Hayden Corp Blog

Unlocking the Potential: The Top Reasons to Use Arc Spray

Thu, 27 Jul 2023 19:43:38 GMT

When it comes to coating technologies, thermal arc spray stands out as a powerful and versatile method that offers a broad range of benefits. By employing an electric arc to generate high temperatures, this process enables the rapid deposition of durable coatings onto various surfaces. In this article, we will explore the top reasons why arc thermal spray has gained popularity across industries and why it is worth considering for your coating needs.

Major Uses of Arc Thermal Spray

Thermal spray technology has made significant progress over the years. It has evolved from spraying basic metals and simple alloys to now being able to spray extremely hard ceramics and carbides. However, these advancements do not diminish the value of arc spray. Different processes have specific applications in the coating world. Twin wire arc spray , for instance, is ideal for tasks such as dimensional restoration, sacrificial corrosion coatings, custom alloy coatings, and bearing surfaces.

Dimensional Restoration
Arc thermal spray is a valuable technique employed for dimensional restoration, allowing the repair and rebuilding of worn or damaged components to their original dimensions. When a component experiences wear, erosion, or corrosion, its critical dimensions can be compromised, affecting its functionality and performance. Arc spray addresses this issue by depositing layers of molten particles onto the damaged surface, effectively restoring the dimensions and integrity of the component. By carefully controlling the deposition process, arc spray enables precise buildup of material, ensuring that the restored component aligns with its original specifications.

In this application, arc spraying has the advantage of being able to deposit material quickly and with good bond strength. Coatings for repair applied by arc spraying lock tightly to the surface because the applied material is fully melted prior to impact. Flexibility makes arc thermal spray a preferred choice in industries such as manufacturing, heavy machinery, and infrastructure, where downtime is at a premium.
Sacrificial Corrosion Coatings
Arc spray is widely utilized for sacrificial corrosion coatings, providing durable protection to metal substrates in corrosive environments. Sacrificial corrosion coatings use a more reactive metal that is applied as a protective layer over the substrate. When exposed to corrosive elements, the sacrificial metal corrodes instead of the underlying substrate, safeguarding it from damage.

Arc spray enables the deposition of sacrificial coatings by melting and projecting particles of the desired sacrificial metal onto the surface. Common sacrificial metals used include zinc, aluminum, and their alloys. These coatings create a barrier that shields the substrate, ensuring that any corrosion occurs primarily on the sacrificial layer.

Arc spraying has the capability to cover substantial surface area quickly, which makes it well suited to large scale corrosion protection work, as with structural steel, bridges, outdoor piping, etc. This application is extensively employed in marine environments , infrastructure exposed to harsh weather conditions, and industrial facilities where corrosive agents are present, effectively extending the service life of coated structures and components.
Custom Alloy Coatings
Arc spray offers a unique method for creating custom alloy coatings, offering tailored solutions to meet specific performance requirements. Since the arc is created between two oppositely charged consumable wires, and the wires are fully melted during spraying, two wires of differing composition can be used to create a coating which is essentially an alloy of the two primary materials.

With arc thermal spray, different alloy compositions can be precisely deposited onto substrates, allowing the formation of coatings with unique properties and characteristics. By carefully selecting the appropriate alloy materials and adjusting the spray parameters, desired attributes such as enhanced strength, wear resistance, or specific thermal properties can be achieved.

Virtually any metallic material that can be drawn into conventional 1/16” wire is useable in this process, facilitating the customization of coatings to suit the specific needs of various industries, including aerospace , automotive, and manufacturing . Whether it's a specialized alloy for high-temperature applications or a unique combination of metals for improved corrosion resistance, arc thermal spray enables the creation of custom alloy coatings that deliver optimal performance and functionality in diverse operating conditions.

Advantages of Arc Spray

Enhanced Coat ing Durability
Arc spray creates coatings with exceptional durability. By fully melting the feedstock wires before deposition, this process forms coatings that exhibit remarkable resistance to wear, corrosion, and erosion. Industries such as aerospace and automotive rely on these robust coatings to protect critical components from harsh environments and extend their lifespan significantly.
Versatility in Material Selection
One of the key advantages of arc spray is its versatility in material selection. This process can utilize a wide range of metals, allowing for tailored coatings that suit specific applications. From high-strength alloys to oxidation-resistant corrosion protection to non-galling bearing materials, arc thermal spray opens doors to diverse material options that can meet the requirements of different industries and unique coating challenges.
Cost-Effectiveness
In addition to its performance benefits, this process is uniquely cost-effective. Due to its simplicity, minimal process requirements, and high deposition rate, arc spraying is often the least expensive thermal spray technology to implement. It minimizes material waste through its high deposition efficiency, reducing overall material consumption. Moreover, the durability and longevity of these coatings translate into significant cost savings over time due to reduced maintenance and reapplication needs.
Improved Surface Restoration:
Arc spray excels at surface restoration, making it an ideal choice for repairing worn or damaged components. By depositing new layers onto degraded surfaces, this process rejuvenates and reinforces the substrates, effectively extending their service life. Industries relying on heavy machinery or industrial equipment can greatly benefit from this coatings ability to restore surfaces, mitigating the need for costly replacements and minimizing downtime.
Enhanced Performance and Functionality:
Beyond surface protection and restoration, arc thermal spray can significantly enhance the performance and functionality of coated components. With precise material selection and control over coating thickness, this process can impart desired characteristics such as heat resistance, electrical conductivity, or insulation properties. Industries such as power generation and oil and gas leverage these improvements to optimize equipment performance and ensure operational efficiency in challenging environments.
Environmental Advantages:
Twin wire arc spray also offers environmental advantages over traditional coating methods. The process generates minimal waste, as it maximizes material utilization and reduces the need for hazardous substances. This aligns with the growing emphasis on sustainability and responsible manufacturing practices. By opting for arc thermal spray, industries can minimize waste generation, lower their environmental footprint, and comply with stringent regulatory standards.

Conclusion:

Arc spray has emerged as a reliable and versatile coating method, offering numerous advantages across various industries. With its enhanced coating durability, versatility in material selection, cost-effectiveness, surface restoration capabilities, improved performance, and environmental benefits, it has become a go-to choice for coating needs. As technology advances further, we can expect even greater potential and advancements in the field of arc thermal spray, unlocking new possibilities for industries seeking reliable and efficient coating solutions.

The Power of Metallizing: Exploring the Advantages and Applications of Thermal Spraying

Thu, 27 Jul 2023 19:37:10 GMT

Metallizing, also known as thermal spraying or metal spraying, is a surface coating process that involves the application of metallic materials onto a substrate. It is a versatile technique used to enhance the properties of the surface, improve its performance, and provide protection against wear, corrosion , or other environmental factors.

During the metallizing process, a feedstock material, typically in the form of wire or powder, is heated to a molten or semi-molten state. The molten material is then propelled onto the substrate using compressed air or another suitable medium. Upon impact with the substrate, the material solidifies, forming a coating that adheres tightly to the surface.

Metallizing offers several advantages. It allows the deposition of a wide range of metals, alloys, and composites. It is suitable for various substrates, such as metal, plastic, concrete, or even fragile materials. It provides excellent bonding strength, creating a durable and long-lasting coating. Metallizing is used in numerous industries , including aerospace , automotive, marine, oil and gas , and heavy manufacturing to improve component performance, extend the lifespan of equipment, and protect against corrosion or wear.

Common Metallizing Materials

Metallizing can involve a variety of materials, including metals, alloys, and metallic composites. The choice of material depends on the specific application requirements and the properties desired for the coating. Here are some of the most common materials:

Pure Metals: Metals such as aluminum, zinc, copper, and nickel are frequently used in metallizing. These materials offer excellent corrosion resistance, thermal conductivity, and electrical conductivity. Aluminum is particularly popular due to its light weight and high resistance to corrosion.
Alloys: Alloy compositions can be customized to meet specific performance requirements. Common alloy materials used include stainless steel, bronze, and nickel- and cobalt-based alloys. These alloys offer a combination of strength, wear resistance, and corrosion resistance, making them suitable for a wide range of applications.
Metallic Composites: Blends or other mixtures of hard materials such as tungsten carbide or chromium carbide with metallic binders like nickel and cobalt can also be sprayed by metallizing. These composite materials often have hardness and wear resistance well in excess of conventional metals and alloys.

It's important to note that the choice of metallizing material depends on factors such as the substrate, environmental conditions, desired properties, and intended application. Different materials offer unique characteristics and performance benefits, allowing for customization to meet specific needs.

Benefits of Metallizing

Metallizing, or thermal spraying , offers several benefits that make it a preferred surface coating technique in various industries. Here are some of the key advantages:

Enha nced Protection: Metallizing provides effective protection against wear, corrosion, erosion, and other environmental factors. The deposited coating acts as a barrier between the substrate and the surrounding environment, preventing direct contact and minimizing damage to the underlying material. This protection extends the service life of components and equipment, reducing maintenance costs and downtime.
Versatility in Material Selection: Metallizing allows for a wide range of material options, including metals, alloys, and composites. This versatility enables the selection of specific materials that possess desired properties such as hardness, wear resistance, thermal conductivity, electrical insulation, or chemical resistance. The ability to customize coatings based on the application requirements is a significant advantage.
Compatibility with Various Substrates: Metallizing can be applied to different substrates, including metals, plastics, concrete, and composites. It ensures excellent adhesion and bonding strength between the coating and the substrate, regardless of the material's composition or surface characteristics. This versatility makes this process suitable for a wide range of industries and applications.
Cost-Effectiveness: Coatings are often a cost-effective solution compared to alternatives such as welding, plating, or full-component replacement. The process minimizes material waste by utilizing a high percentage of the feedstock material, reducing material consumption and associated costs. Additionally, the protective coatings help extend the lifespan of components, reducing the frequency of replacements and maintenance requirements.
Flexibility and Customization: Metallizing offers flexibility in terms of coating thickness, texture, and composition. The process allows for the deposition of coatings with varying thicknesses to meet specific application requirements. Coatings can be tailored to provide specific properties such as increased hardness, improved adhesion, or optimized thermal conductivity.
Rapid Application and Minimal Downtime: Thermal spraying is a relatively quick process, enabling efficient application and minimal downtime. The coatings can be applied rapidly, and the coated components can often be put back into service soon after the process is completed. This efficiency is particularly beneficial for industries that require quick turnaround times and minimal interruption to operations.

Overall, the benefits of metallizing include enhanced protection, material versatility, compatibility with different substrates, cost-effectiveness, flexibility in customization, and efficient application. These advantages contribute to improved performance, extended component lifespan, reduced maintenance costs, and enhanced operational efficiency in various industries and applications .

Defeating the Ravages of Corrosion: How to Stop Saltwater and Freshwater Corrosion

Thu, 27 Jul 2023 19:04:01 GMT

Corrosion poses a significant threat to metal surfaces in saltwater and freshwater environments, leading to safety concerns, reduced lifespan, and increased costs. Understanding the causes and implementing effective preventive measures are crucial to combat this pervasive issue. In this article, we will explore the causes of corrosion, along with practical strategies and maintenance practices to stop corrosion caused by saltwater or freshwater. By taking proactive steps, we can protect valuable metal assets, ensure longevity, and enhance operational efficiency.

Understanding the Causes of Corrosion

Corrosion is a natural process that occurs when metal reacts with its surrounding environment. Several factors contribute to the causes of corrosion, including:

Moisture: The presence of water or moisture is a primary catalyst for corrosion. It provides the necessary medium for electrochemical reactions to occur, allowing ions and electrons to transfer between the metal surface and the environment.
Oxygen: Oxygen plays a vital role in most corrosion processes. It combines with metal atoms to form metal oxides or hydroxides, weakening the metal's structure and causing degradation.
Electrolytes: Corrosive environments often contain electrolytes, such as salts or acids, which increase the conductivity of the surrounding solution. Electrolytes facilitate the flow of ions, accelerating the electrochemical reactions that lead to corrosion.
pH Level: The pH level of the environment influences the corrosion rate. Highly acidic or alkaline conditions can be corrosive to certain metals, causing accelerated degradation.
Temperature: Elevated temperatures can accelerate corrosion processes by increasing the rate of chemical reactions. Thermal fluctuations, such as thermal cycling or exposure to extreme heat, can also contribute to corrosion.
Chemical Exposure: Exposure to chemicals, such as acids, salts, or industrial pollutants, can intensify corrosion processes. Certain chemicals can directly attack the metal surface, initiating or accelerating corrosion.
Galvanic Corrosion: When dissimilar metals come into contact in the presence of an electrolyte, galvanic corrosion can occur. This type of corrosion happens due to the electrochemical potential difference between the metals, leading to the more reactive metal corroding while the less reactive metal remains protected.

It's important to note that the specific corrosion mechanisms and rates can vary depending on the type of metal, the environment, and other factors. Understanding the causes of corrosion is essential for implementing preventive measures and selecting appropriate protective coatings to mitigate or minimize the effects of corrosion.

Preventative Measures

For atmospheric corrosion, such as rust from exposure to weather or water, one effective approach is to apply protective coatings of zinc, aluminum, or zinc and aluminum blends to exposed surfaces. These materials not only shield vulnerable areas but also provide galvanic protection to the underlying steel. By employing this method, one can safeguard against the detrimental effects of corrosion while preserving the integrity of the steel substrate. Aluminum coatings, in particular, will form a hard, protective aluminum oxide “shell” that provides both sealing of any connected porosity and mechanical wear resistance.

Thermal spraying , also known as metalizing, offers a highly effective preventive method for corrosion in various industries. By depositing a protective coating onto metal surfaces, thermal spray coatings act as a barrier against corrosive agents, such as saltwater or chemicals. The versatility of thermal spray allows for the application of corrosion-resistant materials, including metals, alloys, ceramics, and polymers, tailored to specific environmental conditions. These coatings provide enhanced durability, excellent adhesion, and superior resistance to wear, corrosion, and erosion. With its ability to create uniform, dense, and well-bonded coatings, thermal spray effectively safeguards metal components, extends their service life, and minimizes the risk of corrosion-related damage. Additionally, thermal spray coatings can be customized in terms of thickness, composition, and surface texture, allowing for tailored corrosion protection solutions.

Overall, thermal spray proves to be a reliable and versatile preventive method, offering long-lasting corrosion resistance and ensuring the integrity and reliability of metal assets in diverse industrial environments.

Preventive Measures for Saltwater Environments
In saltwater environments, selecting corrosion-resistant materials is crucial to stop saltwater corrosion on metal. Implementing protective coatings, such as galvanization, metallizing, or anodizing, adds an extra layer of defense. Sacrificial anode systems and cathodic protection methods can also be employed to prevent corrosion. Regular maintenance and inspection practices play a vital role in early detection and addressing corrosion concerns.
Preventive Measures for Freshwater Environments
Corrosion in freshwater environments presents unique challenges. Utilizing protective coatings tailored to freshwater conditions helps safeguard metal surfaces. Corrosion inhibitors and passivation techniques can be applied to mitigate corrosion risks. Proper design and installation practices that minimize contact between metal surfaces and water are essential.
Maintenance and Inspection Practices
To combat corrosion, regular cleaning and removal of debris are crucial in preventing accelerated corrosion. Implementing a routine inspection schedule allows for the timely identification of corrosion signs. Prompt repair of damaged coatings or corroded areas is essential, as is monitoring and maintaining cathodic protection systems, if applicable.
Education and Training
Education and training play a significant role in combating corrosion. Educating personnel about corrosion prevention and control helps foster a proactive approach. Proper training on handling, storage, and maintenance of metal equipment in corrosive environments reduces the risk of corrosion-related issues.

Combat Corrosion

Preventing corrosion caused by saltwater and freshwater requires a proactive approach. Understanding the causes, implementing preventive measures, conducting regular maintenance, and investing in education and training are vital steps. By embracing these strategies, we can combat corrosion effectively, extend the lifespan of metal assets, ensure safety, and enhance operational efficiency in both saltwater and freshwater environments. Together, we can defeat the ravages of corrosion and secure a brighter future for metal infrastructure.

Hayden Corp. is Attending the ITSC 2023 Conference in Quebec City, Canada May 22-25, 2023

Mon, 22 May 2023 02:13:17 GMT

ITSC2023 May 22-25 Quebec City, Canada

Hayden Corp will attend the ITSC 2023 Conference, the world's foremost international conference and exposition for thermal spray technologists, researchers, manufacturers, and suppliers. Hayden Corp remains committed to our 100-year history of cutting-edge thermal spraying techniques, and we look forward to presenting at this year's conference.

ITSC2023 - Thermal Spray Conference and Exposition

Visit Hayden Corp. at EASTEC at the Eastern States Exposition in West Springfield May 16th-may 18th 2023

Mon, 01 May 2023 13:27:50 GMT

EASTEC 2023, the largest Northeast manufacturing trade show, will be held at the Eastern States Exposition in West Springfield, Massachusetts

Come visit us this year at EASTEC. Our booth is located in building 5 The Better Living Center, Booth #5372.

