Spray-on repair for worn areas of fan impeller blades

Our company provides repair services for worn areas on fan impellers in cement plants, power plants, and other facilities, as well as surface enhancement coatings for new impellers, which can extend the service life of impellers by several times. We employ a supersonic thermal spraying technique using tungsten carbide coatings, resulting in dense coatings with high hardness and excellent wear resistance, thereby significantly prolonging the service life of components. Tungsten carbide powder coatings—Tungsten carbide (WC) is the primary raw material used in the production of cemented carbides and boasts exceptionally high microhardness. Commonly used WC-based powder coatings include WC 8% Co, WC 12% Co, and WC 17% Co. The addition of cobalt in varying proportions to WC primarily serves as a binder, enhancing the toughness of the coating while preventing excessive carbon burn-off during the spraying process. Chromium carbide (Cr2C3) features high hardness and exhibits excellent resistance to high-temperature oxidation and wear, with a maximum operating temperature of up to 800°C. Typically, Cr2C3 is mixed with Ni-Cr alloys and is mainly applied to high-temperature wear-prone areas. Mechanical component wear-repair coating process using tungsten carbide—tungsten carbide wear-resistant coating parameters: Processing steps: → Sandblasting → Preheating → Primer application → Tungsten carbide spraying (thickness: 0.04–1.0 mm) → Grinding; Processing methods: Plasma or supersonic flame spraying. Tungsten carbide coating performance indicators: Hardness: Up to HRC 70–80; Bonding strength: ≥90 MPa; High-temperature resistance: Above 1200°C; Coating thickness: 0.04 mm–1.0 mm; Service life: 3–6 times longer than that achieved by conventional methods. Processing range: Diameter—from tens of millimeters to hundreds of millimeters; Length—from several millimeters to several meters.

Wear- and corrosion-resistant products and technologies for equipment in power plants, chemical plants, steel mills, and cement plants.

Wear-resistant and corrosion-resistant ceramic tiles are made by high-pressure molding and high-temperature sintering of various hard materials. They exhibit excellent resistance to acid and alkali corrosion and possess exceptionally high hardness.

Application of Thermal Spray Equipment in the Petrochemical Industry

Guangzhou Sanxin Thermal Spraying specializes in the manufacturing of thermal spraying equipment. Our facilities are fully equipped, and our technology is cutting-edge. Below is an introduction to the application of thermal spraying equipment in the petrochemical industry—the application of thermal spraying technology in the chemical and petroleum sectors.

