TECHNICAL BULLETIN • 69a~ Grimastgaipment

analolf.appliee METCO inic. 1101 Prospect Avenue, Westbury, L.I., N.Y. 11590

SUPPLIES

POWDER ISSUED: 1 June 83 SUPERSEDES: 1 Sept 79 FILE: Section lb

METCO 105SFP ALUMINUM OXIDE POWDER

Summary: METCO 105SFP is a superfine premium grade of white, high purity, fused aluminum oxide powder for spraying with the METCO Flame Spray Processes. It was designed to produce hard, dense ceramic coatings with excellent wear resistance.

METCO 105SFP is designated as a premium grade material because it has ex-cellent flow properties, as a result of its narrow particle size distri- bution, controlled particle shape and minimal percentage of ultrafine particles. The excellent flow properties of this material make it suit-able to be applied with both the METCO Plasma Flame Spray System and the ThermoSpray System. Powder feed is smooth and consistent, producing coatings which are uniform and smoother as-sprayed.

In addition, ThermoSpray coatings of METCO 105SFP exhibit higher wear re-sistance than ThermoSpray coatings of either METCO 101 or METCO 105 Aluminum Oxide powders.

METCO 105SFP coatings are recommended for resistance to wear by abrasive grains, hard surfaces, particle erosion and cavitation at all temperatures below 1000 F (540 C). They can be used for many applications in any industry, particularly in mechanical seal areas such as pump seals.

METCO 105SFP should also find use on applications where the requirement for wear resistance is accompanied with a need for a low coefficient of friction, such as computer recording heads or any machine element in contact with fibers and threads in the textile industry. METCO 105SFP coatings can be finished to any one of a number of surface textures, over which the fiber or thread passes, to provide a particular friction characteristic.

METCO 105SFP coatings provide high dielectric strengths, which make them particularly suitable for use in the electronic industry. Plasma coatings typically show 450-500 volts/mil and ThermoSpray show dielectric strengths typically 300-350 volts/mil.

Plasma sprayed coatings of METCO 105SFP are competitive with Union Carbide's LA-2 (DETONATION GUN) and LA-6 (PLASMA) aluminum oxide coatings.

This issue has been revised to:

1. Revise 5P and 6P ThermoSpray Gun gas lighting pressures and flows to reduce the chance of backfiring.

2. To add Type 9MB and 10MB plasma parameters.

- Continued - 10-095

•

METCO 105SFP ALUMINUM OXIDE POWDER

APPLICATIONS:

N/A = Not Available

Coating No. Finish Coating Function Typical Application Equivalent to Linde Coating

(Note 1)

• N/A

N/A

N/A

LA-6

LA-6

LA-6

N/A N/A

N/A N/A

LA-2

N/A

N/A

T105SFP -10

T105SFP -11

P105SFP -10

T105SFP-12 T105SFP-13

P105SFP -12

P105SFP-13 30-60 RMS

P105SFP-14 80-110 RMS

P105SFP-15 140-160 RMS

Resist Abrasive Grains (Low Temperature) Resist Hard Surfaces (Low Temperature) Resist Electrical Current

Resist Abrasive Grains (Low Temperature) Resist Hard Surfaces (Low Temperature) Resist Electrical Current

Resist Cavitation Resist Particle Erosion (Low Temperature)

Resist Cavitation Resist Particle Erosion (Low Temperature)

Resist Fiber and Thread

Resist Fiber and Thread

Resist Fiber and Thread

Slush pump piston rods Pump seals

Soldering iron tips

Slush pump piston rods Pump seals

Soldering iron tips

Water turbine buckets Dump valve plug and seat

Water turbine buckets Dump valve plug and seat

Thread guides

Thread guides

Thread guides

NOTE 1: Coatings are equivalent in density, hardness, as-sprayed texture, and finishing capability, and will perform equally well in wear resistance applications.