Exhibitor Profile

Hayden Corp.
333 River St
W Springfield, MA 01089-3603
https://www.haydencorp.com/

Booth 5372

Thermal Spray Coating & Laser Cladding Applicator: Metallic - Carbide - Ceramic Coatings for EMI Shielding , GE -Turbine components and like, Military & Industrial . On-Site coating field services for repair & roll applications. In-house machining and grinding & full laboratory support. HVOF , PLASMA , ARCWIRE ,LASER CLADDING services. Hardcoating experts.

Ceramic Coatings for Wear Resistance: An Overview of Common Types Used in Thermal Spraying

Sat, 01 Apr 2023 16:37:17 GMT

Ceramic coatings have long been known for their durability, wear resistance, and high-temperature properties. When it comes to wear resistance , these coatings are particularly effective in applications where materials require high hardness, protection from erosion, or chemical resistance. Plasma thermal spray coatings are the most common type of ceramic coating used in wear-resistant applications. These coatings consist of a thin layer of densely packed sprayed particles which lock together due to the high temperature and pressure created by the plasma arc. The resulting coating is highly resistant to abrasion, corrosion, and oxidation, even at extremely high temperatures.

There are several types of ceramic coatings used in thermal spraying , each with unique properties that make them suitable for different applications. In this article, we'll provide an overview of some of the most common types of ceramic coatings used for wear resistance in thermal spraying.

Alumina

Alumina is a frequent solution for several coating challenges. It is harder than many other ceramic coatings, is an excellent electrical insulator, and the nearly pure white coating can be polished to a good finish. It is often used when electrical isolation is required and where high abrasion resistance is needed.It is also frequently preferred when the coated surface will be visible because of its clean white color.

Coatings of alumina are especially useful in corona treating applications, due to their uniform insulation properties and high wear resistance.

Chrome Oxide

Chrome oxide is a popular ceramic coating due to its high level of wear resistance and low coefficient of friction. It is applied where high-speed rotation is required, such as on bearing surfaces and lip seals, where it can help to reduce friction and minimize wear.

Along with it's wear-resistant properties, chrome oxide is also resistant to oxidation and chemical attack, making it an excellent choice for rotary seal applications in fluid handling equipment. Chrome oxide is comparable to alumina in hardness, but is typically capable of being ground to finer finishes than coatings of alumina.

Titanium Dioxide

Titanium dioxide shares many physical similarities with alumina and chrome oxide, though it is slightly less hard than both of these and is typically easier to grind and polish. Like the other ceramics, it is non-corroding and electrically insulating . Due to its lower hardness, it is often preferred in applications where continuous motion or high-speed contact is less likely.

The ability to grind titanium dioxide to fine finishes makes this coating an ideal mating surface for valve components. Moving and stationary items like balls and seats can both be coated with titanium dioxide and lapped to a precision fit and finish. The two mating surfaces can move freely against one another without galling because there is no metallic material and no opportunity for adhesive wear.

Zirconia

Zirconia is an off-white ceramic with a substantially higher melting point than most other ceramic materials. It is hard and brittle, but its extraordinarily high melting point makes it ideal for thermal insulating applications. For this use, coatings are often applied with an intentionally porous or open structure to minimize the available pathway for heat transfer from the surface of the coating to the substrate. Since the operating environment for these applications is typically open, with only air or hot gas in contact with the coated surface, the lower wear resistance of zirconia coatings is typically not a concern.

Coatings of yttria stabilized zirconia or magnesia zirconia are ideal thermal barrier coatings in the combustion and hot gas path components of turbine engines, where their thermal insulating properties protect metal components from the extreme temperatures of combustion and permit the turbine to be run hotter and at higher power than would be possible without this protection.

These are just a few of the many types of ceramic coatings used in thermal spraying for wear resistance. Each type offers its own unique benefits and can be tailored to fit specific requirements. When selecting the right coating for your application, it's important to consider all of the factors such as temperature, abrasion resistance , corrosion resistance , and electrical insulation . With the right combination of these properties, you can ensure that your components remain in top condition even in the most extreme conditions.

About Hayden Corp.

Hayden Corp. offers a wide range of ceramic coatings for wear resistance and other applications. Our experienced team can help guide you in selecting the coating that is best suited to your application, so you get the highest performance out of your component parts. Contact us today (413) 734-4981 for more information or request a quote online .

Maximize the Life Span of Mining Equipment and Their Components

Tue, 07 Mar 2023 16:21:43 GMT

Mining is an essential process that helps to produce and obtain the mineral resources necessary for our everyday lives. However, the process can be dangerous and strenuous on equipment. In order to keep mining operations running smoothly, it is vital to protect mining equipment and extend its life. In this article, we will discuss the various types of mining equipment and explore how laser clad overlays can help maximize the life of mining equipment and its components.

Mining Proces s

The mining process involves selecting, surveying and evaluating the site, digging and drilling into the earth, and extracting materials or minerals. To efficiently and safely complete these operations, mining companies use a variety of heavy-duty mining equipment such as traditional excavators and bulldozers to remove overburden or top layers of soil; drills to create tunnels; specialized shearers to release deposits; haulage equipment for removal of material; loading machines for transferring materials from longer haul trucks, and scrapers for cleaning up areas. Environmental concerns associated with mining also require advanced monitoring devices such as water sampling systems to prevent pollution. Whether it's metal ore or coal, the mining process is complex with many interrelated steps requiring specialized heavy equipment operating in abrasive environments.

Mining Equipment and Components

Mining equipment is an integral part of the mining process and includes a variety of items such as trucks, excavators, conveyors, drills and pumps. These machines are designed to withstand extreme temperatures and environmental conditions due to their use in hazardous locations. Let’s look at some of the most common mining equipment and components:

Excavators

These powerful machines provide the essential service of removing and transporting large amounts of earth, materials, and debris. Highly engineered modern excavators provide remarkable strength and accuracy throughout every mining operation, allowing for quick and efficient results with minimal effort. The combination of power and precision that these machines bring to any project make them an indispensable tool in the industry.

Conveyor belts

Conveyor belts are an essential piece of equipment used in mining processes to help move material from one area to another quickly and efficiently. They feature pulleys, drivers and rollers that rotate the belt smoothly over two or more pulleys to transfer materials. To ensure these belts are running safely, effectively and continuously for extended periods of time it’s important to regularly maintain their parts like drive and belt scrapers, roller bearings and the belt itself. Doing so can lead to better productivity, fewer interruptions and improved safety on mining sites.

Drills

Drills are an essential part of the mining process, as large amounts of rock must be removed in order to reach ore deposits. These pieces of equipment use bursts of energy to quickly break up the hard earth and rocks in order to collect them. Air drills, electric drills, hydraulic drills, and rotary shearers are all used depending on the type of mine and material being mined. To keep these tools running efficiently, it is important to maintain their various parts: air compressors, motors, chains and sprockets, carburetors, fuel systems, gears, hoses and clamps. With proper maintenance and upkeep on these components you can help ensure that your drilling operation runs smoothly.

Wear Protection Benefits for Mining Equipment and Components

The extreme operating conditions associated with mining can cause rapid wear on the equipment, leading to costly repairs or replacement. To extend their life expectancy and reduce repair costs, many mining operations are now utilizing laser clad overlays. The process creates a thick protective barrier that will last much longer than painted or brazed on coatings and provide additional benefits including increased durability, improved corrosion resistance, and better lubricity. Laser cladding helps reduce downtime on mining sites and extend the life of the equipment, ultimately resulting in a more efficient and cost-effective mining operation.

Mining is a complex process that requires specialized equipment to help ensure safety and accuracy. From excavators and conveyor belts to drills, these components provide the critical support needed to extract valuable materials. Laser clad overlays, in particular, help extend the life of mining equipment and components while providing additional benefits such as improved corrosion resistance . With the right tools and processes in place, mining operations can be more efficient and cost-effective.

Hayden Corp Thermal Spray Coaters is a leader in the laser cladding industry, providing services to companies across a variety of industries. With decades of experience and skilled technicians, Hayden Corp provides quality coatings that meet the performance requirements of each individual customer. Our laser clad overlays are trusted by top mining companies around the world for their durability and reliability in even the harshest conditions. Contact us today to learn more about our thermal spray coating services and how we can help you improve the performance of your mining equipment.

The Power of Thermal Spray Coatings: 5 Benefits for the Oil & Gas Industry

Tue, 07 Mar 2023 16:10:13 GMT

Thermal spray coatings offer several powerful benefits for the oil and gas exploration and processing industries. From increasing corrosion resistance to improving wear characteristics, these versatile coatings can help extend the life of critical components and protect against environmental factors that could otherwise cause expensive equipment damage.

Here are five key benefits of using thermal spray coatings in the oil & gas industry:

Enhanced Co rrosion Resistance

This unique process can help to mitigate wear due to exposure to temperature extremes, abrasive materials, and harsh chemicals found in the oil and gas sector. Thermal spray coatings can provide protection from high-temperature oxidation, galvanic corrosion, stress corrosion cracking, fretting and other forms of degradation.

Improved Wear Characteristics

Petroleum processing exposes components to a range of environmental conditions that can cause wear. By applying a specialized coatings such as carbides, ceramics, or other high-strength materials over the existing surfaces of a part, components can be protected from intense friction and abrasion. Benefits include longer-lasting pumps and valves that operate more effectively and efficiently, reducing the need for costly repairs or replacements down the road.

Increased Operational Efficiency

The cost of equipment downtime and reduced lifespan in the oil and gas industry is exorbitant, drastically burdening businesses with enormous annual financial losses that could otherwise be avoided. Protective coatings offer a solution to this dilemma, allowing components to perform more efficiently while simultaneously shielding them from wear or environmental damage that can lead to premature failure. These coatings have not only vastly improved the operational efficiency of equipment but have also significantly curtailed many companies’ maintenance costs.

Enhanced Performance in Harsh Environments

High-performance equipment in the oil and gas industry must be able to work reliably in challenging environments, with extreme temperatures and hostile chemical atmospheres. Thermal spray coatings give these high-value products the protection they need to perform their duties effectively, even when conditions are harsh and abrasive. These precision coatings can withstand all types of environmental stress, ensuring that equipment remains robust even in the most difficult of circumstances.

Protect Against Chemical Corrosion

Oil and gas exploration, production, and processing operations involve harsh chemicals with extreme pH levels, which can quickly erode unprotected materials. Sprayed and fused and laser clad coatings are impermeable to even the most aggressive fluids, providing a reliable barrier that’s capable of withstanding long-term exposures to corrosive agents. As such, these coatings provide superior protection from highly reactive chemicals, helping to extend the life of components and keeping operational costs low.

In Summary

Overall, thermal spray coatings offer an ideal solution for the oil & gas industry . By providing enhanced corrosion resistance, improved wear characteristics, increased operational efficiency and protection against both environmental stressors and chemical corrosion, these coatings can be invaluable in boosting performance and productivity throughout the sector.

For these reasons, thermal spray coatings are increasingly being used in oil and gas production operations to ensure that components remain durable, reliable and cost-effective for years to come. Hayden Corp. Thermal Spray Coaters has extensive experience in providing high-quality thermal spray coatings for the oil and gas sector, enabling companies to benefit from improved performance and reduced maintenance costs. Contact us today to learn more about our services.

Why Thermal Spray Coating is an Optimal Choice for Military and Defense Equipment

Mon, 06 Feb 2023 20:30:20 GMT

Military hardware and vehicles need to be able to withstand the harshest environments. Thermal Spray Coatings ensure that these pieces of equipment are durable, reliable, and capable in extreme conditions - keeping our troops safe on operational missions. With their ease of implementation and high resistance to wear and corrosion they provide ultimate protection while allowing greater flexibility when it comes to design options. Thermal Spray Coatings are an indispensable asset for any defense installation or system that needs long-term reliability under harsh conditions.

Cost-Effective and Reliable Protection

Thermal spray coatings provide a cost-effective and reliable means of protecting military and defense systems against wear, corrosion, and electromagnetic interference. Unlike other forms of protective coating such as paint or galvanization, thermal spraying does not require solvents, disposal of hazardous waste, or complex masking operations. Thermal spray coatings also offer superior performance and can be used to provide protection in extreme environmental conditions.

Highly Versat ile

Thermal spray coatings are also highly versatile, allowing for a variety of materials such as metals and ceramics to be applied to a wide range of surfaces. This allows for complex designs with intricate detail that may not be possible with more traditional coating methods. Thermal spray coatings also offer superior adhesion and can be used to create a seamless bond between two surfaces. Additionally, they offer excellent protection against wear and are ideal for high-temperature applications.

Easy Integration and Maintenance

Thermal spray coatings are also relatively easy to integrate into new or existing designs and are simple to maintain, requiring minimal training or specialized equipment. This makes them an attractive option for the military and defense industry, where budgets and personnel can be limited. Additionally, the coatings are durable and can withstand extreme temperatures, chemical exposure, and impacts. Thermal spray coatings also offer excellent protection against corrosive elements such as seawater and salt air, making them ideal for marine applications. Finally, they require minimal maintenance as they do not need to be repainted or refinished like other coating processes.

In summary, thermal spray coatings are a cost-effective and reliable means of protecting military and defense systems against wear, corrosion, and chemical attacks. They offer superior performance for high-temperature applications and can be applied to a wide range of surfaces with minimal training or specialized equipment. Thermal spray coatings also offer excellent protection against corrosive elements, require minimal maintenance, and are highly durable. As such, they are an ideal option for the military and defense industry.

About Hayden Corp.

Hayden Corp. is proud to offer top-tier thermal spray coatings tailored specifically for use in military and defense operations. Take advantage of our thermal spray process to improve the performance and resilience of metal surfaces. Thermal spray coatings provide increased resistance to wear, corrosion and abrasion, making them vital in military applications such as naval vessels, submarines, vehicles armored, helicopters, jets & weapons systems. Our expansive experience has provided us with a profound understanding of the unique obstacles that are encountered by military and defense industries. Thus, we're able to deliver custom-crafted solutions that fulfill the individual needs of our clients. If you're looking for a reliable source of advanced wear protection and corrosion resistance solutions, Hayden is your ideal partner. Our expertise and certifications enable us to deliver quality thermal spray coatings tailored to the needs of military and defense applications. Get in touch with us today so that we can discuss how Hayden's solutions will benefit your mission.

How to Decide When to use Plasma Spray or HVOF

Mon, 06 Feb 2023 19:00:01 GMT

Secure your components with two of the most dependable protective coating technologies available: plasma spray and HVOF (high-velocity oxygen fuel). To ensure maximum performance, consider when to employ each process.

Use Plasma Spray for Parts That Require Superior Heat Resistance

Plasma Spray ensures your parts can handle extreme heat stress with its reliable and durable coatings. The higher temperature of the torch creates a dense coating of high melting point materials, resulting in more durable protection. This makes it ideal for parts with extremely high temperatures or that are subject to thermal cycling. Plasma spray also works well on components with complex geometries and large surface areas. Use plasma spray for parts that require superior heat resistance.

Use HVOF For Parts That Face Severe Wear (Abrasion Stress)

If your parts are facing severe abrasion stress, HVOF coating is the ideal solution for long-term protection. With its ability to provide a hard, wear-resistant surface that maintains dimensional accuracy and improves corrosion resistance, high-velocity oxygen fuel (HVOF) offers unbeatable quality assurance guarantees so you can rest easy knowing your parts will remain in top condition no matter what conditions they're exposed to.

If parts are expected to encounter high levels of abrasion and wear, HVOF is the way to go. For example, aerospace components must be able to withstand turbulent conditions, so HVOF delivers the hard-wearing strength that makes them suitable for use in such demanding environments. This coating also works well on parts with smaller surface areas, as it applies coatings with a higher bond strength that is more resistant to damage.

Choosing the Right Coating

Ultimately, both plasma spray and HVOF will protect your components from corrosion and wear, so it is up to you to decide which process would best suit your particular needs. By taking the time to understand the different applications and capabilities of each, you can ensure that you choose the right coating for maximum performance and longevity.

Both plasma spray and HVOF are excellent protective coatings, and it can be difficult to decide which one best suits your needs. Consider the expected environment and working conditions of the components, as well as their surface area size, geometry complexity, and temperature resistance requirements. With these factors in mind, you can make an informed decision about which coating to use for maximum protection.

Key Takeaways:

Plasma spray is great for parts with extreme heat stress or complex geometries and large surface areas.
HVOF is ideal for components exposed to extreme abrasion and wear.
Consider the environment and working conditions of components when deciding which coating process to use.
With the right information, you can choose the best protective coating for maximum protection and performance.

About Hayden Corp

Hayden Corp is a leading provider of thermal coatings and insulating solutions for the aerospace, defense, and industrial sectors. We are committed to providing high-quality products that meet our customers' stringent requirements. Our expertise in plasma spray and HVOF spray coating processes helps ensure that

How Can Thermal Spray Benefit Paper Manufacturing Industry?

Mon, 06 Feb 2023 17:56:36 GMT

Thermal spray technology has numerous benefits to offer the paper manufacturing industry. The thermal spray process can be used to increase surface hardness, improve wear and abrasion resistance, reduce coating costs, and increase product performance. Thermal spraying of metallic coatings provides a cost-effective solution for extending the lifecycle of capital intensive papermaking machinery parts without sacrificing quality. The thermal spray process can also be used to reduce maintenance and repair costs, protect against corrosion, and provide protection from extreme temperatures. Thermal spraying also offers improved traction of web-handling components, reducing overall downtime for machine maintenance. In addition to these benefits, thermal sprayed coatings are environmentally friendly, energy-efficient, and long-lasting.

