38-42 HRC RR RR R R R Hot wear, corrosion Corec 12 ST12 44-55 HRC R RR RR RR R Hot wear, corrosion Corec 21 ST21 28-32 HRC RRR RR R Hot wear, corrosion Corec F F 38-45 HRC R RRR RR RR R Hot wear, corrosion Corec 400 T400 51-56 HRC RR RR RR RR RR Hi temperature wear, metal to wetal wear Corec 800 T800 54-62 HRC RR RR RR RR RR Hi temperature wear, metal to wetal wear FEREC 02 NOREM 02 36-44 HRC RR R R RR Friction and galling resistance FEREC M12 M12 steel 54-62 HRC R R RRR Wear, cutting edges FEREC 307 AISI 307 22-25 HRC R R Buffer layer, size rebuilding, self hardening upto 45HRC, versatile FEREC 309L AISI 309L 250 HB RR Buffer layer, size rebuilding, buffer layer for ferritic stainless steel FEREC 316 AISI 316 160-190 RRR Size rebuilding for AISI 316L FEREC 410 AISI 410 37-42 HRC R R R RR Corrosion, friction wear FEREC 420 AISI 420 45-52HRC R R R RR Corrosion, friction wear FEREC 430 AISI 430 20-37 HRC R RR Buffer layer for AISI 410 and 420 NIREC 1 SF1 58-62 HRC RR R RR Corrosion, friction wear, abrasion wear NIREC 6 SF6 38-42 HRC RR R RR Corrosion, friction wear, abrasion wear NIREC 625 IN 625 200 HB RRR RRR RRR High temperature corrosion NIREC 718 IN 718 250-410 HB RRR RRR RRR High temperature corrosion NIREC HC Hastelloy C RRR RR RRR Corrosion and petroleum corrosion NIREC WCA Ni WCA >70 HRC RR Abrasion wear, friction wear NIREC WCS Ni WCS >70 HRC RRR Abrasion wear, friction wear 121024 PF 14

PTA-PHE - Typical coating morphologies Nirec alloy - NiCr based Corec grade 1 Corec grade 6 Angular tungsten carbide Spherical tungsten carbide High chrome 121024 PF 15

Benchmarking PTA-PHE versus other welding processes Chapter 4

Welding processes - reminder FLAME WELDING ELECTRODE GMAW rod nozzle fuel/o 2 flame metal skin dross nozzle wire shielding gas T.I.G. WELDING FLUX WELDING P.T.A. / P.H.E. TM rod nozzle argon tungstene flux wire contact tube flux shielding gas powder tungstene nozzle slag GMAW, TIG, FCAW = WELDING PROCESSES Use to be thick coatings (3 to 7 mm) Applied in several layers (Minimum 2 layers) High dilution (10 to 25 %) 121024 PF 17

Welding process comparison PROCESS GMAW DESCRIPTION Electrode : metal Shield gas : Ar DEPO- -SITION RATE 2 to 6 kg/h THICKNESS / LAYER 6 mm EFFI- CIENCY >90 % DILUTIO N RATE 10-30 COATING MATERIALS Wire INVESTMENT MANU AUTO yes yes M TIG Electrode : W Shield gas : Ar 2 kg/h 3 mm <90 % 8-20 Wire or rod yes yes M ELECTRODE Encased rod or casting rod 2 to 4 Kg/h 5 mm <90 % 15-35 Rod yes no S OXY-GAS TORCH PTA PTA-HE Brazing torch powder Electrode : W Plasma gas : Ar Shield gas : ArH2 Electrode : W Plasma gas : Ar Shield gas : ArH2 2 to 4 kg/h 2 to 6 (20) kg/h 1,5 to 3 kg/h 2 mm 4 mm 2 mm >95% yes no S FCAW Electrode : metal 7 to 15 6 mm >90 % 15-40 Wire no yes L kg/h LASER CO2 laser power 1,5 2 mm 70 % <5 Powder no yes XXXXL source kg/hg 98 % 95 % <3 5-15 <5 Rod Powder Powder no no yes yes L L 121024 PF 18