POWDER CHARACTERISTICS:

Typical Composition:

Typical Size Range:

Aluminum Oxide Other oxides

-20 +5 microns

3700 °F (2038 ° C)

- Continued -

99.5% 0.5%

Melting Point:

•

• •

METCO 105SFP ALUMINUM OXIDE POWDER

Page 3

TYPICAL PHYSICAL PROPERTIES OF COATINGS:

T105SFP

P105SFP

UNION CARBIDE

-10,-12

Texture, As-Sprayed, Microinches aa 140-160

Microns 3.6-4.1 As-Brushed, Microinches aa 80-110

Microns 2-2.8 As-Ground, Microinches aa 15-25

Microns .4-.6 As-Lapped, Microinches aa 2-4

Microns .05-.1

Hardness, Macrohardness Rc62 Cross Sectional (DPH300 ) 725-775

Density (glee)

3.4

Porosity (%)

3%

Coating Weight (1b/ft2/.001") .018

(kg/m2/.1mm) .346

Bond Strength: METCOLITE VF Blasted Low Carbon Steel, psi 2 3000

N/cm 2010

Dielectric Strength: Volts/Mil. As-Sprayed-Unsealed Coatings .003"-.004" (.08-.1mm) thick 300

As-Sprayed-Sealed Coatings .003"-.004" (.08-.1mm) thick

350

-11,-13 -10 -12 -13 -14 -15 LA2 LA6

150-170 3.8-4.3 80-110 2-2.8

15-25 .4-.6 2-4

110-140 2.8-3.6 60-80

1.5-2 15-20 .4-.5 2-4

110-140 2.8-3.6 60-80

1.5-2 15-20 .4-.5 2-4

50-100 1.3-2.5 30-60 .8-1.5 15-20 .4-.5 2-4

100-150 2.5-3.8 80-110 2-2.8

15-20 .4-.5 2-4

150-200 3.8-5.1 140-160 3.6-4.1 15-20 .4-.5 2-4

125-150 3.2-3.8 30-40 .8-1.1

1-2

100-150 2.5-3.8

2-4 .05-.1 .05-.1 .05-.1 .05-.1 .05-.1 .05-.1 .025-.05 .05-.1

Rc64 Rc65 Rc65 Rc66 Rc66 Rc66 725-775 850-1000 850-1000 850-1000 850-1000 850-1000 1100 700-950

3.4 3.43 3.43 3.46 3.46 3.46 3.45 3.38

2% NEGLIGIBLE .5-1% 2-3%

.018 .018

.346 .346

4000 5000 2160 3450

300 450 1275-450 275-400 >

350 500

-CONTINUED-

Page 4 METCO 105SFP ALUMINUM OXIDE POWDER •

THICKNESS LIMITATION:

Do not apply METCO 105SFP to a thickness greater than .020" (.50 mm) with either the ThermoSpray or Plasma Systems. With thicker coatings there is a risk of cracking.

WEAR RESISTANCE:

Abrasive wear tests, using a water slurry of aluminum oxide, have been conducted to determine the relative abrasive grain wear resistance of METCO 105SFP coatings.

•

Coatings of METCO 105SFP, produced with the Type 6P ThermoSpray System, exhibit wear resistance approximately 100% higher than ThermoSpray coatings of METCO 101 or METCO 105.

Coatings of METCO 105SFP, produced with the Type 5P ThermoSpray System, exhibit slightly better wear resistance than ThermoSpray coatings of METCO 101 or METCO 105.

DIELECTRIC STRENGTH:

Laboratory tests show that the dielectric strength of METCO 105SFP coatings will vary with the method of spraying and the type of surface preparation. The values shown in the "Typical Physical Properties of the Coatings" were obtained on different sample coatings of 105SFP.

In order to obtain the maximum dielectric strength for any particular coating, it is recommended that an additional .002" (.05 mm) of coating be applied to compensate for any measurement error. The use of a phenolic sealant such as METCOSEAL AP or METCOSEAL BP will effectively increase the dielectric strength.

The lower dielectric strength of the as-sprayed coating is the result of the inability to accurately measure the true effective thickness of these coatings. This measurement error became significant when testing thin coatings (.003-.004") (.08-.1 mm) because of the surface asperities. The T105SFP-10 and T105SFP-11 as-sprayed surfaces are slightly coarser than the P105SFP-10 and P105SFP-13 coatings. The T105SFP coatings are slightly more porous than the P105SFP coatings and as a result the dielectric strength is somewhat lower.

