Factors for Thermal spray wire material selection

Wire is a recommended feed material for diverse coating operations because of lower material cost and easy handling. The wire operations are usually featured by high deposition rates and great efficiency. The common applications for thermal spray wire is the combustion wire process and wire arc spray process which uses total pounds of wire per year when compared to combustion wire.

The applications include the coating materials that can be developed into a malleable wire.

The wire production process is what limits what materials you can develop in thermal spray wire. The basic process includes forging or hot rolling to a moderate size. The eventual processing needs cold drawing uses hardened dies that also includes heat processing procedures to avoid cold process from the drawing process. In case of extremely hard or brittle material for cold drawing, it may not as thermal spray wire.

Wires are classified as base material, the metal that is predominant in wire. The wires for electric arc and combustion spray includes aluminium, cobalt, copper, iron, molybdenum, nickel, zinc and tin. Titanium wire is used for electric-arc spray however not combustion arc spraying as titanium has a higher melting temperature that is available with combustion spray. Lead wire is recommended for combustion spray however not electric-arc spray due to low electric conductivity of lead.

A key factor is the wire size. In various industries, wire sizes are usually expressed as gauge. Although, there are several conflicting definitions of gauge, wire gauge, US standard for stainless steel. AWG is utilized for non-ferrous wire and SWG is utilized for ferrous wire. As it is important to have a close match between the thermal spray gun set-up and the wire size, it is preferred that wire size is specified in mm instead in gauge.

Wire feed for spray systems

Wire feed is crucial for any wire based thermal spray operation. A single wire feed is preferred for flame spray systems while twin wires are specifically utilized for electric arc spray systems. The generic wire produced for other industries can cause major grief. Standard industrial wire may have surface scaling that result to wire feed jams, extensive wear of feed components and result to inclusions in the final coating. Additionally, other industries may not be related with offering wire rolls free of kinks, weld joints or other characteristics that could lead to feed issues. Many wires have lubrication added to the surface during the even spooling process. The level winding process is used during the spooling process that is a method of wire coiling on the spool so it is wound single level layer.

In establishing the wire feed system, sufficient space is required to permit for free wire feeding without binding. It is particularly essential for wire guns that utilize a pull drive only. The wire-straightener system in the feed is also advantageous for smooth and trouble-free thermal spray operation. When wire is wound, it releases the spool without getting tangled.

Moreover to solid wire, there is certainly hollow wire filled with powder. These are recommended as cored wires in that they have a hollow core filled with powder. These are preferred as cored wires in that they have a hollow core filled with powder. 

Use of highly adaptable and heavy duty Mesh trays in industries

A mesh tray acts an effective and consistent support for cables. The mechanical function of mesh tray products ensures that they safely support wires in a wide range of applications. We manufacture the tray systems that offer one-step locking and do not need extra hardware to secure the support. The mesh trays are designed to support any load.

Mesh Material Type

To receive the best performance from mesh tray, it is essential to choose the right metal mesh to provide good corrosion resistance and mechanical strength. Corrosion is an uncontrollable and recurrent problem in all applications that involve the use of metals. It may adversely affect the performance and lifetime of the device. The trays are widely exposed to atmospheric corrosion, so the conditions in which the trays functions is a crucial factor in the choice of metal. Atmospheric corrosion reduces the performance of metals due to in reaction between air/ water/ moisture/ rain and metal surface.

The mesh tray has main applications in Building services, infrastructure, heavy industry and processing plants.

Full Food safety

The smooth mesh minimizes the chance of entrance of dust and particles on the surface. Whether used horizontally or sideways, mesh offers easy inspection of the food to confirm that it is clean. Any foreign material or bacterial growth can be found in the initial stage

The pollution or unknown production can be prevented by blowing, vacuuming and power cleaning. These steps can be followed regularly or after inspection. In Sideway installation, the chances of dust and debris accumulation on the mesh surface widely decrease.

Adaptable Trays

Easily adaptable Nichromemesh trays and steel mesh trays are fit for any installation method. The premium mesh tray has the wide contribution in the food industry.  Nichrome and stainless steel mesh are also highly corrosion resistant therefore they offer longer performance than traditional materials.

Protection from electric shocks

Irrespective of the electrical security of the equipment, energy flow is always risky to people and their belongings. Therefore we test the trays for short circuits before their delivery. The mesh tray is subjected to large mechanical stress for some time and the process is repeated to confirm that the mesh structure is able to deal with the short circuit.

