flame spray company profile 2016
TRANSCRIPT
In 1969 Flame Spray was established as the first Italian job shop to actively promote Thermal Spray coating technologies and activities.
Today it is an international benchmark for applications in these markets: Energy, Oil & Gas, Printing, Steel, Transport, Aerospace.
Beyond Thermal Spray, Diffusion coatings, Slurry coatings, Cladding and Welding are today commonly applied processes at Flame Spray.
The Company’s well established know how is developed daily in the research and production center of Roncello (Italy) and also in the excellence production sites of Montefino (Italy), Szada (Hungary), Varazdin (Croatia) and Fountain Inn (USA)
The new Shop in the Shop sited in Morra de Sanctis (Avellino), in partnership with Ema (Rolls Royce Group), will be the key of success in the Aeronautic market.
Technology and Company
Background
Weld OverlaySlurry Diffusion
All thermal spray processes rely on the same principle of heating a feedstock (powder or wire), accelerating it to high velocity and then allowing the particles to strike the substrate.Particles will then deform and freeze onto the substrate.The coating is formed when millions of particles are deposited on the top of each other.Those particles are bonded to the substrate by either mechanical or metallurgical bonding.
Slurry technique consists in the application of a corrosion resistant inorganic coating operating at temperatures up to 600 °C.This coating protects metals from corrosion on the basis of galvanic principle.These coatings are qualified for several industrial applications.
Diffusion Aluminizing has proven to be a cost effective way to increase the resistance of metals from corrosion and oxidation.Flame Spray proprietary technologies are optimized to be applied on components of different geometries, dimensions and materials
Coating technologies at Flame Spray
Thermal spray
Weld overlay provides protective welded layers with high thickness and optimized metallurgical bonding.This technology is mainly used for highly corrosive environments.
Technology and Company
Market. Turnover. People
IGT
Energy- not IGT (incl. renewable and fossil)
Oil and Gas
Paper, cardboard and printing
Aeronautic
Systems
General engineering
2000 12,2 mil €
2005 25,3 mil €
2010 37,1 mil €
2011 41,0 mil €
2012 47,5 mil €
2013 50,0 mil €
2014 54,0 mil €
2015 62,0 mil €
Turnover trend
Oil & Gas - MTM Valves
< 2002 2004 2006
APS + HVOFTBCMCrAlYWearAbradable
BrazingHoneycombBlade tipsPlates
Diffusion aluminizing
Internal aluminizing
on cooling passagesSlurry / Gel
2008
Welding
Cascade Plasma
2012
Cold Spray
2013
Technologies
Technologies
Cold Spray
20142010 2011
Internal HVOF
Pt/Al Coatings
2016
HVAF
R&D Excellences
R&D Internal Developments
• implementation of 3D Optical Scan system to check the coating thickness, where standard NDT are not possible.
• Introduction of Spray Watch Camera for continuous process
monitoring.
• Installation of a SEM-EDX system(Scan Electron Microscopy – Energy Dispersive X-ray analysis)
R&D Projects
Since 15 years Flame Spray attend to several European Projects including:
• H2IGCC coordinated by ETN• LOWBRASYS coordinated by BREMBO• MACPLUS coordinated by CSM
8
Iso 9001 Certified
Fountain Inn, South Carolina, USACoating Application Center
Roncello, ItalyHeadquarters R&D DepartmentGeneral EngineeringCoating and machine job-shop
Varazdin, CroatiaCoating Application Center
Montefino, ItalyCenter of excellence for Printing Machines Applications
Szada, HungaryCenter of excellence for Turbogas Coating Applications
Weiherhammer, DeutschlandFlame Spray shop-in-the-shop at BHS Corrugated
Morra de Sanctis, ItalyCenter of excellence for Heat Treatments and Aeronautical Applications
Flame Spray around the world
Profile
Flame Spray Italy
• Headquarters
• Large production capacity
• Productions for all the markets
• Tools and booths to handle also very large parts
• First development of technologies
• Center for training and technology transfer
• Founded in 1969 • Covered surface: 14.500 m2
• Headcount (Dec ’15): 184• Applied technologies
• Thermal spray (APS + HVOF +Internal HVOF, HVAF, Cold Spray,)
• Slurry for compressor blades• Arc, CMT and PTA cladding• Diffusion aluminizing• Vacuum Heat treatment/brazing• Chemical stripping
• Equipment• 23 Spray booths with APS, Cascade
Plasma, HVOF and Wire spray (max size 12 m x 6 m x 5 m)
• 6 environmentally controlled slurry booth• 4 air + 2 Argon furnaces• Fully equipped Laboratory • ISO 9001 and ISO 18000 certified
Flame Spray Roncello ItalyResources
Flame Spray Hungary
Profile• Center of excellence for IGT and aerospace market
• Integrated production line (TS, Diffusion Coating, brazing, HT)
• Structured organization with
scheduling tools
• Specific engineering group
for part oriented process development
• Qualified for aerospace
(ISO 9001, NADCAP, S-1000)
• Founded in 2002• Covered surface : 8.500 m2
• Headcount (Dec ’15): 117• Available technologies
• Thermal spray (APS + HVOF)• Heat treatment• Slurry for compressor blades• Diffusion aluminizing• Honeycomb brazing• Shot peening• Welding/Weld overlay• PT/Al Coatings
• Equipment: 9 APS booths, 4 HVOF booths, 2 Cascade Plasma, 2 vacuum furnaces, 4 argon furnaces, 1 air furnace, aluminizing line, 3 MIG CMT for automatic weld overlay, 1 internal aluminizing line, 1 Z-notch Mig Station
• Full equipped Laboratory with Metcut approval
• ISO 9001, 9100, 14001 and NADCAP certified
Flame Spray HungaryResources
Flame Spray Croatia
Profile
• Application center for IGT market
• Born as Shop near the Shop for
Alstom Karlovac
• Structured organization with scheduling tools
• Focused on TBC and Hardfacing coatings
for combustion components
• ISO 9001 Certified
• Founded in 2008• Covered surface : 2.000 m2
• Headcount (Dec ’15): 19• Available technologies
• Thermal spray (APS + HVOF)
• Equipment: 2 APS/HVOF Large sizes (8x7x4,5m) booths
1 Large sandblasting room2 Cranes with up to 25 ton lift load
• Shop in the Shop in Weiherhammer with BHS Corrugated that is the world’s largest provider of solutions for the corrugated industry.
