The Welding Alloys Group launched a thermal spray solution for applications in the waste to energy, biomass and fossil fuel boilers. This process is also, among others, suitable for black liquor boilers, fume extraction hoods, and ducts in the steel industry, and can be tailored for a large range of other applications, including abrasion, corrosion, and erosion at room temperature.
The SprayClad solution is an arc spray process developed to deliver a bond and hard coat, finished with a sealant that reduces slagging and the need for frequent cleaning. The bond layer, applied to the base material, provides a level of corrosion resistance, engineered for thermal expansion, and provides a secure strong adhesion between the base material and subsequent layers like hard coat. The hard coat or hardfacing layer can be applied using various material from the Welding Alloys consumables portfolio to protect against erosion, corrosion, or both, depending on the wear mechanism. The final layer, a sealant, is applied consisting of advanced ceramics offering corrosion and erosion protection with the added benefit of exhibiting smooth anti-fouling properties.
Designed to withstand long exposure to corrosive gases and salts at high temperatures that corrode and erode the boiler and heater tubes, SprayClad can be customized to help solve the challenges faced by customers and contribute significantly to reduce thinning of tube walls, boiler downtime, and the cost of in-situ tube cladding.
SprayClad was developed in collaboration with world-leading academic organizations and tested with leading OEMs and international welding and materials experts. It has proven to increase the lifetime and performance in many applications and is deposited up to 75 percent faster than traditional cladding techniques, meaning repairs can be carried out quicker. Using WA Mill kits to perform repairs and maintenance allows for rapid deposition rates. Being a “cold process,” distortion and adverse metallurgical effects on the base material are non-existent, and the process is carried out without the need of water inside the heat exchanger tubes.
Teams of expert engineers are located at 25 Integra centers around the globe and have more than 30 years’ experience providing advanced wear solutions in the repair and maintenance sectors across a number of industries. Offering wear audits of parts, installations, and equipment located within the plant to assess wear mechanisms and phenomenon, allows the company to recommend and provide the best possible wear solutions to its customers, making WA the total solution provider.
Welding Alloys’ experience is drawn from more than 50 years of commitment to research and development of specialized products and solutions and covers more than 150 countries and territories throughout a network of more than 28 subsidiaries and with more than 1,000 employees and specialists in different disciplines.
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