The mesh trays are also fire resistant. The mechanical properties of the wires and mesh tray ensure the durability of the installation for a required time period.

Nichrome mesh tray is constructed of precision engineered and high quality mesh and is the result of wide experience gained from the manufacturing of the large magnitude of mesh tray across the globe.  The mesh tray has performed in the various applications varying from heavy power pathways on oil drilling units to electrical and data installation in the advanced office buildings.  

Various applications of Nichrome mesh tray include thermistor sintering, silver sintering, semiconductor sintering, ceramic capacitor, chip sensor sintering, battery anode and photovoltaic wafer sintering. Nichrome mesh offers good heat resistance and corrosion resistance by which it performs for a long term in the various application media.

Use of Monel 400 and Inconel 600 in chlorinated application media

Chlorinated hydrocarbon solvents are greatly used in dry cleaning, metal degreasing a great range of solvent extraction procedures in the chemical plants. When water is eliminated and at natural temperatures, the solvents are not attacking and steel equipment can be used to deal them. However of entrained water or water layer and specifically at the elevated temperatures that occurs in distillation and recovery of solvents, the essential hydrolysis with development of dilute hydrochloric acid.

The development of acidity is increased by nominal light and aeration. The steel is sharply attacked. For a great service of numerous years, Monel 400 and Nickel have offered supreme resistance to corrosion in these media of a great range of chlorinated hydrocarbons. The alloys are utilized for distillation and recovery equipment in the development and application of solvents.

In the development of chlorinated solvents while their development, the corrosive conditions are very vigorous in the static media or reboiler in the edge parts of distilling columns where water accumulates. Monel 400, Nickel and Inconel600 wire provide high resistance to corrosive media, these alloys are used for distillation and recovery equipment in the development and service of solvents.

An evaluation of resistance offered by metals and alloys to corrosion by different chlorinated solvents and mixtures of the solvents with water at room and boiling temperatures.  In the refinement of chlorinated solvents while their development, the corrosive media are harsh in the static or reboiler or in the edge segments of distilling columns where water deposits. It is discovered by the results of plant corrosion evaluation in regular process for refinement of crude carbon tetrachloride.

The main applications of Monel 400 and nickel are in the development of dry cleaning systems, for components need in solvent recovery stills and condensers, washer cylinders, water distillation, lint traps and solvent storage containers. These equipments use a wide range of solvents like carbon tetrachloride, trichloroethylene, perchloroethylene and solvent mixtures.

For metal degreasing applications, various chlorinated solvents are used including trichloroethylene, carbon tetrachloride, perchlorethylene, ethylene dichloride, propylene dichloride and more. Monel 400 and Nickel are used for degreasing containers and solvent recovery equipments.

In the solvent use of animal and vegetable oils, various chlorinated solvents are used. Monel 400 is used for solvent recovery equipment for cod liver extraction using ethylene dichloride.

A large count of organic chlorination is in the set of dry raw materials. For organic chlorination, Monel 400 and Inconel 600 are used. They offer good corrosion resistance and have no catalytic influence on the color of the product.

About Manufacturer

Heanjia Super-Metals is a premier supplier of corrosion resistant super alloys that offer supreme performance for a long term. We produce nickel based alloys that are widely used in the severe application media such as in chemical and petrochemical, oil and gas, aerospace and land based gas turbines. These alloys have been in service for several years and are gradually used in the advanced applications to meet the challenging corrosion resistance demands of the industries in the modern time.

Use of filter discs in metallurgical industries

The disc filters have common applications in heavy duty processes for example dewatering of iron, copper concentration, floats concentration and other industrial processes. The filter discs were extensively used in 60s in the metallurgical plants.

The filter is made of many discs about 15 in the large size equipments, each part consists of sectors that are joined together to build the disc. The benefit is that disc filters cover nominal floor space and cost per operation is much lower as compare to vacuum filters.

Filter disc in operation

During the operation, every sector enters submergence and a cake is developed on the face of discs. It then emerges to the drying region, the liquid drains to the middle barrel from there via a valve to the vacuum receiver. The valve monitors the timing so that as soon as sector exits the drying region, it goes over a separation bridge and a snap or low pressure blow is applied to cake discharge. Scraper blades on every disc side direct the cake to discharge chutes that are located between adjacent discs and are sufficiently wide to prevent clogged by dropping cake. An agitator positioned at the end of tank collect slurry in suspension that in other metallurgical processes collects solids with high specific gravity that are abrasive.