Thermal spraying of coatings is an ideal solution for the paper manufacturing industry, providing cost savings and increased product performance. With thermal spray technology, manufacturers can improve operational efficiency, reduce downtime, and increase the life of their machinery parts. The most common coatings include traction coatings, traction control coating including HC series, and Anti-skid and release coatings.

What are traction coatings?

Traction coat ings are designed to reduce slippage and improve the coefficient of friction on papermaking machinery surfaces. These coatings also act as a hardcoat and provide protection from wear and tear. Common applications include rollers, pulleys, chutes, decks, deck plates, and more.

What are Anti-skid and release coatings?

Anti-skid coatings are designed to reduce sliding on wet and contaminated surfaces such as those found no papermaking machinery surfaces. These coatings also help improve the wear characteristics of surfaces, reduce build-up and clean easily. Common applications include machine frames, catwalks, and outdoor structures..

Thermal spray coatings are a cost-effective and efficient solution for improving the performance of papermaking machinery in the paper manufacturing industry.

Thermal spray coatings are an excellent solution for improving the performance of components in the paper manufacturing industry. This technology offers numerous benefits including increased surface hardness, improved wear and abrasion resistance , reduced maintenance costs, and improved product performance. Thermal-sprayed coatings can also help reduce repair costs, protect against corrosion , and provide protection from extreme temperatures. By using thermal spray technology to extend the life of papermaking machinery components without sacrificing quality, manufacturers can benefit from lower operational costs and improved efficiency.

Manufacturers and Mills in the paper and film industry turn to Hayden for wear and corrosion solutions , friction control, and added longevity of component performance.

Hayden Corporation Acquires Falmer Thermal Spray

Tue, 01 Nov 2022 15:04:01 GMT

West Springfield, MA — Hayden Corporation today announced the acquisition of Falmer Thermal Spray. Founded in 1962 and with over a century of experience between their team members, Falmer Thermal Spray offers thermal spray coating as well as R&D and post coating services to efficiently take care of all manufacturing needs in one place. The company's products are used in a variety of industries, including aerospace, automotive, energy, and medical.

This acquisition is part of Hayden's strategy to grow its presence in the global thermal spray market.

"Falmer is a great addition to the Hayden family," said Daniel Hayden, President and 4 ^th -Generation leader of Hayden Corporation. "Their products and technology will allow us to better serve our customers in a variety of industries. Our company’s core competencies have evolved and expanded quite a bit over time, but the fundamental factors driving that change remain true,” added Hayden.

“We expand our expertise in response to the needs expressed by our customers and the unmet needs we see in the marketplace. Doing that work has always required that we have a highly-skilled and hardworking staff. It’s those talented people that have carried us through our century of existence, and will carry us into the next.”

"We are excited to join forces with Hayden," said Stacy Ames, owner of Falmer Thermal Spray. "This is a great opportunity for our company and our employees. We are confident that Hayden is the right partner to help us grow and continue to provide our customers with the best products and services. I look forward to staying on and working with Daniel and the entire Hayden organization to ensure a seamless transition."

About Hayden Corporation

Hayden is a leading provider of thermal spray services and equipment. Hayden Wire Works opened its doors in 1919 under the entrepreneurial vision of Charles E. Hayden, servicing New England’s many paper mills. Today, under the leadership of Daniel Hayden, the company is an active thought leader in its field and continues to expand its thermal spray, laser cladding and field services to new industries, applications, and customer partners across North America. Hayden is headquartered in West Springfield, MA, USA.

The Advantages and Disadvantages of Thermal Spray

Thu, 20 Oct 2022 01:22:17 GMT

Thermal spraying is a technique that has been used for centuries to apply a coating to a variety of surfaces. The process can be used to improve the wear resistance , corrosion resistance, and thermal insulation of an object. In this article, we will explore the advantages and disadvantages of thermal spray technology so that you can make an informed decision about whether or not it is right for your application.

The Advantages of Thermal Spray

Thermal spray is a versatile process that has many different applications in a variety of industries. One of the main advantages of thermal spray is its ability to strengthen and repair worn or damaged surfaces. In addition, this technique allows for the deposition of materials like ceramics, metals, and alloys in places where traditional fabrication methods may be difficult or impossible. Another key benefit of thermal spray is its ability to improve the performance of heat-sensitive components by thermally insulating them against excessive thermal loads. Used in both manufacturing and maintenance contexts, thermal spray can help companies achieve a wide range of goals and improve their products or processes in numerous ways. Whether you are looking to improve wear resistance, modulus, corrosion protection, heat dissipation, electrical insulation, or radiative properties, thermal spraying can help you achieve your goals.

Benefits of Thermal Spray Coating Include:

Excellent wear resistance

Thermal spray coating provides a hard and durable surface that can withstand high levels of wear and tear. This is especially beneficial for applications where there is friction, such as in bearings or gears.

Corrosion resistance

Thermal spray coatings can also protect against corrosion, chemical attack, and other forms of environmental degradation. This makes them ideal for use in harsh or hostile environments.

Thermal insulation

Thermal spray coatings can act as a thermal barrier , helping to keep heat in or out, depending on the application. This can be beneficial for both energy efficiency and personal safety.

The Disadvantages of Thermal Spray Technology

While the thermal spray coating process has many advantages, it also comes with a number of important disadvantages. One of the main drawbacks of thermal spray is that it requires high temperatures to bond properly with the underlying surface, making it difficult or even impossible to operate in a sealed environment. Moreover, thermal spray processes are often unsuitable for certain types of substrates due to their thermochemical properties or their tendency to react negatively to exposure to extreme heat and/or pressure. In addition, the high cost of thermal spray equipment and the skilled labor required to operate it can make this process prohibitively expensive for some companies. Finally, thermal spray coatings are typically much thicker than those applied using other methods, which can lead to problems with dimensional accuracy and material build-up.

Thermal spray technology disadvantages include:

High operating temperatures
Difficulty bonding with certain substrates
Cost of equipment and skilled labor

In Conclusion

Thermal spray technology is a versatile process that can be used to apply a variety of coatings to a wide range of materials. However, it is important to consider the thermal spraying advantages and disadvantages before deciding if it is the right choice for your application. The decision of whether or not to use thermal spray technology should be based on a careful evaluation of the specific needs of your application.

Breaking Down the Differences Between Laser Cladding and Thermal Spray

Wed, 19 Oct 2022 16:33:59 GMT

Laser cladding and thermal spray are similar yet distinct processes used to improve the surface properties of a substrate. Both methods involve depositing a protective or functional layer onto the substrate, but the two have several key differences. Let's take a closer look at laser cladding and thermal spray and explore the advantages and disadvantages of each method.

Laser Cladding

Laser cladding is a process that uses a laser beam to melt and deposit material onto the surface of a substrate. The laser energy also slightly melts the substrate, allowing the deposited material and the substrate to blend and allow. This melted material then cools and forms a metallurgically bonded layer on the substrate. Laser cladding can be used to deposit virtually any metallic material that can be welded.

Laser Cladding Advantages

Low Heat Input : laser cladding produces a very localized heat input, which minimizes the risk of distortion and thermal damage to the substrate.

Precise Deposition : laser cladding deposits a narrow, controlled weld bead, using a high-accuracy CNC machine tool, which allows for very precise deposition of material onto the substrate. This makes it ideal for repairing or adding features to delicate components.

Alloying and Cladding : laser cladding can be applied to create new alloys or cladding materials not possible with traditional methods. Multiple metallic materials can be injected and melted simultaneously.

Repairability: laser cladding can repair damaged or worn parts, restoring them to their original condition.

Laser Cladding Disadvantages

High Equipment Costs: laser cladding equipment is relatively expensive and requires a high level of operator training and experience.

Limited Material Selection: laser cladding is typically only possible with metals and alloys, and is not suitable for depositing ceramics or polymers.

Slow Process: laser cladding is a relatively slow process, making it unsuitable for high-volume production runs.

Thermal Spray

Thermal spray is a process in which a stream of molten or heated material is sprayed onto the surface of a substrate. The deposited material bonds mechanically to the roughened surface. This material then forms a coating on the substrate as it cools and solidifies. Thermal spray is a versatile technology with a wide range of applications. It is commonly used to improve the wear resistance, corrosion resistance, or electrical conductivity of surfaces.

Thermal Spray Advantages

High deposition rates: thermal spray can deposit material onto the substrate very quickly, making it suitable for high-volume production runs.

Protection from extreme conditions: thermal spray coatings can provide superior protection from extreme temperatures, chemicals, or abrasion.

Flexibility: Thermal spray can be applied to hard-to-reach places or irregularly shaped surfaces.

Wide range of materials: thermal spray can be used to deposit metals, alloys, ceramics, polymers, and even composite materials.

Extends the life of components: thermal spray coatings can significantly extend the life of components by protecting them from wear, corrosion, and other forms of damage.

Thermal Spray Disadvantages

High level of operator training and experience needed: thermal spray requires a high level of operator training and experience to produce consistent, high-quality results.

Risk of substrate damage: thermal spray can cause distortion and thermal damage to the substrate if not properly controlled.

Cost: thermal spray equipment is relatively expensive, and the process itself can be quite costly.

Now that you know a little bit more about laser cladding and thermal spray, you can decide which process is right for your application. If you need any help choosing the best coating method for your project, our team of experts at Hayden Corp would be happy to assist you. With over 100 years in business, we're experts in thermal spray coating and laser cladding services. Contact us to learn more about our laser cladding and thermal spray services.

Understanding Thermal Barrier Coatings

Wed, 19 Oct 2022 16:18:07 GMT

Thermal barrier coatings (TBC) are thick coatings of very high melting point and low-heat-transmission material applied to metal components to protect them from thermal damage. They are commonly used in industrial and commercial applications, such as gas turbines, jet engines, and industrial furnaces. TBCs typically consist of a ceramic top layer that is bonded to the metal substrate with a metallic bond coat. The TBC layer's thickness is generally in the range of 500-1000 microns. The primary function of the TBC is to reflect heat away from the metal substrate, thus preventing it from reaching temperatures that would cause thermal damage. In addition, TBCs can also help improve the overall efficiency of industrial equipment by reducing heat losses.

How are Thermal Barrier Coatings Applied?

Thermal barrier coatings are commonly applied using a thermal spray process. In this process, the TBC coating is atomized into microscopic particles and then sprayed onto the metal substrate. The particles impact, cool, and become bonded to the surface of the substrate. Various thermal spray processes can be used, including plasma spraying and high-velocity oxygen fuel spraying (HVOF).

Applications Include:

Turbine blades
Exhaust nozzles
Combustion chambers
Piston rings

What are the main benefits of Thermal Barrier Coatings?

Thermal Barrier Coatings offer several benefits, including:

Protecting metal components from thermal damage
Improving the efficiency of industrial equipment
Reducing heat losses
Increasing the service life of components
Withstands high temperatures and thermal cycling better than uncoated metals.

These benefits make thermal barrier coatings essential to many industrial and commercial applications.

What industries use thermal barrier coatings most frequently?

Thermal barrier coatings can be found in a variety of industries, including:

Aerospace

TBCs are used to protect engine components from the high temperatures generated during combustion of fuel in the engines. TBCs can also be used to improve the efficiency of gas turbines by reducing heat loss through the engine's walls.

Power generation

In the power generation industry, TBCs are often used on turbine blades and other hot section components to prolong their lifespan and prevent damage from overheating. The most common types of TBCs are made from yttria-stabilized zirconia (YSZ), which is a highly durable material that can withstand temperatures of up to 3000 degrees Fahrenheit. In addition to protecting turbine blades from damage, TBCs can also improve the efficiency of power plants by keeping heat inside the combustion chamber, where it can be used to generate electricity. As the demand for cleaner and more efficient power generation increases, thermal barrier coatings will likely play an increasingly important role.

Automotive

Thermal barrier coatings are also used in the automotive industry to protect engine components from the high temperatures generated by internal combustion. TBCs can be used on various engine parts, including piston rings, exhaust valves, and turbocharger housings. In addition to thermal protection, TBCs can also improve the efficiency of engines by reducing heat losses.

Protect Your Metal Components

Thermal barrier coatings are an essential part of many industrial and commercial applications. If you are looking for a way to protect your metal components from thermal damage, or improve the efficiency of your equipment, then thermal barrier coatings may be the right solution for you.

If you have any questions about thermal barrier coatings or how they can be utilized in your application, please contact Hayden Corp. We would be happy to discuss your specific needs and requirements.

Printing and Paper Manufacturing - Benefits of Thermal Spray Traction and Anti-Skid Surface Coatings

Wed, 19 Oct 2022 16:09:02 GMT

In the printing and paper manufacturing industries, a high degree of precision is essential. Uneven surfaces can cause paper to slip and tear or impede the function of moving parts. A thermal spray anti-skid surface coating can alleviate these issues by providing a textured, durable surface that helps grip materials and maintain uniform sheet tension and smooth movement. Thermal spray coatings are applied using specialized equipment that heats the coating material to a high temperature before spraying it onto the surface, where it quickly cools and solidifies. The resulting coating is extremely hard and wear-resistant, making it ideal for applications where a high level of friction is needed. In addition, the textured surface of the coating helps to prevent slippage, ensuring that materials move smoothly through the manufacturing process. By investing in a thermal spray anti-skid surface coating, businesses in the printing and paper manufacturing industries can improve the consistency and quality of their products.

4 Main Benefits of Anti-Skid Traction Coatings

There are man y benefits to using thermal spray anti-skid coatings, including:

Improve The Grip of Rollers and Other Machinery:

In the printing and paper industry, smooth and even movement is essential to avoiding jams and other disruptions in the manufacturing process. By improving the grip of rollers and other machinery, anti-skid coatings can help keep materials moving smoothly.

Reduce Downtime:

Uneven surfaces can cause friction that leads to wear and tear on machinery. This can eventually lead to breakdowns and other mechanical problems in the manufacturing process. By using an anti-skid coating, businesses can reduce downtime by ensuring that their machinery runs efficiently and reliably.

Improve Product Quality:

Product quality is of the utmost importance in the printing and paper manufacturing industry. Any deviation in machinery can result in an imperfect final product. Anti-slip coatings ensure that the printing process is smooth and uninterrupted, resulting in a higher-quality product.

Extend Life of Equipment:

In addition to reducing downtime, thermal spray anti-skid coatings can also extend the life of equipment by protecting it from wear and tear. This can save businesses money in the long run by reducing the need for frequent repairs or replacements.

Methods Used to Achieve Anti-Slip Surface Coatings

There are several methods that can be used to achieve an anti-skid surface coating, including:

Plasma Spray

Plasma spray is a thermal spray process that uses a high temperature plasma jet to heat and propel coating material onto a surface. Plasma thermal spray coatings are effective for friction, wear, and dielectric applications such as corona treater rolls.

Arc Wire Spray

Arc wire spray is a thermal spray process that uses an electric arc to melt and propel wire coating material onto a surface. Arc wire is efficient and ideal when covering a large surface area. It is also capable of creating very rough, high-traction finishes.

Flame Spray

Flame spray uses an oxy-actylene flame to heat and propel coating material onto a surface. This method is often used for small, delicate surfaces and is especially suitable for on-site application.

Improve The Quality and Efficiency of Your Manufacturing Process

Thermal spray traction coatings provide several benefits for businesses in the printing and paper manufacturing industry. These coatings improve the grip of rollers and other machinery, reduce downtime, improve product quality, and extend the life of the equipment. There are several methods that can be used to achieve an anti-skid surface coating, including plasma spray, arc wire spray, and flame spray. By investing in a thermal spray anti-skid surface coating, businesses can improve the efficiency and quality of their manufacturing process.

Hayden Corp. specializes in providing businesses with high-quality thermal spray coatings. We use the latest technology and equipment to ensure that our coatings meet the needs of our clients. Our experienced team is dedicated to providing the best possible service and customer satisfaction. To learn more about our thermal spray coating services, contact us today.

How Thermal Spray Coating on a Pump can Eliminate Cavitation

Tue, 04 Oct 2022 20:25:31 GMT

Since the invention of the modern centrifugal pump some 300 years ago, man has been aware of and working to prevent cavitation. Cavitation is the process by which tiny bubbles of vapor form in a liquid due to localized areas of low pressure.

Cavitation is similar to the bubbles seen in boiling water. Instead of being created by heat, it results from a pressure differential as fluid is pushed through a pump. Practically all liquids are susceptible to this effect. When these bubbles form and burst in the more congested sections of a pump, serious harm might result from their erosive effect.

Thankfully, the effects of cavitation in pumps may be reduced or mitigated by thermal spray coating. In the following paragraphs, We will delve even deeper into this topic.

Understanding How Thermal Spray May Reduce or Mitigate Cavitation in Pumps

Can Cavitatio n Be Stopped?

