Coatings in chemical industry are used for pressure and storage vessels with Hastelloy B or C, Inconel 600. In heat-affected zones, the solutions used in gas turbines are often employed. In some chemical reactors dealing with strong acids in combination with organic solvents, glass lining are used and can be repaired by APS sprayed tantalum coatings, bonding well to the glass with an overlay of chromium oxide Davis.
For oil, gas, and petrochemical industries the following components are protected with thermal sprayed coatings : mud drill rotors, pump impellers, plunger, turbine, rotor shaft of centrifugal compressor/pump, pump shafts, boiler tube, mixing screw, mandrels, actuator shafts and housings, housings and valves, valve gates and seats, ball valve with large diameter, progressive cavity mud motor rotors, rock drill bits, riser tensioner rods, impeller /blade drilling and production risers, sub-sea piping, wellhead connectors, fasteners, compressor rods, mechanical seals, pump impellers, tank linings, external pipe coatings, structural steel coating….
The coating material may be in the form of powder, ceramic rod, wire or molten materials. The central part of the system is a torch converting the supplied energy (chemical energy for combustion or electrical energy for plasma- and arc-based processes), into a stream of hot gases. The coating material is heated, eventually melted, and accelerated by this high temperature, high-velocity gas stream towards a substrate. It impacts on the substrate in the form of a stream of droplets that are generated by the melting of powders or of the tips of wires or rods in the high-energy gas stream. The droplets flatten or deform on the substrate and generate lamellae called “splats”. The piling up of multiple layered splats forms the coating.
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