Other disc filter types

Disc filters can serve as vacuum disc filters or pressurized disc filters. Due to differential pressure application on both sides of Hastelloy mesh filter discs, the effective filter area is significantly larger than drum filter for the same floor area.

Pressurized disc filters:

a.       Pressurized disc filter involves the application of lower pressure gas to the slurry side

b.      The compressed gas develops the essential pressure differential for filtration

c.       The filter is configured in an air-tight housing.

d.      Filtration starts when the disc quits the slurry

e.      Internal valves and piping channel the filtrate far from all discs and towards a receiver.

f.        The filter housing is created to comprise of a redistributed process gases. It can be developed from different materials.

Vacuum Disc Filters

a.       Cake development: An internal valve opens that allows vacuum creation inside the filter screen. The cake develops on a part of the submerged drum

b.      Cake drying: With the rotation out of slurry by the slurry, the drying process starts. Vacuum is applied to develop a pressure differential essential to discard the filtrate.

c.       Cake Discharge: An internal valve locks the vacuum at this level. The discharge processes can be a scraper belt, belt or roll. The compressed air is used to eradicate the cake from the filter screen.

Precoat disc filters

A Precoat disc filter performs as vacuum disc or a pressurized disc filter.

Capillary Action disc filters: These filters are used to dewater mineral concentrates and pelletize the feed slurries.  The porous disc replace the traditional filter cloth. The capillary action draws liquid through pores and a small size vacuum pump is needed that significantly lowers the energy consumption. 

Service environments in Paper and Pulp industry

Paper is developed by digesting wood chips with a combination of sodium sulphite and NaOH. The product is sent to the brown stock washers to eradicate the liquor from the brown pulp. Subsequent to screening, pulp go directly to the paper mill to develop unbleached paper, or it is directed first to the bleach plant to develop white paper.

The digester vapors are condensed and the condensate is pumped to brown stock washers. The black liquor from these washers is concentrated and heated with sodium sulfate to recover sodium carbonate and sodium sulfide. With water dissolution, the green liquor is processed with calcium hydroxide to develop sodium hydroxide to replenish the white liquor. Pulp bleaching includes treatment of different chemicals such as chlorine, chlorine dioxide, peroxide, caustic soda, quicklime or oxygen.

The sulphite processes utilize a liquor in the digester that is unlike to that used in kraft process. This liquor consists of free SO2 dissolved in water with sulfide dioxide as bisulfite. The chemistries of the specific liquors is different. Sulfur dioxide for the cooking liquor is developed by burning elemental sulfur , cooling quickly, absorption of SO2 in a weak alkaline solution and strengthen the raw acid.

Different alloys are chosen for various corrosive media occurring in pulp and paper mills. The mill headboxes are usually produced from stainless steel 316 plate with excellent surface finish and electropolished to avoid scaling that may affect pulp flow.

The evaporators and reheaters handle the severely attacking liquors and should decrease scaling to develop adequate heat flow. Stainless steel 304 welded tubing is used in kraft black liquor evaporators. Cleaning is usually performed with HCl that attacks ferrite. In the sulphite process, stainless steel 316 is used in black liquor evaporators. Digetester liquor heaters in the krafy and sulphite processes use stainless steel to prevent corrosion in caustic or chlorides Stress corrosion cracking.

The bleach plants have utilized SS 316 to austenitic grade containing molybdenum in the problem areas.  High oil units are now using SS 904l instead SS 316.

Pulp mill bleach plants use austenitic stainless steels for their excellent corrosion resistance and weldability. Although, bleach plants are highly corrosive that over two decades they have closed washwater units and reduced effluent volumes. In advanced closed bleach plants, the traditional  steels are no longer fit for prolong service and several mills have recommended to use high alloy stainless steels, the nickel based alloys and titanium for greater corrosion resistance.

Super alloys are stronger and have good fatigue characteristics and they offer good corrosion resistance without the need of much maintenance. Although, the corrosion resistant alloys are expensive, there is also a challenge to select a suitable alloy with adequate resistance to prevent corrosion issues. The super Duplex stainless steel 2205 offer great corrosion resistance with prevention of pitting and crevice corrosion. The nickel based super alloys are perfect for use in pulp and paper industry for their good strength, durability and outstanding corrosion resistant properties. Additionally they offer prolong performance that make them ideal for service in the pulp and paper plants. 