The most effective method for reducing cavitation is to let pumps operate at their designed flow rate while keeping in mind the pump’s designed operational curve. It is not always possible to avoid cavitation, and it is often advisable to construct pump housings and impellers out of durable, hard wearing materials.

A pump constructed from tougher, more durable alloys can be significantly more expensive than traditional cast steel or bronze. This cost can be reduced by constructing the pump and its parts from conventional materials but lining the interior fluid handling surfaces with cavitation resistant thermal sprayed coatings..

Cavitation constantly threatens a pump's durability because it can be difficult to detect while the pump is running, and, once it begins, the erosion caused by cavitation can quickly accelerate. If cavitation is identified to be a problem, a protective coating on the anticipated affected areas of new components can substantially delay the initiation of erosive wear.

How Does Thermal Spray Help?

Thermal spraying is a process for applying thin metallic or ceramic coatings to metal components in a manner similar to spray painting; any surface that is accessible by line of sight can be coated. Some metallic coating alloys are especially resistant to the action of cavitation, and thin coatings of these materials on cavitation-prone areas of the pump interior can effectively reduce or eliminate the action of cavitation erosion without affecting pump performance.

These coatings are useful both for protecting new pump components intended for use in applications where cavitation has been a problem, and also for rebuilding and restoring pump parts that have previously been damaged by cavitation.

The actual efficacy of commonly applied cavitation resistant coatings is dependent upon several factors, including the design of the particular pump being coated and the fluid it is handling. In practice, however, coated pump components can extend the operational life of a pump and its performance by multiples. Coating chemistry and hardness can also be selected for optimum performance in a specific application.

The most common coatings for cavitation resistance are HVOF-applied superalloys and carbides. Their exceptional density and high bond strength make them especially resilient against the action of cavitation erosion. HVAF coatings and some ceramics can offer even greater protection for some applications, depending on pump design and operating parameters and the fluid being conveyed.

Thermal Spray Coatings Can Protect and Extend the Life of Your Pumps

Thermal spray coating can be an effective means of eliminating cavitation in pumps. By creating a smooth, uniform, hard surface on the pump impeller and/or housing, cavitation and the resulting damage to the pump can be reduced or eliminated. Thermal spray coating can also extend the pump's life by protecting fluid handling surfaces from wear and tear. For this reason, investing in this treatment can save operators significantly in maintenance and repair costs in the long term.

Hayden Corporation has been in the thermal spray coating industry for over 100 years, and our team of experts can help you find the best coating solution for your needs. Thermal spray coatings, such as HVOF coatings, are among the many options we provide, and our team is here to assist you in identifying the best one for your purposes. Inquire about our thermal spray services today!

What is HVOF Thermal Spray and Why Is It Important

Tue, 04 Oct 2022 20:15:03 GMT

HVOF coatings are among the most common thermal spray coatings requested in industry today. This class of coatings was first developed in the 1980s, and established a new standard for thermal spray coating density and adhesion strength. Chiefly used for high-performance alloy coatings and carbide composites, HVOF coatings are the de facto standard for wear protection and turbine-class metal-on-metal protection.

Common Types of HVOF Thermal Spray Coatings

1. Carbides ( Tungsten Carbide Cobalt, Tungsten Carbide Nickel Chromium, Chromium Carbide Nickel Chromium)

Carbides are the hardest and most wear-resistant HVOF thermal spray coatings. They are often used in mining, construction, oil and gas, turbine engine, and pump applications. All of these coatings consist of carbide grains (tungsten carbide, chromium carbide, or a blend of both) suspended in a metallic binder (usually cobalt or nickel chromium). These coatings are extremely hard wearing, and can provide protection even at very low thickness.

2. Nickel and Cobalt Superalloys

Coatings of Stellite and Tribaloy cobalt alloys and similar materials are designed to withstand repeated metal on metal contact, even under high load and high temperature, without galling or adhering. Coatings in this class are often used on the mating components of turbine engines, which operate at high temperature and often with substantial vibration. The coatings ensure that mating metal components continue to move freely against one another without wearing.

Where Is HVOF Thermal Spray Used?

HVOF thermal spray coatings are widely used in various industries for their excellent wear and corrosion resistance properties. Some of the common applications of HVOF coatings include:

1. Automotive Industry

HVOF coatings are used on various automotive parts such as exhaust valves, cylinder bores, and piston rings. They help to improve the performance of engines by reducing friction and wear.

2. Aerospace Industry

HVOF coatings are used on aircraft turbine blades to protect them from particle erosion encountered during operation.

3. Oil and Gas Industry

HVOF coatings are used on valves and other components in the oil and gas industry to protect them from erosion and wear.

4. Medical Industry

HVOF coatings are used on medical implants such as hip joints and knee replacements. They enhance the surface of these components to promote bone growth.

Why is HVOF Thermal Spray Important?

HVOF coatings are denser than other thermal spray coatings. An HVOF gun creates a gas stream with a velocity higher than the speed of sound, much like a fighter jet engine, but of course much smaller. This super fast gas jet accelerates coatings particles to very high speeds so that they impact the substrate with tremendous force. This high velocity and high impact force causes the deposited material to compress and densify, reducing or removing the pores and gaps that would otherwise form using other thermal spray methods.

The high density and tight bonding of HVOF coatings has two primary advantages:

The coating has fewer, if any, pathways to allow corrosive fluids to penetrate the coating and attack the substrate. For this reason, HVOF coatings are less corrosion-prone than plasma or flame spray coatings.
The dense structure ensures that HVOF coatings are better adhered to the substrate. All thermal spray coatings are mechanically bonded, and the tighter packing of HVOF particles means that more of the coating material’s surface area is in intimate contact with the substrate. Bond strengths of HVOF coatings are often several thousand PSI higher than comparable plasma applied coatings.

Conclusion

The HVOF process can provide many benefits for components. These benefits include improved wear resistance, corrosion resistance, appearance, and performance.

If you are looking for coatings for steel parts in the USA, then you can get them from us at Hayden Corporation. We offer thermal spray coating, as well as hardface welding and machining. Get in touch with us for more information.

Why Your Industrial Workspace Needs Thermal Spray Coatings

Tue, 04 Oct 2022 19:58:25 GMT

Thermal spray coating is a process where a spray of finely divided semi-molten and molten droplets deposits coatings of cermets, metals, polymers, and ceramics onto metallic and non-metallic surfaces. This process is beneficial because it allows for precision protection with high performance materials and can deposit coatings in layers ranging from 0.1mm to 1mm. Here are some reasons why your workspace needs thermal spray coatings:

Fast and Effe ctive Repair of Worn Metal Components:

Coatings applied by thermal spraying can quickly build up damaged or worn areas, where metal has been lost to vibration, wear, rubbing, or galling. These materials can restore dimension to get equipment back in operation quickly, with minimal distortion, and with like-new performance. Harder wearing materials can also be applied so that the repaired surface performs better and longer than the original equipment.

High-Performance Materials Where You Need Them

Thermal spray coatings are used to protect surfaces from corrosion or wear. Coatings can be applied to specific areas affected by surface attacks so that only the area that needs special protection is treated. This is more efficient than creating a full component from costlier materials for corrosion protection or wear resistance, or plating the entire component.

No More Need for Exotic Billets, Forgings, and Bars

Creating components from high performance alloys such as Inconel, Hastalloy, or bronze requires time, effort, and expense, often using custom castings or forgings. Thermal spray coatings make it possible to use the outstanding characteristics of these materials on components made from more accessible, and often more machinable materials.

Various Applications on Plastics and Most Metallic Substrates

Thermal spray coatings are not affected by metallurgical interactions with the substrate that would make some material pairings un-weldable. For example, aluminum can be applied to steel or tungsten carbide to copper without issue. Metallic coatings can even be applied to some plastics and carbon fiber reinforced plastic. There is a wide variety of coating metallic and ceramic materials available that can be applied to the target substrate. This yields great flexibility regarding what can be coated and how it can be used.

Wide Ranges of Wear and Corrosion Resistance

Thermal spraying can apply a broad spectrum of metallic and ceramic materials, each with unique thermal characteristics, hardness, resistance or interaction with chemicals and compounds, electrical resistivity and conductivity. Coatings can be tailored to meet the specific needs of an application; there is no one-size-fits-all solution. Whatever the particular needs of your project are, Hayden can help you select the right coating to improve your surface.

Layering of Materials for Tailored Performance

Thermal sprayed coatings are typically deposited at about 0.001” (0.025mm) per layer, and one layer of deposited material will not metallurgically interact with the layer beneath it. As such, multiple materials can be deposited sequentially to create overlays that change in composition or behavior through their cross section. Common examples include the addition of bond coats beneath some hard or rigid top coats, insulating layers beneath conducting layers to create sprayed-on heating elements, and materials of varying dielectric properties to create batteries and capacitors.

Formable Electrical Conductors and Insulators

Aluminum, copper, tungsten, and zinc are materials often used in electrical applications because they have low electrical resistance. This means they can easily conduct electricity and help protect surfaces from electrical damage or interference when applied as a gasket, shield, or barrier. Customized traces can also be applied onto surfaces such as antennas, equipment housings, and photovoltaic cells.

Some Coatings Are Effective Thermal Heat Barriers

Thermal spray coatings of some very high melting point ceramics can be sprayed onto metals to protect them from extreme temperatures. These coatings are effective at guarding against temperatures in hydrocarbon combustion, but have also been adapted for use in high performance automotive applications to mitigate heat transfer.

Minimal Impact on Substrates

Parts being coated by thermal spraying typically remain below 300 degrees Fahrenheit. Although the coating materials themselves sometimes have very high melting points, the coating process ensures that the target surface remains much cooler. There is often virtually no risk of distortion due to the application of a sprayed coating, and so finished parts with tight tolerances can be coated or repaired without jeopardizing fit.

Get Quality, Precision, and Flexible Thermal Spray Coatings from Hayden Corporation

At Hayden Corporation, we stake our reputation on long-standing thermal spray coating expertise. Our customers turn to us as their strategic thermal spray partner because of our focus on flexibility and quality, with handling capacities up to six tons, 72 inches in diameter, and 400 inches in length, along with customized thermal spray coating applications for your components. To learn more, visit our website today!

6 Advantages of Thermal Spray Coating for Weld Cladding

Wed, 21 Sep 2022 16:22:52 GMT

Thermal spray coating is a process in which a material is applied to a surface using heat and velocity. This process can be used to apply a variety of materials, including metals, ceramics, and plastics. Of course, there are many ways to protect surfaces, but thermal spraying creates a smooth and uniform deposit with very little risk to the substrate.

That being said, let's delve into a few advantages of using thermal spray coating:

1. Thermal Spray Coating Can Be Used to Apply a Wide Range of Materials

One of the great things about thermal spray coating is that it can be used to apply a wide range of materials from soft thermoplastics and conventional metals like steel and bronze to hard coatings like tungsten carbide and ceramics. This means that you can choose the best material for your particular application, whether it's for dimensional restoration, clearance control, surface conductivity, wear resistance, corrosion resistance, or heat resistance..

2. Thermal Spray Coatings Can Be Applied Very Thinly

Another advantage of thermal spray coating is that it can be applied as little as 0.003” thick. This is important when a larger dimensional change would adversely affect performance. With thermal spray coating, you can apply a very thin layer of material, which will provide the desired protection without affecting the function of the part.

3. Thermal Spray Coatings Are Very Durable

When properly engineered and used as designed, thermal spray coatings can withstand substantial wear and remain effective for years. Coatings for both wear and corrosion applications can extend surface life by many multiples. In one well documented study, corrosion protection by thermal spraying lasted more than 19 years, well beyond the planned life of the study.

4. Thermal Spray Coatings Are Resistant to High Temperatures

High temperature can significantly reduce the wear resistance of even high-performance alloys. Some thermal spray coating materials are specifically designed to perform at high temperatures to protect critical surfaces in hot environments like power generation boilers and turbine engines.

5. Thermal Spray Coating Is Relatively Inexpensive

Since even thin thermal spray coatings can offer substantial protection, the cost of adding a protective coating is frequently much more favorable than engineering a thicker, heavier part or switching to a more costly, higher-performing alloy. Thermal spray coatings offer savings in both fabrication cost and weight.

6. Thermal Spray Coating Can Be Applied to Complex Shapes and Geometries

Coatings applied by thermal spraying are conformal, and can be sprayed over most complex and curved surfaces, provided the surface is accessible. Some commonly coated examples of complex surfaces include turbine blades and pump impellers.

Conclusion

Thermal spray coating offers a number of advantages for surface protection, including the ability to apply a wide range of materials, the ability to be applied very thinly, and the fact that it can offer substantial life extension to critical surfaces. If you're looking for an option that is resistant to high temperatures and that is adaptive to various shapes, then thermal spray coating is a perfect choice. Thermal spray coatings are depended upon in a variety of industries, including automotive, aerospace, and oil and gas. So if you're looking for an option that is versatile and durable, then thermal spraying is the way to go.

Hayden Corporation is the leading provider of thermal metal spray coatings in Massachusetts . We offer our coating services nationwide and in a variety of industries, including aerospace, military, and more. Our coatings are designed to provide superior durability and strength, and our team of experts is dedicated to providing the highest quality coating solutions possible. If you are in need of thermal spray coating, reach out to us today! We would be happy to discuss your specific needs and provide a quote for our services. Thank you for considering Hayden Corporation.

Arc Spray: What is it and How Does it Work?

Fri, 02 Sep 2022 13:15:46 GMT

Arc spray is a thermal spraying process that uses an electric arc struck between two consumable feedstock wires to heat and melt the coating material. This molten material is then projected by a gas stream onto the target surface, where it instantly solidifies and bonds to the substrate. Arc spray is used to apply coatings to metal parts in a variety of industries, including aerospace, automotive, and energy production. In this article, we will discuss what arc spray is, how it works, and some of its advantages and disadvantages.

What is Arc Spray?

By definition, arc spraying is a thermal spray process wherein molten droplets are sprayed onto a substrate to form an interlocking surface deposit. In arc spraying, two consumable wire electrodes are used to form the electric arc. The heat of the electric arc melts the metal of the wire electrodes, and the resulting molten droplets are sprayed onto the substrate by a gas jet immediately behind the arc zone. The arc spray process is often used to apply coatings of zinc, aluminum, or other metals onto metallic substrates. The deposited metal coatings provide corrosion resistance and wear resistance properties.

Arc Wire Spraying Applications

Compared with other common thermal spray techniques, arc spray coating is particularly cost-effective/ It is typically utilized for the high speed application of metals like stainless steel, aluminum, and brass. Arc spray also offers a range of adjustment for different coating textures. Application sectors for arc spraying include:

Energy Production

In the energy production industry , arc spray is used to apply corrosion-resistant coatings to pipelines, storage tanks, and other metal surfaces that are exposed to harsh outdoor and marine environments. Coatings applied by arc spraying can protect against corrosion from salt water, chemical attack, wear, and abrasion.

Roll Resurfacing

Arc spray can also be used to resurface rolls used in the paper, textile, and metals industries. By applying a hard, wear-resistant coating to the surface of a roll, arc spray can extend its service life and improve its performance.

Advantages of Arc Spray

Can be used on a variety of metals

The arc spray process can be used to apply coatings of zinc, aluminum, stainless steel, and other metals onto most metallic substrates. Virtually any metallic material that can be drawn into wire form can be sprayed by arc wire spraying. Most commercially available MIG welding wires are compatible with arc spraying equipment. Certain specialty coatings can be created by running two wires of differing chemistry. This creates a spray deposit which is essentially a blend of the characteristics of both.

Rapid deposition

Arc spraying has deposition rates that far exceed most other conventional spraying methods. For this reason, arc spraying is advantageous for coating large surface areas and/or applying very thick coatings.

Economical operation

Most arc spraying requires only electricity and compressed air, making it simpler to apply in the field and less costly and complex, in terms of utility requirements and logistics. Arc spraying is often the preferred technique for field-applied coatings.

How Does Arc Spray Work?

The arc spraying process uses an electric arc to heat and melt the coating material. Two feedstock wires are electrically connected to the opposite poles of a high-current power supply. As the two conducting wires come into contact, an electric arc is struck that melts the wire and breaks the connection. Motorized pinch rollers advance the wire forward re-striking the arc, and spraying is sustained. The molten material is projected forward using a compressed gas jet located immediately behind the arc zone. The shower of molten droplets impact the target surface, where it instantly solidifies and forms a dense, adherent coating. Spraying can optionally be performed using an inert gas such as argon or nitrogen, instead of compressed air, to reduce the formation of oxides in the coating and create a cleaner deposit.

Flexible Quality Surface Treatment

Arc wire offers a portable and simple option for thermal spray applications. By bringing MIG welding technology to the field of thermal spray, arc wire makes it possible to apply a quality surface treatment at virtually any location. With its ability to provide an even coating and high deposition rates, arc wire is quickly becoming a popular choice for thermal spray applications.

Arc Wire Thermal Spray Experts

If you need arc wire for your next thermal spray application, look no further than Hayden Corp. Our solutions-based expert team of craftsmen and technicians will work with you to find the best solutions that affect your parts. Contact Hayden Corp. today to schedule a free consultation.

