Академический Документы
Профессиональный Документы
Культура Документы
TM
Aluminum-Bronze Powder
Summary: Metco 445 is a Copper-Aluminum composite powder which was especially developed to
produce self-bonding, good wear resistance, Aluminum-Bronze type coatings for soft-bearing
applications. This material offers two major advantages: One-Step spraying and High Integrity coatings.
Less undercutting required. The allowance for bond coat thickness is eliminated.
Less technique dependence. Reducing the number of steps required to produce the coating also
reduces the chance of error.
More convenience. One-step coatings eliminate having to change materials and spraying parameters.
Metco 445 was designed to produce coatings which have high abrasive wear resistance as compared
to existing Metco aluminum-bronze materials. Coatings of Metco 445 will resist abrasive wear from
hard surfaces at low temperatures. They are recommended for salvage and buildup applications on
copper alloy substrates. They make excellent soft-bearing surfaces.
Features
Metco 445 can be sprayed with minimum dependence on technique. Coatings of unlimited thick-
ness can be applied. The properties of the coatings produced with Metco 445 provide a number of
additional benefits.
Good Bond Strength- Coating tensile bond strengths of 3,000 psi (2070 N/cm2) with ThermoSpray,
and 3,000 psi (2070 N/cm2) with Plasma, are typical.
Good Wear Resistance- Resistance to abrasive wear is 2-3 times better than coatings of Metco 51 or
combustion-sprayed Sprabronze AA.
Low Shrink- Coatings of unlimited thickness can be applied without cracking, which makes Metco
445 ideally suitable for machine-element applications.
Good Finishing Capability- Coatings of Metco 445 can be easily machined to finishes ranging from
good to excellent.
Metco 445 can be sprayed with either the Metco Type 5P or 6P ThermoSpray Guns, and with the
Metco Plasma Flame Spray System. Metco 445 is not recommended for use with a Metco Type N
Gun because of the amount of smoke generated.
Coating Selection
Coating T445-10 can be produced with either a Type 5P, 5PT Extension or 6P Gun. Coating P445-10
can be produced with either a 3M or 7M Plasma System.
P445-10 Coatings are slightly more dense than T445-10 Coatings, and will exhibit wear resistance
and corrosion resistance properties equal or better than T445-10 Coatings.
Powder Characteristics
T445-10 P445-10
Texture, as sprayed,
microinches aa (microns): 450-650 (11-17) 500-800 (12.7-20)
Finish, machined
microinches aa (microns): 35-45 (.9-1.1) 35-50 (.9-1.3)
Macrohardness: Rb50 Rb50
Density (g/cc): 6.7 6.7
Porosity (Volume %): less than 3% less than 3%
Bond Strength
Metco 445 is similar to Metco 450 in that the self-bonding property is a direct result of the exothermic
reaction which takes place between the copper and aluminum constituents. The heat generated by
this reaction not only assures consistent bonding, but also causes better interparticle bonding which
results in greater coating integrity.
On ground substrates of low carbon steel and free-cutting brass and bronze, bond tests conducted in
accordance with ASTM C 633 indicate that self-bonding tensile strengths, in excess of 2,000 psi
(1380 N/cm2), are typical for coatings applied with ThermoSpray; and self-bonding tensile strengths,
in excess of 3,000 psi (2070 N/cm2), are typical of plasma sprayed coatings.
Metco 445 is not self-bonding to materials where Metco 405 or Metco 450 are not self-bonding, such
as pure copper substrates.
Thickness Limitation
There is no thickness limitation. Heavy buildup of Metco 445 coatings can be applied without cracking.
Similar to other copper base alloys, exposing Metco 445 coatings to temperatures in excess of 230 C
(450 F) in service can result in excessive oxide formation, which will adversely affect the internal
strength of the coating.
Standard laboratory slurry abrasive wear tests showed that Metco 445 coatings exhibit 2-3 times
better abrasive wear resistance than either Metco 51 coatings or combustion-sprayed Sprabronze AA
1
coatings. Also, Metco 445 coatings exhibit 1-1 /2 times better abrasive wear resistance than arc-
sprayed Sprabronze AA.
The improved wear resistance is the result of a higher oxide content, and the presence of hard copper-
aluminide particles in the coating.
Corrosion Resistance
Metco 445 coatings are not recommended for general use in applications where corrosion resistance
equal to that of an aluminum-bronze alloy coating, is of primary importance. The presence of some free
(unreacted) aluminum in the coating could cause internal corrosion in some atmospheres.
Metco 445 coatings readily oxidize. If coated parts are to be stored for any period of time, prior to use,
it is recommended that they be coated with a film of mineral oil, compatible with aluminum and copper.
Surface Preparation
Coatings of Metco 445 are self-bonding. When they are used for the presently recommended coating
functions, thorough cleaning of the substrate is the only preparation necessary. Surface oxidation must
be removed, and preheating to prevent the formation of condensate is required.