FINISHING: •

Because the as-sprayed texture of the coating is so smooth, finishes down to 20 microinches as (.5 microns) are readily obtainable by brushing. Good finishes have been obtained by using a urethane backed flexible brush (#167, manufactured by Minnesota Mining and Manufacturing) with Clover brand Grade A lapping compound (-280 grit) and with a slurry of 240-280 grit silicon carbide in water.

The coating changes color from white to gray when brushed with lapping compound, because of the oil in the lapping compound. The discoloration is easily removed by vapor degreasing.

The coatings can be wet ground with 150 grit and 400 grit diamond wheels, using standard speeds and feeds for grinding ceramics.

The coatings can also be lapped, using standard lapping compounds, tools and procedures.

SPRAYING:

Coatings of METCO 105SFP should be applied with the spray parameters recommended in this bulletin.

METCO 105SFP has been successfully applied over a wide range of traverse speeds. The most important factor governing the traverse speed is the substrate temperature. It is extremely important not to cause localized overheating by traversing too slowly. A traverse speed of at least 25 ft./min. is recommended. Rotating parts, such as 1-2 inch (25-50 mm) diameter shafts, have been successfully sprayed at gun traverse speeds of 5 feet/minute (0.03 m/s) with the part rotating at approximately 200 SFPM (1.02 m/s).

Substrate Preheat Temperature: Normal 200°-250°F (90°-120°C). Substrate Temperature During Spraying: Normal 400 ° F Maximum (200°C).

SAFETY MEASURES:

Flame spraying is a completely safe process when performed in accordance with "METCO's Safety Measures". Familiarize yourself with local safety regulations before starting spraying operations. DO NOT operate your spraying equipment or use the spray material supplied before you have thoroughly read the METCO Instruction Manual.

• DISREGARDING THESE INSTRUCTIONS MAY BE DANGEROUS TO YOUR HEALTH.

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METCO 105SFP ALUMINUM OXIDE POWDER Page 5

SYSTEM PARAMETERS ThermoSpray

SET #1 SET #2 SPRAY GUN Type: 5P 6P Nozzle: P7-G P7A-D Siphon Plug: Standard Standard Air Cap: Standard Standard Metering Valve: 15 N/A Air Jet Unit: Yes Yes

Air Pressure, psi: 50 50 bars: 3.5 3.5

Cross Jets, inches: 2 2 mm: 50 50

Vibrator: 5PV N/A GAS Pressure - Oxygen, psi: (Note 1) 25 25

bars: (Note 1) 1.7 1.7 Acetylene, psi: (Note 1) 15 15

bars: (Note 1) 1.03 1.03 Flow - Oxygen: (Note 1) 34 42

Acetylene: (Note 1) 34 50 POWDER FEED

5-7 N/A N/A N/A N/A

N/A 3MP

10 Yes

Flow Control Valve - clicks open: (Note 2) Unit: Meter Wheel:

RPM: (Note 2) Air Vibrator:

Vibrator Air Pressure, psi: N/A 40 bars: N/A 2.8

Nitrogen Carrier Gas - Pressure, psi: N/A 55 bars: N/A 3.8

Flow: N/A 37 SPRAYING Spray Distance, inches: 2.5 (Note 3) 2.5 (Note 3)

mm: 64 (Note 3) 64 (Note 3) Spray Rate, lb/hr: 2.5 (Note 3) 2.5 (Note 3)

kg/hr: 1.1 (Note 3) 1.1 (Note 3) Gas Consumption - Oxygen, ft 3/hr: 60 95

m3/hr: 1.7 2.7 Acetylene, ft 3/hr: 33 59

m 3/hr: .93 1.7 Nitrogen, ft 3/hr: N/A 10

m3/hr: N/A .28 Coverage, ft2/hr/.001": 83 97

m2/hr/O. lmm: 2.0 2.3 Powder Required, lb/ft2/.001": .030 .020

kg/m2/0.lmm: .58 .50 Deposit Efficiency: (Note 4) 60 70 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. Use as a starting point. Adjust as necessary to obtain spray rate shown. 3. The spray rate and spray distance values are critical. 4. Deposit efficiencies are approximate and have been rounded off for easy calculation.