Mesh applications in candle filter and leaf discs

Candle filters

The metal mesh filters are made in both cylindrical and square shapes for standard industrial designs and are custom made to fit in the specific housing. These are made in sintered metal fiber and woven wire mesh.

The designs include heavy duty mesh that offer sufficient strength to withstand high differential pressures about 120 bar in fact higher too if needed. Low carbon steels are widely used to offer supreme corrosion resistance. The thread coatings are offered when essential to prevent the galling of material.

Sufficient care is taken to confirm that the design is free from stagnant flow areas that could slow down the polymer, cross-link and affect. The mesh are offered with internal volume reducers at the closed end to support in it and usually have flow divert characteristics to offer good flow distribution over the mesh when the polymer enters.

In the various designs, the open end can of the candle is made to sink into the tubesheet to confirm extending the filter medium.

For several applications, the Hastelloy mesh pleated candles are used for extended surface area and prolong active life. For few polymers such as polypropylene, it is discovered that the large viscosities refer that there is nominal flow among the pleats and on-stream life is not significantly more than a plain cylindrical candle. The plain candles are preferred in this media.

Uses:

a.       Polyester bottle

b.      Polyester fibre

c.       Cellulose acetate fibre

d.      Nylon fibre

Advantages and characteristics

a.       Sturdiness for cleaning and frequent use

b.      Prolong life

c.       Service at the high temperature media

d.      Supreme carbon resistance

e.      Good filtration area for pleated candle design

The candle mesh filters are customizable to fit any specific housing. They are made in sintered metal fibre and woven wire mesh. The filtration ratings vary from 3 to 100 microns, these are normally delivered with an external guard t secure the media and to permit reverse flow while cleaning. The candle mesh is easily cleanable with advanced technology. The candles are developed with separable hardware fitting and replaceable media to offer lower service costs. They are fit for any industrial designs and can be customized for specific housing.

Leaf discs

Leaf disc and solid plate filters are made for critical hot melt polymer filtration applications to achieve great gel control by offering smooth flow and hence higher gel retention on the filter.

Additionally to offer a great range of filter media, the leaf disc filters provide the great design characteristics ensuring low pressure drops to offer longer stream life. The firm structure permits several cleaning cycles hence decrease overall life costs.

With our extensive experience and great range of filer media, the application and design engineers can custom design adequate filtration products for every product and process, it includes support during design process to attain active performance for the long terms.

We characterize our media and elements service by evaluating them through flow tests, microscopy, chemical test, tensile test, metallography and quantification of polymer contaminant with image analysis. 

Waterjet cutting of superalloys for aerospace applications

The waterjet cutting system implements Dynamic Waterjet Technology. It has active tolerance control to offer unprecedented speed, accuracy and versatility. The patent system develops components with tight tolerances even at the large paces that practically discards taper by using angular compensation. It utilizes an advanced sophisticated motion system that comprises of new mathematical cutting models to monitor the small articulated wrist associated with the cutting head.

It is possible to title the cutting head in any direction by using the wrist to compensate the stream lag and taper occurring with the traditional waterjet cutting systems. For the traditional waterjets, it is essential to decelerate the process to reduce or discard the finished component tolerance errors because of the stream lag and taper. By using waterjet, it is possible to overcome these drawbacks. The position of cutting head can be dynamically controlled by using software that can level the tilt ant rotation required at the various incremental points with a cutting path.

An appropriate cutting speed can be maintained with this software to keep the components taper- free and within tolerance. It is essential to increase the tilt while increasing the cutting pace and in many cases, fast cutting speed can be obtained with the potential to tilt the cutting head. Therefore, Waterjet can develop excellent components at the larger speeds as compared to the traditional waterjet cutting equipments.

Wateret cutting machine capability

a.       Accuracy of +/- 0.0015 inch per 3 feet and speed limit about 0 to 500 ipm

b.      Cutting area about 2m x 2m cutting bed with lengthy pieces having indexing potential

c.       Several tolerance levels and fine cut

d.      Mix and match edge styles on the same part depending on their use

e.      Nominal machining is required on components because of tighter tolerances and outstanding edge quality and highly available due to no need to handle the scrap

f.        Nesting, flattening, kitting, toll cutting and JIT service

g.       Small edge stress and no heat affected region so fit for the elevated temperature and corrosion resistance applications.