Metco 445 coatings have been successfully machined to a feather-edge. However, for such applications,
it is recommended that the substrate be roughened by at least grit blasting.
Spraying
To produce Metco 445 coatings with their outstanding characteristics, the recommended spraying
parameters must be followed.
Both the spray rate and the spray distance are critical variables in the proper spraying of Metco 445.
Excessively fast spray rates or spray distances less than the recommended values will inhibit the
exothermic reaction needed to produce the excellent bond and internal strength typical of Metco 445
coatings.
Metco 445 coatings can be machined to excellent finishes using standard carbide tools. Good
machined finishes were obtained over a wide range of work speeds.
Good results on both large and small diameter shafts were obtained by dry machining under the
following conditions:
Safety Measures
Flame spraying is a completely safe process when performed in accordance with Metcos Safety
Measures. Familiarize yourself with local safety regulations before starting operations. Do Not
operate your spraying equipment or use the spray material supplied before you have thoroughly
read the Metco Instruction Manual.
SET #1 SET #2
Spray Gun:
Type: 5P with 5PT 5P 6P
Nozzle: P7-F P7-B P7A-M
Siphon Plug: Standard Standard 6P 205
Air Cap: Standard Standard 6P 3
Metering Valve: 15 15 N/A
Vibrator: Yes Yes N/A
Gas:
Pressure - Oxygen, psi: 30 30 40
bars: 2.1 2.1 2.8
Acetylene, psi: 15 15 15
bars: 1.0 1.0 1.0
Flow - Oxygen: (Note1) 30 33 45
Acetylene: (Note 1) 36 33 55
Powder Feed:
Flow Control Valve -
clicks open: (Note 3) 6-10 6-10 N/A
Unit: N/A N/A 3MP
Meter Wheel: N/A N/A S
RPM: (Note3) N/A N/A 12
Nitrogen Carrier Gas -
Pressure, psi: N/A N/A 55
bars: N/A N/A 3.8
Flow: N/A N/A 37
Notes:
1. Type 2GF Flowmeter. When using Type GF Flowmeter, reduce pressure for oxygen 10 psi (.69 bars)
and also reduce pressure for acetylene 2-4 psi (.14-.28 bars) to obtain flowmeter readings shown.
2. Orient Air Cap with cool side out.
3. Use as a starting point. Powder flow rate is critical. Adjust as necessary to obtain rate shown.
4. Some deposit may form on the face of the nozzle when spraying for extended periods. The nozzle
face should be wiped at regular intervals. Do not file or scrape.
5. For the best bond, preheat recommendations should be followed.
6. Deposit efficiencies shown are approximate and have been rounded off for easy calculation.
7. Deposit efficiencies shown in the Type 5PT spray table are for an 80 spray head. A 45 spray head
will lower the deposit efficiencies by five to fifteen percent.
8. Spray rates and deposit efficiencies shown were obtained by skilled operators with all equipment in
first-class condition.
Gas:
Pressure - Primary, psi: 50 100 75
bars: 3.45 6.89 5.17
Secondary, psi: 50 50 Note 4
bars: 3.45 3.45 ---
Flow - Primary: 150 80 150
Secondary: 15 (Note 3) 15 (Note 3) -0- (Note 4)
Power:
Unit: (Note 5)
Arc Amps: 500 500 400
Arc Volts: 74-80 64-70 60-70
Powder Feed:
Unit: 3MP 3MP 3MP
or 3MP-Dual or 3MP-dual or 3MP-dual
Meter Wheel: H H H
RPM: (Note 6) 25 25 30
Carrier Gas Flow: 37 37 37
Spraying:
Spray Distance, inches: 4-6 2-3 4-6
mm: 100-150 50-75 100-150
Spray Rate, lb/hr: 20 20 25
kg/hr: 9.1 9.1 11.3
Coverage, ft /hr/.001":
2
400 400 530
m2/hr/0.1mm: 9.5 9.5 12.5
Powder Required, lb/ft2/.001": .050 .050 .047
kg/m2/0.1mm: .96 .96 .91
Deposit Efficiency: (Note 7) 70% 70% 70%
Deposition Rate, lb/hr: 14.0 14.0 17.5
kg/hr: 6.4 6.4 7.9
The information provided in this document is for the convenience of Sulzer Metcos customers for the
purpose of evaluation and proper use of the Sulzer Metco product(s) described herein. This document
and the information contained herein is the property of Sulzer Metco and shall not be used, disclosed,
or reproduced in whole or in part for any purpose other than for the use of said product(s). Nor shall
this information be used in any way with goods not manufactured and sold by Sulzer Metco. Sulzer
Metco makes no warranties, express or implied, as to the information contained herein.