Industrial Ceramic Coating

Sun, 21 Aug 2022 15:38:25 GMT

Industrial ceramic coatings are specialized coatings that are applied to metal surfaces in order to improve durability and resistance to wear and corrosion. The term "industrial ceramic coating" can refer to various types of coatings, each with its unique set of properties. However, all industrial ceramic coatings share two key features: they are extremely hard and they are virtually chemically inert. For these reasons, ceramics have often been used in pumps and valves to restore dimension and significantly increase component life.

Advantages of Ceramic Coatings

Industrial ceramic coatings offer a variety of advantages over traditional metal coatings. Advantages include:

Improved durability: Ceramic coatings are much harder than metal coatings, making them more resistant to wear and tear. This improved durability can lead to a longer lifespan for the coated surface.
Increased resistance to corrosion: Corrosion is a major problem for metal surfaces exposed to the elements. Over time, the metal will break down, causing structural damage and compromising the integrity of the material. One way to protect metal surfaces from corrosion and improve corrosion protection is to apply a ceramic coating. Ceramic coatings act as a barrier between the metal and the environment, preventing moisture as well as other corrosive materials from coming into contact with the surface. In addition, ceramic coatings can help to reflect heat away from the metal, keeping it cooler and preventing thermal expansion and contraction.
Increased Wear Resistance: Wear is the process of material loss on a surface due to contact with another object. Over time, this can lead to serious damage and even failure of the affected parts. There are many different causes of wear, but some of the most common include friction, abrasion, and corrosion. Industrial ceramic coatings can help increase wear resistance in parts by providing a tough, durable barrier against these forces. By increasing wear resistance, industrial ceramic coatings can help prolong the life of parts and reduce downtime and repair costs.
Improved appearance: The high gloss finish of a ground or polished ceramic coating can give metal surfaces a more attractive appearance.
Electrical insulation: Ceramic coatings can help to insulate metal surfaces from electricity, preventing electrical current from flowing through the surface. This can be beneficial in many industrial and commercial applications where electrical safety is a concern.

Industrial Applications of Ceramic Coatings

Industrial ceramic coatings are used in a variety of industries and applications. Some common examples include:

Aerospace : Ceramic thermal barrier coatings are used in the aerospace industry to protect aircraft engine components from the high temperatures generated during engine operation. The coatings are applied to engine parts, such as turbine blades, exhaust nozzles, and combustion liners. They act as a protective barrier between the metal substrate and the hot gas and fuel residue of combustion, preventing heat from damaging the metal. Ceramic coatings also have good wear resistance, which helps extend the life of critical engine parts. The use of ceramic coatings in the aerospace industry has increased in recent years as airlines look for ways to improve fuel efficiency and reduce emissions.

Oil and Gas Industry : Ceramic coatings are gaining popularity in the oil and gas industry , especially in the offshore sector. They offer superior corrosion and wear resistance compared to conventional coatings and can withstand higher temperatures. Ceramic coatings are typically applied to pipes, valves, and other equipment that is exposed to harsh conditions. For example, ceramic coatings can protect against the corrosive effects of salt water and high pressure in fluid handling equipment. In addition, ceramic coatings can be used to repair damaged equipment and help extend the service life of critical components and minimize downtime.

How Are Industrial Ceramic Thermal Spray Coatings Applied?

Ceramic thermal spray coatings are typically applied using the plasma spray process. In this process, an electric arc generates a stream of ionized gas (plasma) from an inert gas. The resulting plasma is extremely hot, which allows it to melt ceramic materials with very high melting points. The plasma spray process can be used to apply a variety of materials, some include:

Yttria Stabilized Zirconia - A durable thermal barrier. Yttria stabilized zirconia produces a brittle, abrasion-resistant surface with excellent thermal stability and thermal shock resistance.
Aluminum Oxide - Excellent dielectric and thermal resistance properties. Wear resistant and readily ground to a smooth finish.
Chrome Oxide - Highly resistant to sliding and abrasive wear, cavitation, and corrosion.

Learn more about thermal spray materials

Industrial Ceramic Coating Experts - Hayden Corp.

Hayden Corp. is the leading provider of industrial ceramic coating solutions. We have over 100 years of experience in the industry, and our coatings are used by major manufacturers worldwide. We offer a broad range of thermal spray coatings for all industries, and our team of experts can customize a solution to meet your specific needs. If you are looking for the best protection for your critical components, contact Hayden Corp. today.

Ceramic Coating FAQ's

The Advantages of High-Velocity Oxygen Fuel Thermal Spray Coating

Mon, 25 Jul 2022 01:14:13 GMT

There are many benefits of HVOF spraying over other thermal spray processes, which is why demand for this process has increased substantially in recent years. In this article, we will cover some of the top advantages of using high-velocity oxygen fuel spraying to coat your parts and components. If you are looking for a more durable, longer lasting, harder wearing coating, then HVOF spraying may be the right choice for you!

What is HVOF spraying?

High-velocity oxygen fuel (HVOF) spraying is a thermal spray coating process that uses a supersonic stream of gas to deliver metallic, ceramic, or composite material to a surface. The material is typically in the form of powder or wire. The high velocity of the gas stream accelerates the particles of coating material so much that they deform and flatten almost completely upon impact with the target surface. In other words, HVOF spraying is less dependent upon heat to melt and soften coating material and more dependent upon speed and energy to hammer it into the target surface.

Advantages of HVOF spraying include:

Higher durability

HVOF spray coatings are known for their durability. The dense structure of the coating helps to resist wear and tear, and the lack of porosity makes it less likely to chip or flake off. This makes HVOF coatings an ideal choice for high-wear applications such as turbine engine components, centrifuges, and pumps. In addition, the dense structure of the coating also provides good corrosion resistance. This is due to the fact that dense coatings provide fewer porous pathways for corrosive elements to attack the substrate. For these reasons, HVOF coatings are often used in applications where corrosion resistance is critical, such as in offshore oil exploration, chemical processing, and refinery environments.

Better Bond to Substrate

HVOF coatings have a substantially higher bond to the substrate than traditional thermal spray coatings, sometimes as much as double the bond strength. This is due to the fact that the high velocity of the gas stream maximizes surface contact of deposited particles with the substrate. This develops a strong physical bond between the coating and the substrate, and helps to improve the durability of the coating.

In addition, the bond between the coating and the substrate is less likely to be damaged by thermal cycling or vibration. This makes HVOF coatings an ideal choice for components that are subject to high temperatures or extreme temperature changes.

Flexible Applications

HVOF coatings can be customized to meet the specific needs of many applications. Commonly sprayed materials include metal superalloys and carbides. The HVOF thermal spray process is best used to apply hard materials, including wear-resistant coatings, corrosion-resistant coatings, and non-galling protection.

Smooth & Consistent Surface Finish

HVOF thermal spray coatings are distinguished by their smooth and consistent surface finish, even in the as-sprayed condition. This characteristic makes HVOF coatings ideal for a variety of applications where a smooth surface is critical, such as in bearings and turbine blades. The lack of surface irregularities also gives HVOF coatings superior wear resistance, making them ideal for high-stress environments. The density of these coatings also enables them to be ground to much finer finishes than more conventional thermal spray coatings.

HVOF Provides Unparalleled Benefits

HVOF Thermal Spray Coating is an advanced coating technology that offers a number of benefits over traditional coating methods. The high-velocity, oxygen-fuel spray provides a dense, well-bonded coating that is resistant to wear and abrasion. HVOF coatings can be applied quickly and easily to complex shapes, making them ideal for challenging surface shapes. The resulting finish is also extremely smooth and consistent, providing superior protection against corrosion and pitting. Overall, HVOF Thermal Spray Coating can provide unparalleled benefits in terms of durability, performance, and aesthetics.

About Hayden Corp.

Hayden Corp has over 100 years of experience in the thermal spray industry, and our team of thermal spray experts can help you identify the right coating solution for your needs. We offer a wide range of thermal spray coatings , including HVOF coatings , and our team is available to help find the perfect solution for your needs. Contact us today to learn more about our thermal spray solutions!

The Dangers of Corrosion: How It Can Harm Both Human Safety and Equipment

Mon, 25 Jul 2022 00:56:39 GMT

Corrosion is a natural process that happens when metal or metal alloy surfaces come into contact with a corrosive fluid and form an oxide. Corrosion can occur slowly over time or can be accelerated by humidity, heat, salts, and acids, and other similar factors. Rust is the most common form of corrosion, and it can cause significant damage to equipment if left unchecked. This article will discuss the dangers of corrosion and how it can harm both human safety and equipment performance. In addition, we'll provide suggestions for how to prevent corrosion from occurring.

What are the main causes of corrosion?

While many factors can contribute to corrosion, there are three primary causes: poor ventilation, high temperatures, and electrolytic action. Inadequate ventilation can occur when corrosion-prone metals are enclosed such that airflow is prevented from reaching it. This lack of airflow speeds up the corrosion process by allowing condensate moisture to remain on metal surfaces. High temperatures can also accelerate corrosion by causing metal to expand and contract, which weakens its structure, particularly where two metallic bodies make contact, such as at joints and fasteners. Finally, electrolytic action occurs when two dissimilar metals are in contact with each other in an electronically conductive solution. This can create a current that flows between the metals, causing one of them to corrode. Given the many potential causes of corrosion, it's important to take steps to prevent it from occurring. By understanding the root causes of this destructive process, we can take measures to protect metal surfaces from their effects.

Understanding the dangers that corrosion imposes on equipment and their operators

Operators of all types of equipment potentially face dangers from corrosion every day. The danger isn't always obvious, but the risk is always present. Understanding corrosion's dangers to equipment and operators is the first step in preventing accidents and injuries.

Corrosion can weaken the structure of industrial equipment, such as buckets, pump components, tanks and piping, compressors, and valve gates, and making them more likely to fail. This can lead to mechanical failures that can cause injuries to operators and/or damage to the equipment itself. Even small levels of corrosion can have a substantial impact on the safety of equipment.

Corrosion can also create electrical hazards. When metal corrodes, it can create conductive paths that allow electricity to flow where it shouldn't, and can weaken conductors causing them to fail. If the electrical current that is flowing through the corrosive material is strong enough, it can lead to shock hazards for operators or even fires and explosions.

In addition, corrosion can lead to other problems that can be just as dangerous. For example, corrosion can cause leaks in pipes and tanks. These leaks can allow hazardous materials to escape, posing a danger to both operators and the environment. Corrosion can also block drains and vents, leading to flooding and the release of harmful gasses.

The financial impacts of corrosion

The impact of corrosion reaches far beyond the physical damage it causes to equipment. This destructive process also takes a toll on human safety, as well as the economy. In the United States, the cost of corrosion is estimated to be about $276 billion per year. This includes the expense of repairing or replacing damaged equipment, as well as the cost of lost productivity due to corrosion. The financial impact of corrosion is felt by businesses of all sizes, from small manufacturers to large utility companies and governments. In addition, corrosion can cause environmental damage, contaminate soil and water supplies and release harmful toxins into the air. Given the far-reaching effects of corrosion, it is clear that this is a serious problem that needs to be addressed. Thankfully, there are numerous ways of preventing or mitigating corrosion. By understanding the causes and effects of corrosion, we can take steps to protect ourselves, our equipment, and our environment from this destructive force.

What are the main types of corrosion?

In general, there are four main types of corrosion: chemical, electrochemical, galvanic, and environmental. Each type of corrosion occurs under specific conditions and can have different effects on metal.

Chemical Corrosion

Chemical corrosion occurs when the metal comes into contact with a substance that reacts with it, such as an acid. This type of corrosion can cause the metal to weaken or even break down completely.

Electrochemical Corrosion
Electrochemical corrosion occurs when the metal is exposed to an electrical current. This type of corrosion can cause the metal to become oxidized, which can also weaken it or cause it to break down completely.

Galvanic Corrosion
Galvanic corrosion occurs when two metals are in contact with each other in the presence of an electrolyte. This type of corrosion can cause one of the metals to deteriorate while the other remains unchanged.

Environmental Corrosion

Environmental corrosion occurs when the metal is exposed to a combination of environmental factors, such as air, water, and temperature. This type of corrosion can cause the metal to become pitted or rusted.

Preventing Corrosion

The most common method used in preventing corrosion is surface protection, including thermal spray coatings. Thermal spraying involves the application of a protective coating of non-corroding or corrosion resistant metals or ceramics to metal surfaces. The coating can be applied to new surfaces to prevent corrosion from occurring, or it can be used to repair existing damage by restoring dimension. Thermal spraying, especially in conjunction with sealers, is an effective way to protect against corrosion because it creates a physical barrier between metal and the environment. This barrier prevents moisture and other corrosive agents from coming into contact with the metal surface, which in turn prevents rusting and other forms of degradation. Thermal spraying is a cost-effective way to prevent corrosion, and it can extend the life of metal surfaces by years. In one study of thermal sprayed steel plates coated with aluminum and zinc and left exposed to outdoor marine and industrial environments, corrosion levels were so low that the study was stopped after 19 years of observation.

At Hayden Corp, we understand the importance of extending the life of your parts. Whether you are operating in a corrosive environment or simply looking to prevent wear and tear , our thermal spray coatings can give your parts the protection they need. The resulting coating is extremely durable, providing excellent protection against abrasion, corrosion, and high temperatures. Contact us us at Hayden Corp to learn more about our US thermal Spray services and how our spray coatings can help extend the life of your parts.

Tungsten Carbide Coatings

Wed, 25 May 2022 16:24:11 GMT

There are many coating options available for protection of metal parts, but tungsten carbide coatings are some of the most durable and long-lasting. Tungsten carbide is a hard, wear-resistant material that can be applied to virtually any metallic surface. These coatings provide excellent protection against corrosion and abrasion, making them ideal for applications where durability is essential.

What is Tungsten Carbide?

Tungsten carbide is a chemical compound with the formula WC. It is an extremely hard material that is used in a variety of industrial applications, including mining and drilling. Tungsten carbide can be used in powdered, granular form for coatings, in large, crushed particles or agglomerations of very fine tungsten carbide dust, or it can be pressed and sintered into solid tungsten carbide shapes like saw blade teeth or wear pads. Tungsten carbide also has a high melting point and is resistant to corrosion.

Tungsten Carbide Coatings Applied with HVOF

Tungsten carbide coatings are known for their wear resistance and high hardness. When applied using the high-velocity oxygen fuel (HVOF) thermal spray process, these coatings can provide even greater levels of protection. The HVOF thermal spray process deposits tungsten carbide particles onto a substrate at high velocity and pressure, resulting in a coating that is highly densified and extremely smooth. This smooth surface helps to reduce friction and wear, making tungsten carbide coatings ideal for use in sliding wear applications. In addition, the HVOF process can be used to apply tungsten carbide coatings to complex geometries such as pump impellers and casings and turbine runners.

Benefits of Tungsten Carbide Coatings

Tungsten carbide coatings offer a number of benefits for cutting tools and other surfaces. First, tungsten carbide is one of the hardest industrial materials available, making it highly resistant to wear and tear, which can substantially extend the life of tools and surfaces that are subject to heavy use. Second, tungsten carbide coatings resist corrosion and other types of environmental damage. This can be especially helpful in environments where equipment and surfaces are exposed to chemicals or other corrosive substances. Finally, tungsten carbide coatings can improve the appearance of tools and surfaces. Carbide coatings can be ground to a mirror-like finish, adding aesthetic value to extreme durability. For these reasons, tungsten carbide coatings offer exceptional protection and performance.

Tungsten Carbide Coating Applications

Tungsten carbide coatings are often used on components that are subject to high-wear conditions, such as paper and converting machinery rollers, turbine blades, bearings, and pump impellers. In addition, tungsten carbide coatings can be used to repair damaged surfaces and extend the service life of tools and equipment. With their unique combination of hardness and durability, tungsten carbide coatings offer exceptional protection for machinery and components.

Tungsten Carbide Coating Services

Hayden Corporation is a leading provider of thermal spray coating services. We provide a wide range of thermal spray coating services , including HVOF, Plasma Spray , and Arc Spray . We also offer a variety of other services, such as metalizing, laser cladding, and welding. Our team of highly skilled and experienced professionals are dedicated to providing the highest quality services possible. We operate in a state-of-the-art facility in West Springfield, MA that is equipped with the latest technology and equipment. We are AS9100 c ertified , and our commitment to quality is evident in everything we do. Contact us today to learn more about our thermal spray coating services.

A Change in Perspective

Fri, 25 Mar 2022 15:50:45 GMT

My father once told me, when looking for a new employee, hire someone who fixes and rides their own motorcycle. This kind of person, he said, tends to have the perfect mindset for our shop. They tend to be mechanically inclined, to appreciate care and precision over speed, and to be engaged in the world around them. This advice is on my mind because I’ve been rereading Robert Pirsig’s Zen and the Art of Motorcycle Maintenance, a book that, more than anything, reminds me to let go of fear and anxiety, and to be open to seeing the world from a newer, broader perspective. All of this is refreshing, since, like most of us, I have felt trapped indoors and at the mercy of a rapidly changing economy for the last 18 months or so.