PTA-PHE Coating features Chapter 5

PTA-PHE Benefits Low dilution = higher deposit hardness, = better corrosion resistance. Low Heat Affected Zone (HAZ). Residual stress reduced by 25 % to 100% compared GMAW, FCAW, TIG, electrode. Low dilution of the carbides, Finer crystallographic structure (higher hardness, higher abrasion resistance) 121024 PF 20

PTA-PHE Lower dilution GMAW-FCAW-TIG-ELECTRODE High dilution PTA-PHE Low dilution Coating as machined Coating as welded Dilution Heat affected zone Thermally Affected Zone 121024 PF 21

% of Iron PTA-PHE - Low dilution vs GMAW 70 60 50 Fe PHE Fe PHE Fe PTA Fe PTA Fe GMAW 40 30 20 10 0-0,4-0,2 0 0,2 0,4 0,6 0,8 1 1,2 1,4 1,6 1,8 Distance from interface (mm) Lower penetration of the substrate in the deposit material. Reduced Heat Affected Zone of the substrate (low HAZ), Limited diffusion of the substrate towards the deposit (up-to 5% dilution), Nominal hardness reached, even close to the interface, 121024 PF 22

Cobalt Gr6 microstructure vs Welding process GMAW Large dendritic structure PTA Medium dendritic structure PHE Fine dendritic structure 121024 PF 23

PTA-PHE - finer structure - higher hardness Hardness (Hv1) 700 Cobalt Gr 12 COATING 600 500 PTA Hardfacing PHE Hardfacing 400 300 Base metal 200 Grade 12 cobalt base coating 100-0,5-0,3-0,25-0,2-0,15-0,1-0,05 0 0,05 0,1 0,15 0,2 0,25 0,4 0,5 0,75 Bonding Distance to interface (mm) 121024 PF 24

Abrasion wear resistance ASTM G65 Cemented carbide PHE NiCrBSi+WCS SFL NiCrBSi+WCA PHE NiCrBSi+WCA PTA NiCrBSi+WCA Spray and fuse Ni+WC GMAW NI-WC Ni-Hard PTA NiCrBSi 60 HRC CrC D2 steel Hard Cr Hardox 500 1090 Steel PTA-PHE Co Gr 6 Hardox 400 GMAW Co Gr 6 0 20 40 60 80 100 120 140 160 180 200 Volume loss mm3 121024 PF 25

PTA-PHE benefits Chapter 6

PTA-PHE The precision of the Saint-Gobain torch and its high stability of arc during welding, makes possible to produce thin deposit having a controlled low dilution (low HAZ) and fine microstructure of deposit. This particular feature has the PHE TM * allowing to produce deposit without oscillation motion of the PTA torch, thus offering a fast cooling of the coating metal in fusion. * P.H.E. is a SG-CS patented 121024 PF 27

PTA-PHE Benefits PTA PHE cuts cost : Reduction of excessive build-up of coatings: PTA PHE allows to reduce coating thickness requirement from 3-4mm to 1,2 to 2 mm Uniformity and fine metallographic structure allowing higher machining speeds (the first pass of a Cobalt Gr 6 can be machined at 160 m/min), Low roughness of deposit minimizing the machining time (shape tolerance <0,4mm possible), 121024 PF 28

PTA-PHE Benefits Optimum build-up of coatings, Perfect geometry control of the deposit, close to the final geometry. Precision High deposit efficiency (> 95 %). Considerable gains in productivity (up to 100%) upto 65% time savings, upto 80% material saving, Reduction of the machining cost. Low cost of the powder compared to cored wires (-30%), Savings 121024 PF 29

Cost Benefit Analysis PTA / PHE / S&F 300 Relative cost of the coating solution 250 China Other Asia Emerg. Europe 200 Same cost vs PTA, but lower part distorsion 150 100 50 0 Spray and fuse NiWC PTA NiWCA PHE NiWCA PHE NiWCS 121024 PF 30