Benefits

a.       Cut components 25 to 400% more quickly as compared to the traditional flat stock waterjet cutting devices

b.      Cut various materials such as glass, metal and composites

c.       No additional finishing is needed

d.      Improve cut part tolerances and shape at the significantly high speeds

e.      Virtually prevent aper

f.        Decreases component cost

g.       Cut components by using CAD file and draw directly into FlowMaster

Applications

1.       Aerospace- Titanium bodies and engine materials constructed from titanium, aluminium and heat resistant alloys such as Monel 400 and others.

2.       Automotive- Truck bed liners, interior trim, firewall

3.       Gasket for aircraft, automobile, marine, copper and rubber

4.       Stainless glass, Outdoor stone and flooring, wall inlay, flat glass

5.       Acrylics , plastics, ceramics, stainless steel, Inconel, mild steel, titanium, brass

The waterjet cutting technology has made it easier to cut the corrosion resistant alloys that are usually a hard material that need expensive cutting processes. 

Challenges during Inconel grade machining and work hardening

A winning strategy for effective machining of Inconel, includes wise choices of cutting tools and parameters. A common procedure is 3V precision that s used to machine the Inconel grades economically with cycle times about 24 hours. To efficiently use the Inconel components to continue the procedure and turning a profit, the 3V procedure has become more economical as compare to other machining procedures in cutting this metal. The tools and methods used were a beginning point, however the aim is at meeting the challenges and costs related with this alloy.

The procedure is successful because of the dedication, the procedure continues to draw on the type of promise and engagement as the facility gives the hope to handle the hard metals effectively.

The combination of CNC machines in 3V service includes horizontal and vertical machining units. It is essential to have these units otherwise you do not understand the machining. Efficiency comes through fine tuning process for a machine tool thereafter replicating the success by implementing the same method on the similar machines.

On each processing of Inconel alloy, sufficient materials are set up and retain sufficient metal removal rate with every of these pieces therefore the complete machining cycle time is about 24 hours or low. A time length of 24 hours is trusted to be perfect for machining time since an operator who begins on a cycle lasting this long can determine that he will have this job to unload at the same time on the second day. An operator who invests the day setting up and launching single 24 hour machining after another hence has his next day already planned. They need to visit the machine again and load new components or settle new job.

Attaining cycle time quicker than 24 hours is not essentially an achievement. Neither is receiving a large count of samples in the setup if the density has an effect of increasing cycle time above 24 hours. If these changes can develop a cycle that is out of step in balance with other procedures, and breaking rhythm would result into waiting or hurry, causing error or efforts in vain. Specifically in Inconel, 24 hour standard brings lavishness as it refers that there is no pressure to drive the process to attain the last incremental increase in the machining results.

In machining of Inconel718 grade, the work hardening is more dangerous. The metal can be cut productively, however quick cutting has a way of redeveloping into unbeneficial cutting as the hardened metal begins to rapidly affect the costly tools.

The small speeds and feed rates are utilized initially with the parameters bumped after every successful run as long as quick wear sets in the shop arrives at a process for machining a suitable quantity of these components in a cycle of only within 24 hours.

If the roughening tool is worn then the finisher damages quickly and this wear can eventually affect the success of the unattended cycle or sellablity of the component. 

Which is best- Nichrome or Nickel-200 or Titanium or Kanthal or Stainless steel

Various wire materials are used to develop coils. This post describes the difference between nichrome, Nickel 200, titanium, kanthal and stainless steel. These wires will meet the serve purpose, there are basic fundamental applications that place the world apart. It is because as we dig deep in the science of the various wire types, it help you distinguish which wire suits your needs best.

Nichrome Vape Wire

Nichrome is all known for its oxidation resistance properties by which it can perform at the high points without being attacked by oxidation. Nichrome is a popular electric heating element, hot wire foam cutters and domestic equipments and tools. With its potential to quickly heat up with small time, Nichrome is the popular choice for the most of e-cigarette coils and cloud-chasing constructions. As compare to Kanthal, Nichrome 80 wire shows lower melting point and lower highest service temperature. Therefore the service life of nichrome will be generally smaller than kanthal.