The book takes a calm and meditative approach to describing a journey a father and son take by motorcycle from Minnesota to California. The book merges the author’s own philosophy with the journey itself and with the practical, hands-on practice of running and maintaining a well-built machine. As a business owner, I do the same. I balance the welfare of our business, the economic world in which we live, and my own passion for the hands-on work of our shop. At a time when the road ahead has seemed uncertain, Pirsig’s book reminds me not to let my perspective get too narrow.

The author describes a host of ways that once motivated and energetic people can become trapped and stagnated by external things. He also discusses how to be or to become aware of these traps and how to escape them. Right now, there are several things that could tend to make us feel less than optimistic about the near future of our industry in the United States, about the road ahead. Specifically, many of the domestic markets that have been core consumers of our products and services are operating well below historic averages. Some of these are likely facing permanent decline as changes in technology make their activity increasingly less useful. And then there are the challenges of developing, sustaining, and motivating a workforce that can appear to be fading as activity on the shop floor slows, experienced staff chooses earlier retirement, and skilled and energetic new blood seems to be in short supply. Pirsig would call these attitudes “motivation traps” because they can seem like barriers, insurmountable challenges that would make staying in business difficult or impossible. In reality, the end of one road may be the beginning of another, and it is only my own resistance to considering new opportunities that makes me feel trapped.

Thermal Spray Industries in Flux

Aviation

The aviation industry is a heavy consumer of coatings in both new components and repair and refurbishment. An early adopter of thermal spraying , a spectrum of coatings has been incorporated into parts throughout every large commercial aircraft, and the steady beat of commercial aviation’s heart has meant reliable business for our industry for decades. Today, almost two years into a pandemic that virtually decimated much commercial air travel, Bain & Company reports that near-term forecasts for global air travel will continue to decline, due to both consumer hesitancy to travel and continued travel restrictions between the US and EU, to the tune of a 36% reduction in revenues since 2019 [1] . Though this is certainly temporary and should ease as the pandemic fades into history, the lasting impacts for the industry are still uncertain. In the longer term, environmental, social, and governance, so called “ESG” factors, are gaining traction as key metrics of the health and sustainability of publicly traded firms like commercial airlines, and this change is causing major carriers to reconsider their fleets and routes. For example, Qatar Airways and others have accepted substantial losses in permanently grounding very large and expensive relatively new aircraft because the costs of owning and operating long-haul fleets with large carbon footprints become increasingly tough to justify [2] . Of course, flying will continue, air travel will not stay in its current slump, but where will it go, when, and what will it look like for those of us whose businesses depend upon it?

Auto Industry

Speaking of carbon, automobiles are another thermal spray sector that has been impacted recently. Here, two challenges are working simultaneously, with a near-term drought in semiconductors that has paused auto manufacturing due to a parts supply shortage, and a longer-term change in how cars are made as the industry begins a conversion to plug-in hybrid and full electric vehicles. Much of the thermal spray capacity in this sector is captive, that is, the spraying is owned and operated by the vehicle OEM, but there is a good deal that is outsourced to subcontractors, as well. Much of that spraying, too, is tied to internal combustion engines, which trends suggest are on their way out as electric powertrains continue to grow. Shops in this sector have seen a downturn in volume. Pent-up demand is anticipated to lead to an increase over 2020, if still lower than pre-pandemic numbers [3]. What remains unknown for the time being is how the migration to electric and plug-in hybrid vehicles will impact the application and diversity of coating technology in the market.

Green Technology

Also, along the path to green, power generation is a key component of the thermal spray landscape, and this, too, has been experiencing transformation. Vast reductions in the cost and lead times for solar photovoltaic production have seen tremendous expansion in this arena, with on-line solar capacity in the United States growing from 0.34 GW in 2008 to 97.2 GW in 2021. Since 2014, the cost of panels has dropped by a whopping 70% [4]. Utilities are motivated to embrace capacity that requires no fuel (and thus no volatile fuel costs, or emissions, for that matter), and so a significantly increasing percentage of our energy supply is coming from non-combusting, non-rotating equipment. However, it is this last point that means thermal spray’s participation in this sector is also scaling back, as coatings for turbine components were a major portion of the domestic industry’s volume, and many of us are feeling it.

Unpredictable Times

All of these factors have left many of us dazed and wondering about the future of spraying here in the US. Our shop, which has weathered all kinds of ups and downs over its 100-plus years was weirdly quiet last year. With far less work on the floor than usual, we resorted to reducing working hours temporarily, shifting from a five-day work week to four. Though many shops were able to work the first few months of the pandemic with little change in volume, as the summer of 2020 hit, work began to slow and government support, in the form of first- and second-round PPP stimulus, became more and more attractive. Workers in some regions had concerns about continuing to come to work. Others no doubt found that unemployment compensation and stimulus benefits were preferable to a paycheck and a risk of contracting COVID. As a result, workforces shrank, and some firms found it ultimately safer to close than to continue in an unpredictable economic climate.

A Change of Perspective

Pirsig might suggest that this is a good time for a ride, a change of perspective. In times like these, opportunities arise in two ways. ere is space during the lull to attend to things that languish when the shop is busier. These are often things that won’t take long to accomplish, maybe weeks or months, but should pay dividends for years to come. Short timelines are ideal because a pandemic can’t last forever (no matter how much it may seem otherwise). The book on motorcycle maintenance might liken this kind of work to the care of the machine. Taking time to ensure that bolts are tight, components are well lubricated and running smoothly, and necessary spares are on hand places us on a better footing when the inevitable problems do arise. The work itself becomes calming and reassuring because we know it is time well spent. Then, there are opportunities that may take some considerable time to flesh out but that we may never have started if it weren’t for a little downtime.

Maximizing Downtime

There are business improvement and expansion projects with short timelines to make the most of excess capacity while it is available. Here are some examples:

Parameter Development. How many of our day-to-day coatings and processes are refined to the point of verifiable optimization? That is, how certain am I that I am getting the best possible deposition efficiency and coating performance out of the coatings that are running consistently on our shop floor? In truth, when the parameter was developed, we probably did some optimization and experimentation, but the parameter we run today may well be one that we last really explored years ago. If business is slow and material prices are high (tungsten carbide, for instance, is experiencing a rapid rise in cost), efficient use of the material we are spraying is more important than ever. The less material falling to the floor and going up the stack, the better our efficiency and profitability. Parameter development is a time and material intensive exercise, and so it is one that many of us put off when spray booths are better utilized for production. But the investment in careful parameter optimization can make good use of available booth time when things are slow by ensuring that our methods are more efficient going forward. The same holds true for the development of new materials, new hardware, and new processes that we may not have had time to explore when the shop was running at capacity.

Data Analysis: Like parameter development, there are front office tasks, too, that we can back burner indefinitely when things are busy. Inside our mountains of sales and order data, however, are veins of gold to be mined in the form of efficiency information. Which work centers are more profitable and which could be phased out? Which customers and products produce the most consistent margin? Are they underutilized? Is arc wire or combustion spraying a sleeper product that, though it is seldom requested, reliably offers a better-than-average margin? Where do we lack cross training, and who should we be considering for outside classes in robot programming or SolidWorks? Who are the motorcycle mechanics, after all, the ones who have a passion for engaged, hands-on work? All of these are questions that can be answered with a scan of shop floor or order profitability records. And of course, learning to make good use of shop data by developing SQL skills or migrating from a legacy ERP system to a more flexible cloud-based solution can be easier when business is slow.

Automation: It’s a touchy subject because it literally means the replacement of human labor with machinery, but greater automation of processes is key to improving efficiency. It can also improve employees’ job engagement by reducing or eliminating tedious, repetitive, or difficult work. Automation can also be daunting to implement; if it is not done well, it can cost a good deal and provide little return. Data can provide the key to knowing what to automate and how to do it effectively. Operations that are labor intensive but with little value added tend to be good candidates. Tasks that are difficult or unpleasant but repetitive are also excellent targets. Many of us already use robotics in spray cells to address the latter, but robotics are not the only tools for automation. Scheduling a report to run before the start of a shift that lists the materials and quantities for the stock room to allocate for the day’s production is also a form of automation, moving the workload from a high demand time of day to a lower demand time. Again, identifying the jobs that might best benefit from greater use of automation can often be as simple as looking at labor as a percentage of job cost and sorting from highest to lowest.

5S: Sort, set in order, shine, standardize, and sustain. Yes, I said it, it’s time to clean up and paint the shop. I admit it, my building is full of equipment, parts, supplies, tooling and all kinds of other things that I’ve held onto because I believed that someday they would come in handy. Most of it has done nothing more than occupy floorspace and collect dust… for decades. The Japanese practice of clearing out the unnecessary and perfecting what remains pays dividends in workplace morale and job efficiency, but it can also feel like the adult version of being told to clean our room. There is certainly little time or patience for an exercise like this in most shops when production is humming, but downtime can be a prime opportunity to get needed organization, maintenance, and painting done, putting available labor to effective use. Returning to the concept of efficiency once more, it is also true that shop floor space should be efficient as well; space costs, and, if square footage can be better employed to generate revenue, it should be.

Thermal Spray's Role in Upcoming Infrastructure Repair

We’ve covered some of the items that can be handled relatively quickly and using the time and resources that a slowdown has made available. In the language of the book, we have gotten our motorcycle running smoothly, have packed efficiently for the trip, and have a sure route planned. Now, we look outward for the longer-term goals that this change in the business environment will bring; it’s time to get on the road, look outward, and enjoy the scenery.

The same principles that have moved aviation, automotive, and energy to change are also pushing a parallel initiative to make our existing infrastructure more efficient and durable. Congress has acted and is acting to allocate quite literally trillions of dollars toward rebuilding roads, bridges, and railways. If you’re like me, you can’t help but picture all of this work involving heavy equipment, steel manufacturing, and excavation… all of which depend upon the protection offered by thermal spray coatings . Globally, the mining and construction machinery market is expected to see 21.5% growth in 2021, as economies restart and manufacturing attempts to make up for supply chain shortfalls brought on by the pandemic and related shipping issues [5]. The American Jobs Plan, its allied programs in the states, and similar efforts to refresh and renew United States infrastructure represent a massive amount of allocated spending that will directly impact utilities and manufacturing across the country. This should translate into real economic activity for US manufacturers in the heavy equipment and construction materials markets and their suppliers in the coming years. For us, this potentially means activity in carbide and other wear control surfacing, hard chrome replacement, and corrosion control coatings for steel structures.

A Boost in Domestic Manufacturing

The pandemic and its effects have also highlighted the problems of depending upon global suppliers to meet domestic needs. The term “re-shoring” and its synonyms that have been heard throughout the past 20 years or more have taken on new meaning as supply chain issues choked a good portion of the country’s purchases over the last 18 months. While the realities of manufacturing consumer goods at the kinds of prices consumers are willing to pay may mean that we never fully separate from overseas production, certain items like semiconductors and steel have seen increased interest in domestic production. Steel manufacturing is up 21.6% over the same time last year, and will likely remain strong as infrastructure improvement efforts increase the demand. Likewise, government and industry participants have agreed that US manufacturing cannot be hobbled again by a shortage of semiconductors. The drive to increase domestic chip manufacturing is seen as both economically strategic and a matter of national security. Both steelmaking and chip manufacturing rely upon critical process components coated by thermal spraying, and so the rapid increase in production in both sectors is likely to lead to increased demand for coating services and materials ranging from nickel chrome boron to yttria to copper.

Conclusion

These are just a few examples of opportunities that our current business climate has enabled, a few of the wide-open spaces I tended to ignore as I focused on what I perceived to be approaching dead ends. Pirsig makes no claims that his perspectives are inherently right and others are wrong. I, too, make no claim that my view on the thermal spray marketplace is correct. My intent is to share my perspective, and in doing so hopefully to illuminate some of the challenges we’ve faced and how we got past them. Hindsight is 20-20, of course, and much of this information might have been more helpful nine or twelve months ago as the ratchet strap of a tightening economy really began to squeeze. I hope, though, that the broader value of a change in perspective might help us to better weather the next storm that comes our way. To be able to step back when things seem dire and realize that the universe of opportunity is much larger than I might have imagined is a skill that will take time to develop. The truth of our industry is that we are a relatively small and talented community of technicians, engineers, and businesspeople who have the ability to restore the machinery that makes modern life possible and make those machines run longer and more efficiently. With that appreciation, it is perhaps harder to feel pessimistic about the future of our business.

Daniel C. Hayden, president of Hayden Corp., West Springfield, Massachusetts.

References

Weston, G., Schulte, A., Venkataraman, K., and Kurganov, Y. 2021. Air Travel Forecast: When Will Airlines Recover from Covid-19? Retrieved on November 9, 2021, from bain.com/insights/air-travelforecast-when-will-airlines-recover-from-covid-19-interactive.
Boon, T. 2021. Qatar Airways Confirms Impairment On All 10 Airbus A380s. Retrieved on November 9, 2021, from simpleflying.com/qatar-airways-a380-impairment.
Fitch Ratings. 2020. US Auto Industry Outlook Improving in 2021 but Secular Risks Remain. Retrieved on November 9, 2021, from fitchratings.com/research/corporate-finance/us-auto-industry-outlookimproving-in-2021-secular-risks-remain-02-12-2020.
United States Department of Energy. Solar Energy in the United States. Retrieved on November 9, 2021, from energy.gov/eere/solar/ solar-energy-united-states.
Association of Equipment Manufacturers. 2021. Construction Equipment Economic Outlook: Stability Is on the Horizon. Retrieved November 9, 2021, from aem.org/news/construction-equipment-economic-outlook-stability-is-on-the-horizon

Permission

Article running with permission from the American Welding Society and the International Thermal Spray Association .

5 Thermal Spray Coating Processes You Need to Know About

Thu, 24 Mar 2022 20:18:16 GMT

Thermal Spray Coatings are a great way to protect metal surfaces and to increase the performance of precision machinery. Thermal spraying is used for a variety of industries including aerospace, military, automotive, mining, and more. Thermal spray coatings are applied through a variety of processes, each with its own advantages and benefits. In this article, we will discuss the five most common types of thermal spray processes and what you should know about each of them.

HVOF (High-Velocity Oxy-Fuel)

The first type of thermal spray coating is HVOF . HVOF, or high-velocity oxygen fuel, is a process that uses a specially designed torch to accelerate the coating material to a very high speed. The heated material is then shot from the torch and sprayed onto the substrate. Benefits of the HVOF thermal spray coating process include high deposition rates, excellent adhesion to the substrate, and very low porosity.

Flame Spray

Flame spray coatings use a flame to heat the coating material. Materials sprayed using this thermal spray method typically have a low melting point. The molten material is then expelled from the gun and sprayed onto the substrate. This process is often used to apply traction coatings or corrosion protection. It also requires fewer utilities and is easily set up for use in remote locations.

Arc Wire Spray

Arc spray is a thermal spray process that uses an electric arc to melt and spray the coating material. In a twin-wire system, this arc is struck at the merging tips of two oppositely charged wires made of the material to be sprayed. At the intersection of these wires is a jet of compressed air. As the heat from the arc melts the wire, the jet blows molten droplets forward onto the part. Common applications for arc wire spray coatings include: repairing small areas on castings and fabricating new parts, roll resurfacing, exposed outdoor structure protection and more. Due to the wire feedstock, arc wire coatings can be deposited more quickly than other coatings and are especially useful when covering large areas.

Plasma Spray

The plasma spray coating process is the most common type of thermal spray coating. In this process, a gas is heated to tens of thousands of degrees by electric current and then passed through a narrow nozzle. The hot gas is then used to melt the coating material. The molten material is then ejected from the nozzle and sprayed onto the substrate. Plasma spray coatings are typically used to protect metal surfaces from corrosion and wear. The very high temperature of the plasma arc permits the spraying of high melting point materials such as ceramics, molybdenum, and tungsten. Because of their high melting point, thermal barrier coatings are applied using plasma spraying.

Spray and Fuse

The spray and fuse thermal spray coating method is a hybrid of thermal spraying and brazing. In this process, the coating material is applied by a conventional thermal spray process such as plasma or flame spraying. The coating material is then heated to its melting point either by a torch or furnace so that the coating particles flow together and wet into the substrate surface. Fused coatings are tougher and more durable than conventional thermal spray coatings and are typically non-porous. In many cases, the newer laser cladding process can provide a superior surface with less heat input to the substrate.

Identify The Right Process for the Coating You Need

Each of these thermal spray processes has its own benefits and applications . Hayden Corporation can help you identify the right thermal spray coating process for the coating you need. With our years of experience and wide range of coating materials, we can help you find the best way to protect your metal surfaces. Contact us today to learn more about our thermal spray coatings services.

Traction Coatings

Mon, 05 Oct 2020 08:55:07 GMT

Traction Coatings

Hayden Corporation’s plasma sprayed HC 1071 anti-skid coatings provide enhanced traction and longer life for traction components through improved wear resistance and bond strength over conventionally applied “P-Gun” traction coatings.
Series HC 1071 anti-skid coatings have successfully served the pulp and paper and textile industries for more than a decade.
These coatings are also available with release agents to minimize the problem of product embedment in the coating’s textured surface.
Series HC 1071 coatings reduce machine noise and improve productivity and product quality.
Customized textures and traction characteristics are available.
For specific application recommendations and information, call the coating experts at Hayden Corporation.