PTA-PHE Applications Chapter 7

Engine Valve Application PHE Process Cadence : 320 p/h (+60%) Welded coating weight : 2g (-66%) Thickness : 0,8 to 2 mm PTA Process Cadence : 200 p/h Welded coating weight : 6g Thickness : 2 to 5 mm The automotive & heavy engines industry was the first to be interested in the PHE process for the hardfacing of exhaust valve seats using Cobalt F or Coablt 12. 121024 PF 32

Mechanical Application Low thickness & wear resistant coatings hardfaced with PHE process. PHE process can be used as an alternative to hard chrome or thermal spraying (plasma or HVOF) for extreme cases of use. PHE is particularly suitable for parts that are subject to high amounts of stress or shocks, which are very often associated to problems relating to abrasion, wear, or corrosion. PHE Process Thickness : 1,5 to 2,5 mm COREC or NIREC materials PHE Process Thickness : 1,5 to 2,5 mm COREC or NIREC materials 121024 PF 33

Petro-Chem Application Valve obturator & valve seats can be hardfaced with PHE process. The PHE process significantly reduces coating costs by limiting the thickness of the coatings and by reducing machining costs by up to 50 %. This is due: to the perfectly uniform coating of surfaces, to an improved machining capability due to a thinner metallurgical structure. PHE Process Thickness : 2 to 2,5 mm COREC 6 or COREC 21 materials 121024 PF 34

Petro-Chem Application VALVE SEAT MATERIAL : COREC 6, EQUIPMENT : SN-PTA, SN-PHE, FEATURES : Corrosion resistance, wear resistance, 38-42 HRc. BALL VALVE MATERIAL : COREC 6 or COREC 21, EQUIPMENT : SN-PTA, SN-PHE, FEATURES : Corrosion resistance, wear resistance, 38-42 HRc (Corec 6) or 28-32 HRc (Corec 21). Doc SNMI 121024 PF 35

Petro-Chem Application BUTTERFLY BALL VALVE MATERIAL : COREC 6, EQUIPMENT : SN-PTA, SN-PHE, FEATURES : Corrosion resistance, wear resistance, 38-42 HRc. SEAT MATERIAL : COREC 6 or COREC 21, EQUIPMENT : SN-PTA, SN-PHE, FEATURES : Corrosion resistance, wear resistance, 38-42 HRc (Corec 6) or 28-32 HRc (Corec 21). 121024 PF 36

PTA-HE hardfacing with composite Tungsten Carbides 121024 PF 37

PTA-HE hardfacing with composite Tungsten Carbides 4% dilution 1,5mm thick coating 65% of Spherical WC 121024 PF 38

Typical microstructure of WC coatings 121024 PF 39

Oil drilling Application JOURNAL OF DRILLING BIT MATERIAL : COREC, EQUIPMENT : PTA, FEATURES : Wear resistance, >50 HRc. DRILL END / DRILLING TOOLS MATERIAL : WC composite, EQUIPMENT : PTA, FEATURES : abrasion and erosion resistance. Hardness :WC 1800-3000 HV + Matrix >60 HRC. spherical WC 121024 PF 40

Mining Application WEAR PLATES, SCREENING, BUCKET WHEELS, TEETH MATERIAL : WC composite, EQUIPMENT : PTA, FEATURES : abrasion and erosion resistance WC >1800 HV + Matrix 60 HRC. 121024 PF 41

Conclusion Chapter 8

Conclusion PTA PHE is a cost effective coating solution. High deposit efficiency (> 95 %) for saving materials. Perfect geometry control close to the final geometry. Nominal hardness and maximal abrasion resistance can be reached Alternative solution to spray & fuse technology when allowed by the part shape. Technology easy to set-up and for equipment maintenance. 121024 PF 43

Thank you Danke Bedanke Merci Gracias 谢 谢 121024 PF 44