FeCrAl Vape Wire

Kanthal wire popularly developed its appearance in the e-cigarette just after Nichrome and rapidly became famous among the coil manufacturers. For its low price, extensive availability and actually i can be made in several gauges, Kanthal wire offers numerous combinations of various size coils creating various resistances for any vape style. Wire made from Kanthal serves at the higher temperature and has higher melting point as compare to Nichrome, offering a longer service life. Many people believe that Kanthal wire goes off taste due to presence of iron, but not all. The service of kanthal wire  makes it a primary choice of beginners who are looking for the learning opportunities.

Titanium Wire

Titanium wire is somehow new in the market in context to nichrome and kanthal and is used in several sub-ohm tank coils for controlling temperature. It is stronger as compare to Nickel 200 that makes it easier to use. Titanium offers double times resistance as compare to nickel 200 making it fit for achieving required resistance more easily. A factor to be worried about Titanium is that it heats up to the ignition level. If the metal heats, you will see fire that cannot be handled by any fire extinguisher  in which case you have to allow it burning out. Additionally the development of titanium dioxide is also not good for health.

Pure Nickel wire

Nickel 200 has very high temperature coefficient. This is the major reason that many people decide to use Nickel 200 wire for the initial temperature control mod. Nickel is a soft wire and springy, making it harder to work as compare to kanthal or titanium. It is a supreme concept to space the wraps apart so the heat is uniformly distributed over the wire length. For any warp in coil that are in contact of each other, it permits uniform heat supply with tight wraps, although, it can take time.

Results

If you are confused about which is the suitable wire, ask if you will use temperature control or use the variable wattage? This will help you in your work while choosing which wire is suitable- Kanthal, stainless steel and Nichrome. 

Industrial quality conveyors for mining to food applications

The woven wire mesh has the common uses in chemical, plastic, automotive, aerospace, electronics, industrial screening such as in mining, lab sieving, food processing and several other applications. The woven wire cloth has a great aesthetic appeal. The wire mesh is made from the various materials such as:

1.       Steel

2.       Stainless steel

3.       Non-ferrous materials such as aluminium, nickel,  Monel and copper

4.       Super alloys such as Inconel, Incoloy, Hastelloy etc.

The choice of material, quality and treatment are crucial for the characteristics of the woven wire mesh product. Specific needs can be met by using the particular set of materials. The cost for various materials varies broadly. Becoming aware of which is the best fit for specific applications and which processes can be used are particularly crucial for ensuring the meeting needs for function, stability, safety and economy.

We have designed he processed for quality assurance. For reception of wire materials and production and before the delivery our lab conducts special analysis along with the classic materials and quality checks.

Our performance is based on experience, regular research and development of products and manufacturing process, along with the skills of our team. This combination of skills and innovation enable us meeting the needs of our customers.

Mesh belts

Heanjia Super-Metals is a leading supplier of perforated metal conveyor belts that are used across the industries including heat processing, forging, foundry, food processing, snacks, ceramics, glass, automotive and others.

Our conveyor belts fit in almost all applications including tight wire mesh for versatile and conveying small components, smooth surface belts for perfect transfer, belts with bog openings allow easy flow of air and water for simple cleaning of your product. These belts are fit for carrying metal components through copper and aluminium brazing furnaces, bronze and iron components through sintering furnaces, textiles, chemicals for dryers and other applications in which the belts are used for washing, annealing, cooling and polishing of materials.

The metal woven wire mesh conveyor is also used in the food processing industry in clean dry, bake, cook, freeze, salt, can and others.

Our metal woven wire mesh is made in the different sizes to be fit for any process, a wide range of materials are used from carbon steel to high strength alloys. Our conveyor belts can carry light to heavy loads and they perform excellence without the help of an operator. They can serve at the different temperature limits from low to high and withstand the diverse application media such as acids, alkaline, chemical corrosion, abrasion and impact.

The belts are made in the various types such as: furnace belts, mesh belts, baking, metal woven mesh, lehr bels, positive drive belts etc.

Heanjia is specialised in quick deliveries for immediate requirements. We offer the following conveyor belt types:

Balance, Cordweave, Universal DBL balance, chainweave, grid link, precision balance, flatwire and single.

We manufacture heavy duty belts for mining and other industries around the world. Our skills in the significant advancement in the conveyor belt design for the strong and heavy belts are acknowledged by our customers. 