Traction Coating benefits include, but are not limited to the following:

Extended Service Life
Reduced Downtime
Increased Productivity
Application in Shop or Field
Customized Surface Textures
Increased Coating Integrity

Applications:

Paper Machine winder Drums
Rewind Rolls
Printing Rolls
Gripper Rolls
Textile Rolls
Gripper Jaws
Rails

Learn more about traction spray coatings by Hayden Corp.

Carb-O-Knife

Mon, 05 Oct 2020 08:47:27 GMT

Carb-O-Knife

Coatings for the Plastics Industry and Recycling Equipment

Better, More Dense Coating
Lower Manufacturing Cost
Longer Operating Life
Faster Turnaround

Finally, there’s a better, denser carbide coating that reduces manufacturing costs and extends the operating life of granulator and dicer equipment!

As the plastics and recycling equipment industries increase their use of time and cost-saving coatings on machine components, Hayden’s “Carb-O-Knife” Coating leads the way. With “Carb-O-Knife”, the operating life for all types of knives is increased, and more pounds per hour of product can be produced. And because the operating life between knife changes has been extended, production time between changeovers is increased and maintenance costs are reduced.

Hayden's "Carb-O-Knife" Coating, hypersonically applied, is excellent for:

Dicing Knives
Pelletizing Knives
Bed Knives
Perforating Knives
Granulator Knives
Wherever Longevity Is Required

Carbide Coating Services

Mon, 05 Oct 2020 08:42:56 GMT

Hayden Corporation's Expertly Applied Carbide Coatings Provide:

Superior Performance in Abrasive Wear Applications
Excellent Corrosion-Resistance Characteristics
Highest Hardness Values: (typically . Rc70)
Wide-Ranging Material Selection

Hayden Corporation’s Multi-System Carbide Coating Service Capability Provides Customer Choice of HVOF or Plasma Spray

Learn more about HOVF

Learn more about plasma spray coating

Ceramic and Thermal Barrier Coatings

Mon, 05 Oct 2020 08:34:21 GMT

Hayden Corporation's Expertly Applied Ceramic and Thermal Barrier Coatings Provide:

Superior Abrasive Wear Resistance
High Lubricity, Low Friction
Insulating and Thermal Barrier Qualities
Excellent Transfer of Low-Viscosity Liquids
High Hardness Values (Typical Values Rn15 < 75)

Ceramic and Thermal Barrier Coatings Applications:

Wire Metering Wheels
Piston Heads & Cylinders
Pump Seal Rings
Wire Capstans, Sheaves, Pulleys
Hydraulic Valves, Butterfly Valves
Exhaust Fans, Propellers
Cam Followers
Rocker Arms
Sleeves, Spacers, Shafts

Learn more about our Thermal Barrier Coatings .

HVOF 6805

Sat, 03 Oct 2020 04:58:06 GMT

50% Tungsten Carbide,
50% Nickel-Chromium-Silicon-Boron:
A Self-Fluxing Mechanical Alloyed Powder

Description:

HVOF 6805 is a tungsten carbide self-fluxing nickel-chromium-silicon-boron mechanical alloyed composite powder. Coatings produced by the HVOF process are very dense, well bonded, and smooth. Due to the high integrity of the overlay, the coating may be left as sprayed or can be traditionally fused (heat treated) to improve coating properties. Fusion of the coating results in very low coating shrinkage, minimal part distortion, high impact resistance, metallurgical bonding and exceptionally smooth, even coating thickness, when properly applied. Often, parts can be coated to near-finish requirements, unlike common spray and fuse composites of similar chemistry. The powder has very fine grains (1-7 micron), which also have been observed to produce higher wear resistance over traditional spray and fuse composites in many applications. The matrix composition is similar to Deloro™ 50, which has a hardness value of approximately 50 Rc.

C lick Image to enlarge:

COATING CHARACTERISTICS

Thickness Limitations, Unknown

Estimated Hardness Range:

As Sprayed 52-55 Rc

Fused 62-65 Rc

Learn more about HVOF Coating .

HVOF Bond Strength

Sat, 03 Oct 2020 04:52:40 GMT

All coatings were prepared using standard Set A parameters, test method per ASTM C633 on 1020 carbon steel substrates with grit-blasted surface preparation.

Click Image to enlarge:

*In these samples, the failure was in the epoxy. Therefore, the actual bond strength of these coatings is greater than the figures shown, but, it is impossible to determine by how much.

Bond data for JK™ 114 powder was also developed on a substrate of 4340 steel hardened to Rc55-60. Some applications for the JET KOTE™ II System are under development that would be applied to hardened substrates (i.e., cutting knives and blades found in various industries such as paper and plastics). The results show bond strength as good as on a 1020 carbon steel substrate.

The coating was prepared with standard Set A parameters.

Learn more about HVOF coating .

HVOF Wear

Sat, 03 Oct 2020 04:42:33 GMT

Sample coatings were applied to bars of 4140 steel as follows:

Nitrided-to approximately .007 - .010 inch depth
Chrome plated - .002 - .003 - inch depth
Plasma spray - tungesten carbide powder
JK 558, Tribaloy T-800
JK 591, Nistelle C

The cross-cylinder test uses a 1/2-inch diameter 6 percent cobalt tungsten carbide cutter blank rotating at 1,760RPM with a 15lb. load and a nitrogen wipe for a one-hour period. This test was performed by an independent laboratory.

RESULTS:

Click Image to enlarge:

Learn more about HVOF Coating

HVOF Corrosion

Sat, 03 Oct 2020 04:34:20 GMT

This test was performed by an independent laboratory.

The sample coatings were applied to bars of 4140 steel as follows:

Nitrided to approximately .007 - .010-inch depth
Chrome plated, .002- .003 - inch thick
Plasma spray, tungsten carbide/cobalt powder
JK 558 TRIBALO ™® T-800
JK 591 NISTELLE ™® C
JK 112, tungsten carbide/cobalt powder

The lower third of the surfaces were immersed in acid concentrates at elevated temperatures. Corrosion was measured by weight loss. The acids and conditions were as follows:

Click Image to Enlarge

Data courtesy TAFA, Inc., Concord, NH.

The Federal Communications Commission specifies that most devices must remain passively susceptible to impingent interference.* Minimize risk and reduce compromising emissions with conductive surfaces from Hayden Corporation.

*See FCC 79-555/14686

Learn more about HVOF coating .

Calendar Rolls

Sat, 03 Oct 2020 04:23:55 GMT

Extended Life for Traditional Calendar Rolls

Capital Expansion with Ongoing Payback

Situation:

Abrasives eat away at calendar rolls causing roughness, uneven pressure, and wear on the overall surface. Scratches occur from slippage and doctor blade usage. Calipering diminishes and uniformity of thickness deteriorates. And when paper width changes, deckel edge wear results in inferior product and costly waste.

This pair of Calendar Rolls regains a “like-new” look after carbide coating and finishing.

Traditional Solution:

The rolls are pulled from operation and sent out for regrinding. Time is lost, productivity is reduced, and the ultimate result is only a temporary solution: each time the rolls are ground, the original depth of the hardened material is reduced, ultimately requiring the purchase of new rolls.

The Hayden Solution:

W hether for new rolls or those that have retained up to 50 percent of their original chilled iron, Hayden has the solution that can maximize roll life by two or three times, or even more!

Using a coating of extra-hard tungsten carbide, a Vickers Hardness of 1100-1200 is obtained, significantly reducing or retarding wear on the roll surface. The rolls are then ground and superfinished, assuring maximum performance and consistent PLI, even for changeable, controlled-contour rolls. When Hayden grinds the rolls, we grind the applied coating only, and not the chilled iron.

Case Study:

A paper manufacturer pulled their rolls and sent them out for regrinding on an average of once a month. Rolls lost their chilled iron rapidly, and maintenance costs and paper scrapping rates were high. Additionally, production was greatly affected because of the length of time it took to change the rolls each month; then came the Hayden Solution.

We initially took in a roll and coated and superfinished it. Upon reinstallation, the results were outstanding: the roll performed with maximum effectiveness for six months!

Pleased with the results, the firm then had us recoat and superfinish their “spare pair.” It has now been more than a year since the spare pair have been up and running … and they’re still going strong!

Preliminary inspection of calendar roll after super-finishing maximizes quality control and helps assure the most effective results possible.

The Hayden Benefits:

Extended roll running time
Fewer shutdowns - reduced downtime
Longer production runs - increased productivity
Consistent throughput with maximized quality
Less scrappage
Lower maintenance
Labor savings - rolls are not changed as frequently
Longer overall life of rolls - no continual grinding of the chilled iron
Allows for potential increase in calendar speed
Reduces energy requirements for calendaring - less horsepower is needed because rolls run more efficiently without need for excessive nip pressure
Enables expansion through production of additional paper grades or product lines through quality improvements

Learn more about why Manufacturers and Mills in the paper and film industry turn to Hayden for wear and corrosion solutions, friction control, and added longevity of component performance. Pulp, Paper & Converting >

EMI/RFI Shielding

Sat, 03 Oct 2020 04:08:45 GMT

EMI/RFI Shielding

Keeping sensitive data in and interference out, TEMPEST-qualified EMI/RFI shielding surfaces from Hayden provide a first line of defense in data security. HC302-E and HC303-E thermal sprayed shielding surfaces provide an economical way to maintain the light weight and flexibility of your existing non-conductive enclosures while providing the electrical integrity and security of steel.

Typical Applications:

Computer and Display Housings
Active capture of emissions by grounding of the shield surface significantly reduces the likelihood of effective data piracy through the monitoring of stray emissions.
Navigational and Telemetry Equipment
Directional use of shielding surfaces can provide a barrier against ambient emissions that may detrimentally affect the accuracy of sensitive monitoring equipment.
Communications Transmission Environments
Protection of equipment and personnel in radio and television transmission facilities, microwave rebroadcast units, and similar high-ambient-RF environments.

Developed to meet the needs of government and military contractors, our coatings provide shielding performance superior to metallic paint (see table below), and with far higher bond strength and resistance to flaking. Line-of-sight spray application allows for surfaces of nearly any geometry to be protected, and high deposition rates mean fast process time, rapid turnaround and affordable pricing.

Click Image to Enlarge

Data courtesy TAFA, Inc., Concord, NH.

*See FCC 79-555/14686

Learn more about emi rfi shielding by Hayden Corp.

Laser Cladding Facts

Fri, 02 Oct 2020 21:56:01 GMT

Laser cladding offers an array of unique advantages over the conventional welding and hardfacing methods.

Laser Cladding Facts

High purity, low dilution welded overlay
Overlay chemistry and hardness are undiluted at the surface of the first pass; there is no need for multiple passes or heavy overlay thicknesses that add expense and induce unwanted tensile stress.
Very low heat input, low distortion
Fully machined parts with close tolerances can be welded with little risk of distortion or dimensional deviation. Overlays have been applied to substrates as thin as 0.060” (1.5mm) without warping or distortion.
Welded, fully alloyed bond
Unlike thermal spray, the bonding mechanism is molecular and not mechanical. External physical stresses are unlikely to cause the overlay to disbond, fracture, or spall. Overlays can withstand significant abrasion and direct impact.
Rugged, high toughness protection
Tungsten and titanium carbide composite overlays are regularly used to protect drilling and mining components. Cobalt-based alloy overlays defend against particulate erosion and cavitation in high-pressure pumps, valves, and turbines.
Impermeable corrosion barrier
Uniform, crack- and pore-free overlays prevent permeation and attack of substrate materials by even highly reactive liquids and gases. Overlays can be machined, ground, and lapped to form tight-fitting seals for valves and couplings.
Virtually unlimited metallic overlay-substrate combinations
Most overlay materials can be welded onto nearly any machinable metallic substrate, allowing high-performance alloys or special property materials to be added strategically to less-expensive free machining steels or exotic aerospace alloys.

For additional information, contact Hayden Corp. by phone (413) 734-4981 or by contacting us online. Visit our laser cladding page to learn more.

Laser Cladding for Restoration

Fri, 02 Oct 2020 21:49:06 GMT

Laser Cladding for Restoration

Low heat input and precise control of material deposition make laser cladding a perfect tool for making the old new again.

The combination of low heat input, heard-wearing materials and unbreakable metallic bonding make laser cladding an ideal tool for repairing or rebuilding surfaces that have lost their size or shape to the ravages of time. Bring your worn or damaged part to us, and we’ll bring it back to life.

A collector of antique tractors had a problem: the bearing fits on the steering worm of his 1945 John Deere Model L tractor were badly pitted and worn. While new tapered bearings and cages could be bought off the shelf, the Gemmer worm was no longer available, and the machines that made them ended up in factories in other parts of the world. The collector came to Hayden to see if we could help.

The piece was small, and the amount of material required was minimal, so we decided to take the job on. Fortunately, the gentleman had a similar piece on loan that we could use as a reference for establishing dimensions. We elected to rebuild the area with a hard-wearing steel alloy that would be tough enough to withstand the bearing action but soft enough to avoid risk of cracking.

The complex combination of the worm’s helical gear path, combined with the hourglass shape traced by the pivoting sector cam would make this piece difficult to draft, but a quick three-dimensional scan of the worm produced an accurate solid model that could be used for programming the laser cladding process. To keep heat input minimal, we chose to use a small diameter spot size, and place several thin weld beads close together, rather than apply the material quickly. Contours were programmed to build up the worn tapers by approximately 0.040″ per side, in order to allow enough material to re-establish the correct diameter by grinding, afterward.

The piece was mounted onto an arbor and placed into the rotary position of the laser system. Once the piece was loaded, the processing program could be aligned with the actual part, and a test could be run to ensure proper alignment. Since the program was created in the virtual programming suite based on an accurate three dimensional model of the part, the program fell right into line, tracing the tapers perfectly. Due to the laser’s tight control and minimal heat input, the worm never exceeded 180 degrees Fahrenheit, and the hardened gear body was never at risk of loosing its physical properties.

Once the cladding was complete, the piece moved to the grind shop, where our machinist set the 15-degree taper, cleaned the adjacent face and ground the diameters on both ends to match the sample piece we had on loan. The grind operation restored the surface finish and size required to match the bearings, and the entire assembly could be re-packed and installed to run like new.

Hayden Laser Services, LLC has performed similar repairs to restore original sector shafts for classic Pierce Arrow automobiles, and other irreplaceable components.

Visit our laser cladding page to learn more.

Thermal Spray Facts

Wed, 30 Sep 2020 20:03:40 GMT

Thermal Spray for Precision Protection

Puts high-performance materials where they're needed
Rather than engineer an entire component for wear resistance or corrosion protection, thermal spray coatings allow engineers to identify specific zones where surface attack is occurring and apply targeted protection where it is needed.

Eliminates the need for exotic and expensive forgings, billets, and bars
The ability to selectively apply high-performance materials saves designers and fabricators from machining entire components from costly exotic or heat-treatable high-performance alloys. Instead, many components can be fabricated from lower-cost materials and then thermal spray coated to ensure performance and durability.

Can be applied to nearly any metallic substrate, and many plastics
Since thermal spray coatings are not alloyed with the substrate, chemical or metallurgical interactions that make some material pairings un-weldable (such as steel and aluminum) have no effect on sprayed overlays; nearly any coating material can be applied to most metallic substrates, and to many plastics, as well.

Negligible impact on the component; part temperature remains below 250°F
Since the thermal spray process imparts very little heat to the substrate, there is virtually no risk of the component distorting or warping, as can often be the case with welded overlays. As a result, thermal spray coatings can be applied to fully finished components with very fine tolerances, and are particularly well suited to repairing parts with localized damage, such as a spun bearing.

Wide selection of ceramics, pure metals, alloys, and composites
The thermal spray process allows for the application of a broad array of materials, from metallics to ceramics. Materials can be applied alone or in combination, and materials can be layered to provide a combination of performance characteristics.

Broad range of wear - and corrosion-resistant materials
The variety of materials available for application by thermal spray means that there is likely to be a thermal spray solution for most industrial wear or corrosion challenges. From fly ash erosion to chlorine pump seals, high-temperature galling to molten zinc handling, there is a thermal sprayed coating solution for nearly every challenge.

Thermal barriers for extremely high heat applications
Thermal barrier coatings are a class of thermal sprayed ceramic coatings that are particularly effective at protecting metallic components from the very high temperatures of hydrocarbon combustion. These coatings are used extensively within aerospace and land-based gas turbines, and have also found their way into high-performance auto racing.

Spray formable electrical insulators and conductors
Low-resistance conductors, such as copper, zinc, and tungsten, can be sprayed onto component surfaces, as can strong insulators like aluminum oxide. As a result, thermal spray provides a fast and effective means for applying customized conductive or resistive traces onto antennas, photovoltaic cells, equipment housings, and other similar items.

EMI/RFI shielding
Thermal sprayed zinc, aluminum, tin, and molybdenum are regularly used to effectively block electromagnetic interference and radio frequency radiation from affecting sensitive electronic equipment. Their low-temperature application allows coatings to be applied directly to plastic and composite housings, so intrinsically safe equipment can also be made lightweight and portable. Learn more about EMI RFI Shielding .