Spray rates and deposit efficiencies shown were obtained by skilled operators with all equipment in first-class condition.

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Page 6 METCO 105SFP ALUMINUM OXIDE POWDER

SYSTEM PARAMETERS Plasma Flame

SET #3 SET #4 SET #5 TAIT A/H2 A/H2

SPRAY GUN Type: 3MB/7MB 3MB/7MB 7MB Nozzle: GP GH 700 Powder Port: #2 #2 #2 3M 275 Uni-Jet Ring: (Note 11 Yes Yes N/A Insulator: N/A N/A 7M 50 Cooler: 3M 780 3M 780 7M 80

Air Pressure, psi: bars:

Cross Jets, inches: mm:

75 5.2 3.5 89

75 5.2 3.5 89

75 5.2 3.5 89

GAS Pressure - Primary, psi: 100 100 100

bars: 6.9 6.9 6.9 Secondary, psi: 50 50 75 (Note 31

bars: 3.5 3.5 5.2 Flow - Primary: 150 150 80

Secondary: (Note 2) 10 10 15 POWER Unit: 2MR-4MR-6MR 2MR-4MR-6MR 6MR-7MR Arc Amps: 500 500 600 Arc Volts: 75-80 75-80 60-70 POWDER FEED Unit: 3MP or 3MP-DUAL Meter Wheel: H H H

RPM: (Note 4) 10 10 15 Air Vibrator: Yes Yes Yes

Vibrator Air Pressure, psi: 40 40 40 bars: 2.8 2.8 2.8

Carrier Gas Flow: 60 60 60 SPRAYING Spray Distance, inches: 2.5 2.5 2.5

mm: 64 64 64 Spray Rate, lb/hr: 3 3 6

kg/hr: 1.4 1.4 2.7 Coverage, ft4/hr/.001": 58 92 183

m2/hr/0.lmm: 1.4 2.2 4.3 Powder Required, lb/ft 2/.001": .053 .033 .033

kg/m2/0.lmm: 1.0 .63 .63 Deposit Efficiency, %: (Note 51 35 55 55 Deposition Rate, lb/hr: 1.05 1.65 3.3

kg/hr: .49 .77 1.49 NOTES: 1. Install ring with the 45 ° internal recess facing the nut and with the jet hole toward the top of the

gun, approximately 180 ° from the gas inlet. 2. When using argon as the primary gas, the secondary gas flow shown in the chart may be adjusted as

much as ±5 points, if necessary, to obtain voltage within the range shown; EXCEPT THAT the secondary gas flow may not be reduced to zero, and hydrogen flow may not exceed 25. If the required voltage is not obtained with this preliminary gas flow adjustment, check the equipment for a worn nozzle, a worn electrode, or a gas leak between the flowmeter and the gun. If there is no gas leak, and the nozzle and electrode are not badly worn, further adjustment of the secondary gas flow, up to an additional ±5 points, is permissible, if this second adjustment does not result in a flow of zero or a hydrogen flow exceeding 25. If the required voltage is not then obtained, replace the worn parts.

3. Use the Type 7GH Hydrogen Gas Regulator. 4. Use as a starting point. Adjust as necessary to obtain spray rate shown. 5. Rounded off for easy calculation.

•

•

- Continued -

Page 7

METCO 105SFP ALUMINUM OXIDE POWDER

SYSTEM PARAMETERS Plasma Flame

SET #6 SET #7 SET #8 SET #9 A/H 2 A/H2 A/H 2 A/H2

SPRAY GUN Type: 9MB 9MB LOMB 10MB Nozzle: 733 732 835 807 Powder Port: #2 #2 #2 #2 Insulator: (Note 1) 9M 50 9M 50 Note 1 Note 1 Cooler: (Note 2)