Behavior of Monel 400 in Arabic Gulf seawater

Monel 400 is exposed to the different natural aerated seawater at the different times in the Arabian gulf. Monel is a solid solution alloy that can is hardenable by cold processing. It is widely used in the different applications such as chemical processing, gasoline, fresh water containers, crude petroleum stills, pumps, propeller shafts, seawater fixtures etc. The corrosion of alloy 400 reduces when more nickel content is added.

The natural sea water was collected from Arabian Gulf, Monel plate was used. Alloy 400 rods were used for electrochemical measurements to develop the coupons for use in the sea water. To evaluate the pitting corrosion of alloy in the salt solution, the SEM and EDX tests were performed. The presence of oxygen and carbon in the alloy result in the development of oxide layer and the pit is found to be covered with this layer in addition of other materials.

An enlarged space in the pit occurred on the surface of alloy that is exposed to free aerated stagnant salt solution for 160 days. It is found that the developed pit is deep and broad with corrosion materials stacked in few regions. The presence of chloride ions increases the potential difference across the layer. The regular development of voids result into localized damage of the passive layer that dissolves faster than other components.

The affected regions were found to be enriched of copper whilst the regions around the active sites have higher nickel concentration. The corrosion of alloy 400 occurs by the specific leaching of nickel from the alloy offering a spongy copper rich material in the pit base.

The chlorine and sulphur elements present in the marine water collect in the pit and interact with iron and nickel that are present in the alloy therefore iron and nickel are slightly present in pit as compare to their real availability in the Monel alloy.

With the passage of time, the layer dissolves because of pre-immersion of alloy’s electrode in the salt solution, resulting into pitting. Pits develop in the areas where the adsorbed oxygen on the alloy’s surface is replaced by the vigorous particles for example chloride ions that are found in the Arabian Gulf sea water. It is because the choride ions have smaller diameter that allow their entrance in the protective oxide layer and replaces oxygen at the places where the metal and oxygen are not strongly connected.

The development of corrosion materials nominally secures the alloy because the potential reduced in the positive direction. The reduction in the corrosion rate is made possible by the development corrosion materials as wells as the potential of the salt solution to develop layers on the surface of alloy.

So overall the Monel alloy 400 receives general and localized corrosion in the stagnant Gulf seawater. The pitting is noticed on the alloy caused by chloride ions and dissolution of nickel. Increased exposure reduces the current and increases security potential in the negative direction. The pitting increases with increasing the immersion time length in the sea water.

Durable perforated metal solutions for aesthetic applications

Heanjia Super-Metals offers perforated sheet metals for facades, sun screens, balustrades, cladding, screening, fencing and roofing. We help you in completing your building project with perforated metals. The drawings of sheets are created for your approval before fabrication. Moreover the sheets are also made for your facade in sequence and the count of specific sheets that is advantageous when configuring sheets on the large facade project.

We not only perforated even also cut, bend and shape that is essential for the whole essential finishes. The flat perforated sheets are delivered to you or if needed, we also provide secondary operations such as cutting, bending and surface processing.  

With the higher energy demand, it is essential to focus on the reliable building design and discovering the reliable way to handle the temperature and climate conditions in the buildings. If it is for a new project or the refurbishment of an existing building, the sun screens in the perforated or expanded sheet are constructed from the reliable materials and offer an environmentally friendly solution that helps limiting the need for ventilation and quenching hence reducing the energy use.

Perforated Sun screens

The screens offer the benefit of maintaining the privacy without limiting the view. They permit sufficient magnitude of natural light in the building during the daylight.

With a large count of patterns and screen solutions for you to select from when choosing your perforated screens. If you require a single screen or several thousands of square meters, you can find individual solutions suiting your special needs.

Balustrades

When you are looking for any range of perforated project, Heanjia offers vast range of solutions to make it feasible for you easily. We offer you the privilege of perforated sheets for staircases, balconies and railings and choosing the recommended material such as stainless steel, aluminium or carbon steel.

We offer the wide range of selections in perforated metal sheets for balustrades. Using the perforated sheets for walls and roofs, it is feasible to combine aesthetic factors with the requirement for suitable sound conditions. We offer a wide range of perforating designs that are made to assist architects in designing the solutions to enhance the sound absorption as well as visual appearance of a wall or roof. Although, if you are unable to find the suitable pattern that you are seeking for, we help designing the custom pattern to suit your needs.