Learn more about the advantages of Thermal Spray Coatings >

Thermal Spray Materials

Tue, 29 Sep 2020 22:51:39 GMT

Thermal Spray Material Descriptions

Materials

Alumina Titania

An abrasion-resistant moderate-hardness ceramic, aluminum oxide and titanium dioxide, also know as alumina titania is particularly well suited to applications prone to erosion by fine particles. It is also a good candidate for textile wear applications. Operating environment should be < 1,000°F.

Aluminum

Elemental aluminum exhibits good electrical conductivity and is best known for its corrosion protection characteristics. It tends to oxidize more readily than steels and can prevent corrosion of most steels by “capturing” oxygen atoms before they reach the protected surface. Polishes readily, and may be built up significantly to produce solid-like structures.

Aluminum Bronze

A high-density, moderate-hardness metallic, aluminum and copper. Non-galling, non-seizing, self-lubricating, excellent resistance to adhesive wear. Commonly used for restoration of dimension of bronze, copper, and aluminum parts, and as a bond coat.

Aluminum Graphite

A clad composite, aluminum and carbon. Malleability and abradability make it an excellent candidate for use in clearance control applications. Operating environment should typically be < 900°F.

Aluminum Oxide

A hard, typically white ceramic. Excellent dielectric and thermal resistance properties. Wear resistant and readily ground to a smooth finish. Able to withstand fairly high heat; melting point near 3,700°F.

Aluminum Polyester

A blended material, aluminum, silicon, and polyester resin. Used almost exclusively in clearance control applications for aircraft engines and similar components. Operating environment should typically be < 600°F.

Babbitt Metal

A relatively soft metallic, tin, copper, antimony, and lead. Very dense deposit, non-galling material; ideal solution for adhesive wear problems in high-speed, high-load bearings and journals.

Carbon Steel

A hard durable metallic, iron, carbon, aluminum, and molybdenum. Excellent durability and buildup characteristics make carbon steel alloys a good choice for repair and dimensional restoration of steel and other ferrous components.

Chrome Oxide

A hard, dense ceramic. Commonly used both as-sprayed and finish-ground. Highly resistant to sliding and abrasive wear, cavitation, and corrosion. Low coefficient of friction makes chrome carbide especially useful in combating adhesive wear applications in harsh and corrosive environments.

Chrome Carbide

An extremely hard metallic. Superior hardness and resistance to abrasion. Chromium carbide can exhibit some brittleness depending on the method of application. Overall, exhibits good corrosion resistance, outstanding resistance to abrasive and fretting wear and erosion, and performs well at elevated temperatures.

Chrome Oxide

Cobalt Alloys

Cobalt, alloyed variously with chromium, tungsten, carbon, molybdenum, nickel, and iron, yields exceptional hardness and durability due primarily to high chrome carbide content. Additionally, these alloys remain stable and functional through a vast temperature range, making them ideal for combating abrasive wear and fretting in high-temperature environments.

Copper

Elemental copper, like elemental aluminum, is an excellent conductor of electricity and heat; used for EMI/RFI shielding. Coatings are typically dense, making them ideal for dimensional restoration of copper-based components. Also, like aluminum, copper may be heavily built up to form solid-like structures. Used as a low-temperature mold-making alternative to casting.

Hastalloy ®

A proprietary alloy of Haynes International, Inc., Hastalloy ® exhibits excellent resistance to corrosion, and is an excellent candidate for repair or rebuild of equipment intended for use in and susceptible to highly corrosive environments.

(Hastalloy ® is a registered trademark of Haynes Industries, Inc.)

Magnesia

A high-hardness ceramic, magnesium oxide and zirconium oxide. Excellent thermal barrier characteristics, highlighted by substantial resistance to thermal shock. Non-wetting by most common metallics, such as aluminum, iron/steel, and zinc. Also well resistant to particulate erosion.

Molybdenum

Elemental molybdenum. Demonstrates good bonding characteristics and is often used as a bond coat material under both metallics and ceramics. Good wear resistance and ability to retain lubrication make molybdenum a good choice for repair/rebuild of bearing and other wear surfaces in heavy machinery.

Molybdenum Alloys

Particularly the self-fluxing alloys with nickel, chromium, or aluminum. Hard-wearing, essentially oxide-free coatings. Extremely durable and capable of significant buildup. Wear-resistance characteristics make these coatings especially adequate for protection from harsh abrasive particulate environments.

Nickel Alloys

Nickel Chromium

One of the nickel alloys (see above) particularly developed as a bond coat for high-temperature ceramic applications.

Nickel Graphite

A clad composite, nickel and carbon. Malleability and abradability make it an excellent candidate for use in clearance control applications. Operating environment should typically be < 900°F.

Self-Fluxing Alloys

Nickel or cobalt based with one or more of the following: chromium, iron, boron, silicon, tungsten carbide, copper, or molybdenum. This term covers a range of alloyed materials that have been engineered to perform best after having undergone a high-temperature fusing process. Self-fluxing alloys are applied using a standard thermal spray system, such as flame spray, and then the coating and substrate are flame- or induction-heated until the coating material begins to liquefy and flow over the surface of the part. The fusing process leaves a coating that is structurally and, at times, chemically different from the material applied.

Stainless Steels

Corrosion-resistant steel (iron, carbon) with manganese, chromium, silicon, and one or more of the following: nickel, molybdenum, zirconium, selenium, and others. Grades of stainless steel offer varying degrees of corrosion resistance and malleability. Stainless steels offer excellent machinability and corrosion resistance with good or better wear resistance.

Tungsten Carbide

A very hard metallic with superior wear resistance. Ideal for long-wearing surfaces and edges. Tungsten carbide coating materials may be ground and superfinished to provide an extremely hard mirror-like finish, although carbide coatings are also frequently used as-sprayed for a durable abrasive or wear-resistant protective surface.

Yttria Zirconia

A durable thermal barrier. Yttria zirconia produces a hard, abrasion-resistant surface with excellent thermal stability and thermal shock resistance. High specific heat capacity (SHC) provides a very low rate of heat transfer, even at extreme temperatures, making yttria zirconia ideal for protecting heat-sensitive surfaces and componenture in high-heat environments.

Zinc

Elemental zinc, like aluminum and copper, provides good electrical conductivity. Can be used in EMI/RF shielding applications. Provides galvanic and sacrificial corrosion resistance similar to aluminum. May be spray-deposited to significant thicknesses allowing for the formation of freestanding solid-like structures.

Al-O-Lox™, Com-O-Lox™, Crom-O-Lox™, Met-O-Lox™:

HAYDEN’s trademarked line of high-performance surfaces. Developed to meet the wear and corrosion challenges that we encounter most frequently, these coatings are field-proven to provide outstanding performance in a variety of applications. As with any of the materials listed here, specific material data, such as typical hardness, methods of application, and corrosion performance, are available from our applications engineers and salespeople. E-mail or call us at your convenience.

Questions? We're here to help!

Contact Hayden Corporation (413) 734-4981 or Contact Us Online

Hayden Corp. Celebrates 100 Years

Tue, 08 Sep 2020 19:48:36 GMT

Hayden Corporation is Celebrating a Century in Business

West Springfield, Mass. — Hayden Corporation is celebrating a century in business, having

adapted and thrived across four generations of family ownership through a commitment to continuous innovation and market responsiveness. Today , the company is an ISO 9002-2008-registered provider of specialized thermal spray and laser cladding services to manufacturers and end users in industries where working machinery components are exposed to harsh environmental conditions, including: aviation ; energy and power generation ; fluid control and processing ; mining ; oil and gas ; military equipment ; pumps, centrifuges and valves; plastics ; pulp and paper ; agriculture; automotive;

and more. The company’s applied expertise in wear and corrosion control surfaces helps to protect and prolong lifespan of machine components impacted by abrasion, adhesion, corrosion, heat, and other wear problems.

“We’re proud to have such a rich history, ingrained in the broader American manufacturing story of our region and the town of West Springfield,” said Hayden Corp. President Daniel C. Hayden, the company’s fourth-generation leader. “And this is a special time for our company; you only hit 100 years once.”

Hayden Wire Works opened its doors in 1919 under the entrepreneurial vision of Charles E. Hayden, servicing New England’s many paper mills. The first-generation owner and his team developed a high-quality wire cloth and fulfilled the unmet paper industry need for more comprehensive maintenance and support of paper mill machinery.

Charles’ son, Charles Wesley “Wes” Hayden, carried the company beyond wire cloth and into the fabrication business, where it continues today, in its second generation of ownership. By the 1960s, the Hayden team was composed mostly of field servicemen and in-house machinists, thermal spray processes were developed and business quickly expanded beyond paper production into other industries.

Under the leadership of John Hayden, grandson of Charles E. Hayden, the company grew at an unprecedented rate as it pursued new industries and applications for its thermal spray process.

In 2008, under the leadership of current president Daniel Hayden, Hayden Corp. added laser cladding to its core competencies, a substantial investment in technology for protection of machine components exposed to the harshest environments in the world.

Today, the company is an active thought leader in its field and continues to expand its thermal spray, laser cladding and field services to new industries, applications and customer partners across North America.

“Our company’s core competencies have evolved and expanded quite a bit over time, but the fundamental factors driving that change remain true,” added Hayden. “We expand our expertise in response to the needs expressed by our customers and the unmet needs we see in the marketplace. Doing that work has always required that we have a highly-skilled and hardworking staff. It’s those talented people that have carried us through our century of existence, and will carry us into the next.”

Back to home

Hayden Corp. is Your FAA Certified Aviation Repair Station

Tue, 08 Sep 2020 19:14:28 GMT

Hayden Corp. is your FAA certified aviation repair station.

We’ll restore your aerospace turbines and parts for safety and efficiency.

We are happy to announce that our laser cladding processes are now included in the FAA program!

We also provide the following aviation thermal spray services:

AMS2437 ( plasma spray )

Cost-effective method for substantial application

AMS2447 ( HVOF Coating )

For high-performance density, hardness and bond strength

View our quality certifications here .

AS9100 Certification

FAA Repair Station Certification

Identifying and Solving Wear and Corrosion Issues

Tue, 08 Sep 2020 16:47:10 GMT

Abrasive Wear:

Abrasive wear is the result of a hard particle or protuberance displacing material as it moves along and against a surface. Abrasion includes cutting or gouging of a surface and often results in loss of material rather than transfer or distortion of material. Grinding, grit blasting, tooling, and polishing are all common examples of abrasion, and patterns of abrasive wear exhibit similar features. Journals, rolls, rotary knives, and pumps are all frequently subjected to abrasive wear. Hayden typically suggests replacing the lost material with a harder material that is less likely to be displaced or ground out by the abrasive . Tungsten carbide, chromium carbide, chromium oxide, aluminum oxide, and some others have the inherent hardness to withstand the abuse of most abrasive environments.

Adhesive Wear:

Adhesive wear is characterized by the transfer or mutual loss of material between two parts sliding or rubbing together under significant force. Specifically, adhesive wear does not involve abrasion, only sliding friction. Some common examples of items prone to adhesive wear include bearings, arbors, shafts, and sleeves. Combating adhesive wear requires reducing the force of friction between the mating components. Hayden typically recommends rebuilding the worn area with a malleable, mechanically “slippery” material, such as aluminum bronze, molybdenum, or alumina titania.

Atmospheric and Salt Water Corrosion:

Corrosion results from the chemical conversion of metals to metal oxides, which often happens naturally over time. An accelerator of corrosive oxidization is an electrolytic liquid, such as salt water or acid rain. Both can quickly deteriorate exposed corrodible materials. The need for protection from these elements lead to the development of a unique coating application, sacrificial corrosion protection. In this process, a readily oxidized material, typically aluminum or zinc, is applied to the surface to be protected. The coating will indeed deteriorate over time, but in doing so it will capture oxygen atoms before they can reach the substrate material. Essentially, the coating “sacrifices” itself to protect the underlying material. Furthermore, a few thousandth of an inch of the coating can continue to effectively protect a surface for several years of continuous exposure to corrosive elements. As an added benefit, the “capturing” behavior of these coatings is capable of reducing or preventing corrosion of adjacent non-coated surfaces. This is especially useful in situations where the line-of-sight thermal spray process is not able to coat every possible crevice or hidden surface.

Clearance Control:

Another application of self-sacrificing coatings is for the establishment of extremely tight tolerances in moving machine parts. More commonly used in aircraft and land-based gas turbine engines and similar environments requiring tight mechanical tolerances, an abradable coating can be applied to one of two surfaces which, by their design, must move with a minimum of clearance between them. The other mating surface is then coated with a wear-resistant carbide coating. This coating can enhance reliable rotary shaft seals eliminating material loss and reducing power consumption. As these parts operate, the friction between the coated surfaces will cause the abradable material to wear. The coating will only wear enough, however, to accommodate the movement of these components. The result is a precision fit between the two surfaces, generous enough to allow free movement but small enough to prevent most materials from passing through. Hayden recommends aluminum graphite, aluminum polyester, and nickel graphite for this application.

Corrosion Resistance:

The corrosive nature of papermaking and similar processes often leads to premature deterioration of machine components from pumps and valves to digesters, rolls, and housings. Hayden offers a range of materials for thermal spray and weld applications that are highly resistant to typical corrosive effects. Materials such as chrome oxide, Hastalloy® and the stainless steels perform well on their own while other materials can be encapsulated and sealed with flame sprayed materials.

Electrical Conductivity:

Thermal sprayed metallics can provide electrical conductivity over most continuous surfaces. A frequent use of this property is to provide uniform EMI and RFI shielding throughout the interior of electronic equipment enclosures. Thermal sprayed copper can be applied to almost any common enclosure material, including plastics and resins.

Electrical Resistivity:

Electrically resistive materials like aluminum oxide can be applied to form a continuous resistive layer over a given surface. A resistive layer sandwiched between a conducting substrate and a conductive metallic coating can be used to create a large-surface resistor with fairly uniform current distribution. This arrangement has been successfully used to create heated drums and rollers designed to replace quartz-lamp-heated rollers used in copiers and printers. The solid, stable nature of a ceramic resistive layer has the added benefit of being free from the problem of lamp burnout.

High-Temperature Fretting:

Abrasion and erosion in extremely high temperature environments poses a unique challenge, as most abrasive wear solutions cannot readily withstand extreme temperature variations, and most thermal barrier coatings are less than ideal in abrasive or fretting wear applications. With the widespread demand for fretting protection inside combustion regions of turbine engines, where components must be both tightly secured and easily replaced, exotic cobalt-based alloys with chrome carbide, tungsten, and other metals have found extensive use. These materials provide exceptional hardness, while readily adapting to the thermal and dimensional changes within this extreme environment.

High-Temperature Oxidization:

Metals exposed to high heat in air or another oxygen-rich environment will typically begin to corrode, even when completely dry. Heat sponsors the combination of oxygen atoms with metallic ions to form oxides, or non-metallic scale. Higher heat typically results in greater acceleration of the corrosive process. One common example of high-temperature oxidization is the accelerated rust scale that forms on steel exhaust piping and mufflers in automobiles. Although it is difficult to prevent this reaction, the process can be slowed by applying a protective barrier or sacrificial coating over exposed surfaces. These coatings slow the combination of oxygen atoms with the metal beneath, and can effectively put a halt on corrosion. Aluminum and some of its alloys, and nickel chromium are excellent high-temperature corrosion control coatings for steel.

Restoration of Dimension:

Perhaps one of the most common repair uses of thermal sprayed coatings and hardface weld overlays is to rebuild material lost through one of the deteriorative processes listed here. Parts may be rebuilt with materials matched to their original construction, or the coating can be used to simultaneously address both dimensional and wear-performance needs. Roll resurfacing, including hard chrome replacement, is one common application that can be used to significantly extend the life of a costly machine component. In fact, the coating will often outperform the component’s original surface because it was tailored to the specific environment in which it was to be used.

Thermal Barriers:

Thermal barrier coatings provide an insulative and heat-dispersing layer between temperature-sensitive components and their high-temperature working environments. This application typically requires more than one layer of coating: A metallic layer distributes heat energy from a point source across a greater surface area, and a ceramic layer, with a high specific heat capacity, provides thermal insulation for the component by slowing the transfer of heat energy to its surface. Thermal barriers excel in environments such as engines and turbines where their purpose is to protect exposed surfaces from the extreme temperatures of combustion. Zirconia alloys such as magnesia and yttria-zirconia perform very well in these environments.

Traction Coatings:

Left unfinished, thermal sprayed coatings typically exhibit a somewhat rough surface profile. Roughness is determined by several factors, including the depth of the grit-blasted anchor profile, the method of application used, and type and size of the material sprayed. Although it is common to grind or polish a component after coating, as-sprayed surfaces, particularly those with some distribution of larger, sharper particles, can be an effective alternative to machine knurling for creating a high-profile traction surface. Learn more about traction coatings >

About Hayden Corp.

Hayden Corp. is the Northeast's only full-service supplier of thermal spray coating , hardface welding, and machining. Your application is tough - and your market is even tougher. Our solutions-based expert team of craftsmen and technicians know the best solutions that affect your parts. Contact us for more information and to receive a free estimate.