Production

COMPETENCE IN THE FIELD OF HARDENING

  1. Application of coatings is performed by thermal spraying methods:
  • High Velocity Air-Fuel spraying process
  • Wire Flame Spraying

Modern thermal spraying systems of company Uniquecoat Technologies LLC are fully automated and allowed for higher quality coatings than other existing systems. The Fanuc robot is used for movement of spray gun, that allow to coat parts any geometrical shapes, also provide the repeatability 100%. The vertical and horizontal turner is used for clamping and rotating of parts during the spraying. All equipment is installed in the noisy-protected chambers that equipped with the suction-and-exhaust ventilation.

  1. The production of parts of long-life service parts is performed with the application of thermal spraying technologies.

The production section of thermal spraying is operated as a part of Machine-building plant. This allow to produce parts, nonstandard equipment in addition to thermal spray operation. Machine-building plant is included 6 divisions that equipped with high-performance equipment (blank production shop, machining workshop, heat-treatment shop, shop of assembly-welding operations, shop of machine-assembly operations, packing and painting workshop).

  1. The conduct of research in the area of surface engineering with the application of laboratory and processing equipment.

The staff competences and solid theoretical and practical experience in hardening technology application is allowed UWI – Metallurgy Ltd. to perform researches of coating properties, hardening technology development with the application of modern technologies, development of methods and coatings testing equipment, intellectual property protection. The researches are conducted in close cooperation and with the engineering capabilities involvement of the Ural Federal University, also State Research and Development Institute and commercial laboratory are engaged in researches.

  1. Mechanical treatment of high-strength coatings by diamond grinding

The machining of hardening coatings (microhardness – 900HV and above) is conducted with the application of diamond tooling, the machining are not conducted by carbide wheels and edge tools. The production site of UWI – Metallurgy Ltd. is equipped with grinding machine stock that allowing treat a cylindric surface, flat surface, complex part.

­­­HIGH-STRENGTH COATING ARE:

  • increasing the service-life of wearing parts of industrial equipment by ten
  • high-quality spare parts of imported manufacturing equipment.
  • prompt emergency repair of spare parts using the reconditioning technique.

100 names of various composition  coating:

  • on the basis of tungsten carbide;
  • on the basis of chromium carbide;
  • on the basis of nickel and cobalt alloy;
  • low-alloyed and super-alloyed corrosion
  • resistant steel coverings;
  • coatings based on the nonferrous metals (bronze, copper, zink, aluminum alloy).

Unique properties of high-strength coatings:

  • microhardness – up to 1300 HV (more than 72 HRC);
  • adhesive strength – more than 80 MPa;
  • porosity – no more than 1.0 %;
  • high temperature resistance – up to 900°C;
  • high corrosion resistance.

Surface protection against any external  environment:

  • abrasion wear;
  • effects of corrosion environment (acid, alkali, brines);
  • effects of high temperature and high bearing pres

Additional advantage in comparison with other hardening technique:

  • absence of thermal distortion of spraying part (heating of part during the  spraying – no more than 150°C);
  • potential for building up of joint between dissimilar materials, generation of bimetallic parts;
  • potential for multiple repair of worn part;
  • potential for spraying of coatings in thickness above 10mm;
  • absence of weld residual stresses after spraying of coatings;
  • high processing rate (up to 25 kg/h).

HIGH-TECH METHODS

More than 100 diverse coatings of different composition can be applied by thermal spraying

  • Tungsteen carbide base coatings
  • Chromium carbide base coatings
  • Nickel and cobalt alloys base coatings
  • Iron coatings, ferrous metals-base coatings

High-tech methods of thermal spraying ensures the protection of the surface from numerous environmental impacts: abrasion wear, effects of corrosion environment (acid, alkali, brines etc.), high temperatures and high bearing pressure.

Long-life service is achieved due to the unique qualities of thermal spray coatings:

  • Microhardness – up to 1300 HV (more than 72 HRC)
  • Adhesive strength – more than 80 MPa
  • Porosity – 0.2 – 1.0%
  • High temperature resistance – up to 900 C

Effective application of thermal spraying technologies for production of long-life service parts allows to:

  • Increase the service life wearing parts of industrial equipment in dozens of times
  • Provide production plants with high-quality spare parts of imported manufacturing equipment

Carry out an emergency repair of spare pants in a very short time using the reconditioning technology

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