Air Pressure, psi: 75 75 75 75

bars: 5.2 5.2 5.2 5.2

Cross Jets, inches: 3.5 3.5 3.5 3.5

mm: 89 89 89 89 GAS Pressure - Primary, psi: 100 100 100 100

bars: 6.89 6.89 6.89 6.89 Secondary, psi: 50 50 50 50

bars: 3.5 3.5 3.5 3.5 Flow - Primary: 150 150 150 80

Secondary: 10 10 10 15 POWER Unit: (Note 3) Arc Amps: 500 500 500 800 Arc Volts: 75-80 75-80 75-80 50-60 POWDER FEED Unit: 3MP or 3MP-DUAL H H H H Meter Wheel: RPM: (Note 4) 10 10 10 20

Vibrator Air Pressure, psi: 40 40 40 50 bars: 2.8 2.8 2.8 3.4

Carrier Gas Flow: 60 60 60 60 SPRAYING (Note 5) Spray Distance, inches: 2-1/2 2-1/2 2-1/2 3

mm: 65 65 65 76 Spray Rate, lb/hr: 3 3 3 6

kg/hr: 1.4 1.4 1.4 2.7 Coverage, ft 2/hr/.001": 58 92 58 183

m2/hr/0.1mm: 1.4 2.2 1.4 4.25 Powder Required, lb/ft2/.001": .054 .083 .054 .083

kg/m2/0.1mm: 1.1 .63 1.1 .63 Deposit Efficiency, %: (Note 5) 35 65 35 55 Deposition Rate, lb/hr: 1.05 1.65 1.05 3.3

kg/hr: ,49 ,77 ,49 1.5 NOTES: 1. For the Type 7MB Gun use Cat. No. 7M 50, for the Type 9MB Gun use Cat. No. 9MB 50

and for the Type 10MB Gun use Cat. No. 10MB with Argon. 2. For the Type 7MB Gun install the Cat. No. 7M 80 Cooler Assembly, for the Type 9MB

Gun use Cat. No. 9MB 80 Cooler Assembly and for the Type 10MB Gun use Cat. No. LOMB 80 Dual Powder Port Air Jet Assembly.

3. The METCO Type 6MR or 7MR Power Supply Units can be used. • 4. Use as a starting point. Adjust as necessary to obtain spray rate shown. Rounded off for easy calculation.

5. Spray rates and deposit efficiencies shown were obtained by skilled operators with all equipment in first-class condition.

- Continued -

METCO 105SFP ALUMINUM OXIDE POWDER Page 8

PRODUCING RECOMMENDED COATINGS:

Coating No. Instructions

T105SFP-10

T105SFP-11

T105SFP-12

T105SFP -13

P105SFP -10

P105SFP -12

P105SFP -13

P105SFP -14

P105SFP -15

Surface Preparation: Spraying: Finishing:

Surface Preparation: Spraying: Finishing:

Surface Preparation: Spraying: Sealing:

Finishing:

Surface Preparation: Spraying: Sealing:

Finishing:

Surface Preparation: Spraying: Finishing:

Surface Preparation: Spraying: Sealing:

Finishing:

Surface Preparation:

Spraying:

Finishing:

Surface Preparation:

Spraying:

Finishing:

Surface Preparation:

Spraying:

Finishing:

Any standard method Parameter Set No. 1 Grind, lap

Any standard method Parameter Set No. 2 Grind, lap

Any standard method Parameter Set No. 1 1st choice, METCOSEAL BP 2nd choice, METCOSEAL AP Grind, lap

Any standard method Parameter Set No. 2 1st choice, METCOSEAL BP 2nd choice, METCOSEAL AP Grind, lap

Any standard method Parameter Set No. 4 or 5 Grind, lap

Any standard method Parameter Set No. 4 or 5 1st choice, METCOSEAL BP 2nd choice, METCOSEAL AP Grind, lap

Blast with METCOLITE VF @30 psi air pressure. Parameter Set No. 3, .003"-.005"

thick. Brush, tumble, grind, lap

Blast with METCOLITE C @ 30 psi air pressure. Parameter Set No. 3, .004"-.006"

thick. Brush, tumble

Blast with METCOLITE VF @ 30 psi air pressure. Apply bond coat of METCO 450 (P450-12). Parameter Set No. 3, .006"-.009"

thick. Brush, tumble

RPZ/lm