The choice of surface treatment when repairing critical components

Sustainability is also encouraging reuse

The principle is simple: in this process, components are completely disassembled, cleaned, repaired, modified and/or re-coated so that they are like new again and often even better than that. In this way, the service life is extended and given a 2nd life. Additionally, but not unimportantly, we also save raw materials and material costs, and reduce CO₂-emissions.

A large market of valuable physical assets

In many industries such as textiles, mechanical engineering, aviation, power plants, shipping, infrastructure, earthmoving, agriculture, etc., a large number of parts are subject to wear and tear. Examples include bearings, rods, gears, piping, heat exchangers, gas distribution, landing gear, seals, turbines, pump shafts, wear parts, conveyor rollers, turbines, screws, etc.

Managing these assets is quite a challenge. Ever-increasing demands for availability and reliability must be met, while budget remains limited. Early detection and resolution of problems is very important. Because failures come at the expense of human and machine safety, production loss due to downtime, energy efficiency, and product quality.

Influencing factors

That some critical parts need to be replaced or repaired more quickly has several reasons.

1. Environmental stress & pollution
   The local conditions where the material is placed directly impact to the life of the installation. Critical are offshore, tropical areas, industrial areas and coastal areas with high humidity and aggressive atmosphere, as well as buildings and areas with permanent condensation and high pollution levels. Don't forget components that are/are immersed in salt or fresh water or placed in the ground. Contaminants can occur such as dust, dirt, corrosive particles, water etc. that lead to wear. Various forms of wear are possible. These include corrosive wear, abrasive wear, frictional wear, etc.
   
2. Mechanical load
   Precision in material selection, clearance and tolerances, design and choice of surface treatment are crucial.
   
3. Thermal load
   Expansion and contraction of materials creates stress in the materials. Deformation can lead to metal fatigue resulting in cracking or flaking.

Underhoud

A good maintenance program ensures that problems are detected and recognized early, even before they can lead to damage and failure. A specific maintenance plan should be written out for each application or component that takes into account the following aspects:

• Tax
• Environmental conditions
• Movement speed
• Product specifications.

The right surface treatment

Since critical components are costly and/or unique, purchasing new components is not always possible. The manufacturer does not have replacement parts or the design has changed. The solution is then repair or reproduction. At these stages, it is crucial to also pay attention to the choice of the right surface treatment.

A coating is chosen according to:

• The desired properties (corrosion resistance, wear resistance, adhesion)
• The material (Fe, Al, stainless steel, Ti, ...)
• The process (chemical, physical, ...)
• The assemblability and disassembly of the pieces
• The environment
• ...

Therefore, the choice is not always obvious. Knowledge about the possible solutions is often lacking, resulting in wrong choices being made. Hence the usefulness of describing a number of surface treatments that can be used to repair critical components.

Experts speak out

For the above reason, VOM, together with industrial partners, is taking the initiative to organize a technical day on September 25 that will highlight several techniques such as hard chrome plating, laser cladding, HVOF spraying, ultrasonic and laser cleaning, cold spraying, touch up, etc. Each technique has its raison d'être in its specific domain and application.

This day may count on the expertise of the following leading companies:
Air France Industries KLM Engineering & Maintenance, CZL Tilburg, D'Haene, De Beleyr Engineering, Romarco and Association for Thermal Spraying VTS.

The following topics are covered:

• Importance of repairing critical components
• Hard chrome plating: much discussed but still reliable and durable
• Lasercladding : for sensitive and dimensionally accurate parts
• Reconditioning via ultrasonic cleaning and laser technology
• Gas Dynamic Cold Spraying conquers its market position
• From thermal spraying to HVOF spraying

To demonstrate how it works in practice, we also visit the company De Beleyr Engineering in Zele.

Target audience: 
We welcome service technicians, buyers and quality managers from the following industries: general engineering, hydraulics, aerospace, transportation, petrochemical, agriculture, maritime, earthmoving, etc. Surface treatment providers are also welcome.

Date:
Wednesday, Sept. 25, 2024, 9:30 a.m. to 4 p.m.

Location:
Biznis hotel, Zelebaan 100, B-9160 Lokeren