Understand the Applications of Thermal Spray Processing Technology at a Glance

Thermal spraying technology has a history of nearly a century, dating back to 1910 when Dr. M.U. Schoop from Switzerland developed the first metal-melt spraying apparatus. Initially, thermal spraying was primarily used for applying decorative coatings, with aluminum and zinc wires typically sprayed using oxy-acetylene flames or electric arcs. In the 1930s and 1940s, as flame and arc wire-spraying equipment became more sophisticated and flame powder guns were introduced, thermal spraying evolved from merely applying decorative coatings to repairing mechanical parts with steel wires and to coating steel structures with aluminum or zinc as corrosion-resistant protective layers. In the 1950s, the successful development of detonation spraying and subsequently plasma spraying technologies led to the widespread application of thermal spraying in fields such as aerospace and aviation. Around the same time, self-fluxing alloy powders were developed, enabling the elimination of porosity in coatings through remelting processes and facilitating metallurgical bonding between the coating and the substrate, thereby greatly expanding the application scope of thermal spraying technology. In the early 1980s, supersonic flame spraying technology was successfully developed and gained widespread adoption by the early 1990s, dramatically extending the use of WC-Co hardmetal coatings from aerospace and aviation to various industrial sectors. The emergence of high-energy plasma spraying technologies—such as those with power ratings up to 200 kW, supersonic plasma spraying, and axial-feed plasma spraying, especially the highly efficient supersonic plasma spraying technology—has provided powerful tools for further effective utilization of thermal spraying in diverse industrial applications. As a modern manufacturing technology with broad applicability, relatively simple and flexible processing techniques, wide-ranging applications, and significant economic benefits, thermal spraying can endow surfaces with a variety of functional properties, including wear resistance, corrosion resistance, thermal insulation, heat resistance, electrical conductivity, electrical insulation, erosion resistance, oxidation resistance, friction reduction, lubrication, and radiation protection. Thermal spraying is not only suitable for repairing and strengthening mechanical components but can also be used for manufacturing new parts. Thanks to the wide selection of spray materials, which are not constrained by the need for overall material alloying, it is relatively easy to produce ultra-hard alloys, various ceramic or metal-ceramic coatings, and specialized functional coatings. Moreover, compared to using solid advanced materials throughout, thermal spraying requires significantly less material, making it far more cost-effective than upgrading materials entirely. Consequently, valuable materials can be used boldly without substantially increasing costs, while the surface performance of these materials can be greatly enhanced. Parts repaired by thermal spraying generally have service lives that equal or even exceed several times those of new parts. Thermal spraying technology has a history of nearly a century, dating back to 1910 when Dr. M.U. Schoop from Switzerland developed the first metal-melt spraying apparatus. Initially, thermal spraying was primarily used for applying decorative coatings, with aluminum and zinc wires typically sprayed using oxy-acetylene flames or electric arcs. In the 1930s and 1940s, as flame and arc wire-spraying equipment became more sophisticated and flame powder guns were introduced, thermal spraying evolved from merely applying decorative coatings to repairing mechanical parts with steel wires and to coating steel structures with aluminum or zinc as corrosion-resistant protective layers. In the 1950s, the successful development of detonation spraying and subsequently plasma spraying technologies led to the widespread application of thermal spraying in fields such as aerospace and aviation. Around the same time, self-fluxing alloy powders were developed, enabling the elimination of porosity in coatings through remelting processes and facilitating metallurgical bonding between the coating and the substrate, thereby greatly expanding the application scope of thermal spraying technology. In the early 1980s, supersonic flame spraying technology was successfully developed and gained widespread adoption by the early 1990s, dramatically extending the use of WC-Co hardmetal coatings from aerospace and aviation to various industrial sectors. The emergence of high-energy plasma spraying technologies—such as those with power ratings up to 200 kW, supersonic plasma spraying, and axial-feed plasma spraying, especially the highly efficient supersonic plasma spraying technology—has provided powerful tools for further effective utilization of thermal spraying in diverse industrial applications. As a modern manufacturing technology with broad applicability, relatively simple and flexible processing techniques, wide-ranging applications, and significant economic benefits, thermal spraying can endow surfaces with a variety of functional properties, including wear resistance, corrosion resistance, thermal insulation, heat resistance, electrical conductivity, electrical insulation, erosion resistance, oxidation resistance, friction reduction, lubrication, and radiation protection. Thermal spraying is not only suitable for repairing and strengthening mechanical components but can also be used for manufacturing new parts. Thanks to the wide selection of spray materials, which are not constrained by the need for overall material alloying, it is relatively easy to produce ultra-hard alloys, various ceramic or metal-ceramic coatings, and specialized functional coatings. Moreover, compared to using solid advanced materials throughout, thermal spraying requires significantly less material, making it far more cost-effective than upgrading materials entirely. Consequently, valuable materials can be used boldly without substantially increasing costs, while the surface performance of these materials can be greatly enhanced. Parts repaired by thermal spraying generally have service lives that equal or even exceed several times those of new parts.

A single image to understand the application of thermal spraying technology in the petroleum industry.

We specialize in thermal spray coating services for various industries.

If your products have high requirements for surface finish and dimensional accuracy, or if they will be in long-term contact with liquids and thus demand enhanced wear resistance and corrosion protection, you should choose our company’s tungsten carbide coating applied using the American Praxair JP8000 equipment. From materials to equipment, processes to solutions—we’ve got it all covered in coatings.

Tungsten Carbide Spraying and Processing

In the new-energy lithium-battery industry, various types of equipment—such as screw shafts, screw conveyors, battery raw-material crushers, mixers, conical hoppers, powder feeders, and feeding machines—are coated with wear-resistant tungsten carbide coatings on their surfaces.

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