Equipment: 1 Hvof,2 polishing machines,1 automatic sandblasting machine
Flame Spray Croatia
Resources
Flame Spray USA
Profile• Coating center dedicated to
gas turbine applications
• All coating technologies available
• Tools and booths to handle also large parts
• Standardized coating cells to allow quick transfer of processes already qualified in Europe
• ISO 9001 Certified
Flame Spray USA
• Established in 2011• Covered surface : 7.200 m2
• Headcount: (Dec ’15) :75• Available technologies
• Thermal spray (APS + HVOF)• Heat treatment• Slurry• Diffusion aluminizing• Cold Spray• Shot peening
• Equipment:• 3 Robotized APS booths• 4 Robotized Advanced APS booths• 2 Robotized HVOF booth• 1 Robotized HVOF & advanced APS booth• 1 Robotized HVOF & Cold Spray booth • 1 Robotized advance APS & HVOF booth• 2 Argon furnaces,3 Air furnaces , Climate
controlled slurry booth,aluminizing booth, shot peening machine , large grit blasting room
Resources
Flame Spray Montefino
Profile• Coating center dedicated to
the coating and grinding of Anilox roll for printing applications.
• Tools and booths to handle also large parts
Flame Spray performs ceramic coating on anilox rolls that are laser engraved, finished and introduced on the market for flexo printing OEMs by the company Simec spa. Simec owns an experience of more 15.000 anilox rollers and sleeves for flexo market since more than 10 years.
• ISO 9001 and ISO 18000 Certified
• Founded in 1992• Covered surface : 1.500 m2
• Headcount (Dec ’15): 10• Available technologies
• Thermal spray (APS +Wire Spray)• Heat treatment
• Equipment: 1 APS booth, 1 Simplex booth, air furnace
• ISO 9001, 18000 certified
Flame Spray MontefinoResources
Shop in the Shop Morra de Sanctis
Profile• Shop in the shop with Ema Spa (Rolls Royce
Group)
Flame Spray, member of Poema Network since 2014, will be responsible of vacuum heat treatment and surface coating of Aerospace and IGT components.
POEMA
(European Center for Aeronautic High Precision Casting a/k/a Polo Europeo Microfusioni Aeronautiche) is the first industrial network for aerospace investment casting components. It was established in Morra de Sanctis (Avellino, Italy) by companies that represent the excellence in technologies and processes for the production of components for aerospace engines
• ISO 9001 and ISO 18000 Certified
• Founded in 2015 • Covered surface : 1.200 m2
• Headcount (Dec ’16): 6• Available technologies
• APS , Heat treatment, Slurry• Equipment (Dec ’16):
• 1 APS booth• 5 vacuum furnace for aircraft blades
heat treatment • 1 furnace for Aluminising ,• 1 controlled atmosphere furnace for
heat treatment after Aluminising
Resources
Shop in the Shop Morra de Sanctis
Technology Transfer Projects
Coating on Hydro Power
PlantsBhutan
Coating on Ball Valves
Pune-India
Coating on Turbine
components Malaysia
Coating on paper rolls
Curitiba-Brazil
Coating on paper rollsTennessee
USA
Coating on Turbine
componentsFlorence-Italy
Coating on Turbine
componentsAlgeria
Coating on Turbine
componentsHungary
Cern Spinn offRenewable
energy
On Site Coating
AT OEM FOR LOGISTIC ISSUES
• Coating on Hydro components • Coating and cladding on boilers• Coating on gas turbine components• Coating on defence components
ON SITE COATING AT END USERS FOR SERVICE PURPOSE• Cladding and thermal spray on water waste boilers (approx.15.000 m2) in
Italy, Slovakia, France, Spain, Belgium, Finland, Sweden• Coating on Geothermal Plants in Italy• Coating at Paper Rolls industry in Egypt, Germany, Hungary, Greece• Coating at Refinery in Italy
Flame Spray Spa Headquarters20877 Roncello (Monza e Brianza) [email protected]
Coating production center
Roncello (Monza e Brianza) ItalyPh +39 039 695 7216Fax+39 039 695 331
Flame Spray Hungary Kft
Ipary Park út2111 Szada,Ph +36 28514175Fax [email protected]
Flame Spray North America Inc.
576 International Boulevard Fountain Inn,SC 29644 (USA)ph +1 864 862 2730fax +1 864 862 7465