Ceramic Coating Services-KeepSake Engineering Consultancy Pvt. Ltd.

Flame spraying is a coating process using heat. A flame produces heat which is used to melt the thermal spray material, normally in powder, wire, or ceramic rod form. The molten particles are then propelled onto the surface to be sprayed, compressed air is used on the wire flame spray so that the molten particles are atomized and then propelled onto the substrate. When using the powder flame spray, the metal or ceramic powder particles are softened by the flame, then this softened powder is sprayed onto the surface to be coated by the use of the flame gases through the nozzle.

• • • • • • • Wire Flame Spray

wire flame spray

With the wire flame spray process, the wire spray material is melted in a gaseous oxygen-fuel flame. The fuel gas can be acetylene, propane or hydrogen. The wire is fed concentrically into the flame, where it is melted and atomized by the addition of compressed air that also directs the melted material towards the workpiece surface.

• Powder Flame Spray

powder coating

This coating process is based on the same operational principle as the wire flame spray process, with the difference that the coating material is a spray powder. Thus, a larger selection of spray materials is available, as not all spray materials can be manufactured in wire form.

In Ceramic coating, the feedstock material is fed continuously to the tip of the spray gun where it is melted in a fuel gas flame and propelled to the substrate in a stream of atomizing gas. Common fuel gas is acetylene. Air is typically used as the atomization gas.

Equipment: Ceramic coatings on pump equipment

Name of the part: Ceramic Coated Sleeves and Plungers

Plunger and Sleeve

A major expense associated with pump operation is the replacement of sleeves/plungers.

Wear on these components necessitates:
1) Frequent packing adjustment to compensate for dimensional changes caused by wear.

2) Packing material failure due to sleeve surface roughness.

3) Premature pump stoppage due to leaks.

Abrasion, Corrosion, and friction are the main causes of the problem

The Solution we provide Coatings that provide a long-lasting wear-resistant surface using ceramic oxides or metallic carbides. We have a robotic Plasma transferred arc system (PTA) and flame spray equipment to apply coatings of tungsten carbide in a nickel chrome boron matrix and chromium oxides. The coating thickness is selected based on application wear potential and varies from 0.5mm to 1.5mm in thickness. For severe wear applications, PTA coated sleeves last longer.

The Compositions used in ceramic coating are Chromium oxide, Alumina Titanium, Zirconia, Nickel alloys, Aluminium Bronze.

Industries in which these parts are used are Thermal power plants, Sugar industries, Oil and gas sector and chemical process plants. These are our major consumers.

KECPL is an Ahmedabad based professionally run decade and half old co. specialized in the field of thermal spray coatings & carbide wear parts. Team is headed by a technocrat who has decades of stint with engineering icons L & T. To produce quality coatings we have an excellent thermal spraying facility and highly skilled and trained team of engineers to do the job successfully. During the period of time co. has renewed their facilities according to the technical advancement adopted in the industry. We are presently equipped with Six axis articulated arm robot to operate our Plasma transferred arc pulsed 350 amp power source, High velocity oxy-fuel systems, Arc spray systems and flame spray guns. We also have manipulators for down hand welding capability.

KeepSake Engineering Consultancy is a manufacturer, job shop and a specialised engineering firm. The one thing that its products and services have in common is that they reduce wear caused by abrasion, friction, heat and corrosion. The company specialises in applying Thermal Spray Coatings to solve problems related to wear. It has five categories of thermal spray systems, viz., Flame spray (Rod rokide, powder), HVOF (tungsten carbide), Arc Spray, Plasma Transferred Arc, Spray and Fuse. It applies ceramic, carbide, cobalt and Nickel alloy coatings.

We aim to employ this unique technology for life enhancement of wear prone parts belonging to various industries. To achieve that goal we have developed special kind of jigs and fixtures to maintain uniformity and accuracy of dimensions of coated parts. This efforts and care resulted in to a sound clientele of OEMs and big end users who are highly satisfied with the performance improvement they are getting by such coatings and wear parts.

We are well aware that we are in the maintenance field where emergency is very routine phenomena. That’s why at the customer level we have customer support engineers, who continuously work with customers to solve their wear and corrosion related problems.