The perforated metal panels with sound fiber can be the perfect solution to act as sound absorber hence offering a suitable service media.

With stainless steel and aluminium perforated metal, an aesthetic solutions can be delivered for new or renovated building projects.

The fences and screens in the perforated metal are widely used beneficially in the diverse range of applications. For instance, if you need a solid and secure solution for shielding a region or if you need to make a shelter then perforated metal is the prime solution in such cases. The perforated metal offers adequate covering and flow of light and air, hence it is fully reliable for use. 

Expanded metal durability and aesthetic features

Expanded metal mesh is a uniform material that doesn’t stretch. It is very easy to deal with expanded metal sheet as it is highly slip resistant and its production is very economical.

Over the years, the use of expanded metals has been increased widely almost in all fields for example electric equipments, acoustics, firing, automobiles, vessels, machine shielding, road guards, buildings, households, shelves, bird cages and stands.

The expanded metals are commonly made from steel plate, stainless steel, nickel, aluminium, silver, titanium etc.  The common uses of expanded metals are in EMI shielding, jewellery, mechanical apparatus, filters, chemical systems and more.

Basically expanded metal is a intermediate material permitting the passage of air and light, it is more rigid as compare to plan sheet from which it is made. It is fabricated from malleable metal sheet or coil in the diamond shaped holes. These holes are in equal size throughout the sheet.

The decorative expanded meshes are made in smaller diamond sizes or equal openings.

The architectural meshes are made with special shaped openings that offer supreme appeal for architects and designers.

The special fine mesh is an accurate, mini type of traditional expanded metal that is developed from the different types of metals. The fine mesh can be flattened or raised and is delivered in coil and sheet forms.

In order to order the expanded metal, you need to specify the following designations:

Strands- It describes the metal sides.

Strand Thickness- It describes the thickness of the expanded metal that is used to fabricate the expanded sheet.

Strand Width-Magnitude of metal sent to dies to develop single strand.

Strand thickness and width- It can vary to develop various holes. The strand width should same or surpass the metal thickness.

How expanded metal is beneficial

These sheets offer natural percentage of openings. This magnitude or percentage can be adjusted to contain the architect or the specific needs of designer. By altering the pattern sizes or strand width, it is feasible to control the open area % hence controlling the passage of air and light flow according to your application needs. Moreover, the light flow can be limited by the orientation or pattern pitch.

The set of uniform angles of the threads and bonds treating as facets reflect or improve the lighting. The expanded sheet has become highly demanding among the architects as it offers special characteristic.

The expanded metal is fit for a special style or design. The extent of angles and various types of slits, stretches and indentions may also depend on application requirements. The expanded sheets for architectural, decorative or traditional purposes are slit and stretched into a durable and non-ravelling sheet. The metal twist that is noticed during its expanding results into offering greater durability and strength as compare to the original sheet of the raw material. The metal can be used for aesthetic appeal in fact also for the structural features obtained.

An expanded sheet can withstand 90 degree bend with ¼ inch in the radius in any direction without cracking. 

Hastelloy mesh for service at the elevated temperature media

Hastelloy X is a high performance nickel-chromium-iron-molybdenum alloy made for service at the elevated temperatures. It attains a combination of supreme oxidation resistance, fabrication and strength at the high temperature. Hastelloy X describes supreme ductility after prolong service to elevated temperatures about 870oC and has supreme forming and welding properties. The alloy has a significant service in gas turbine engines for burning component zones for example transition ducts, combustor cans and flame holders and heaters. It is also preferred for service in the industrial furnace applications as it has extremely great resistance to oxidation in the reducing and neutral atmospheres.

The initial step was to select the development process for the mesh, it included wire cutting, weaving and eradication from the jig. The mesh, as a reinforcement structure was developed by initial cutting and inserting wires in the jig. To develop the reinforcement structure, the Hastelloy wire mesh is developed to offer strength by weaving the warp and weft wires.

Resistance welding is a traditional electric welding process utilized by the industries. The resistance weld is attained by heat and pressure combination. The electrical resistance of the material is welded causing the localized heating in the compartment. The essential magnitude of welding period is found by material type and thickness, current and cross-sectional area of the welding tip contact surfaces. The benefits of spot welding include spot welding includes energy consumption, part deformation, development rates, automation, no need of filler materials, nominal heat supply to weld metal and expert welder.

Hastelloy X mesh maintains a uniform aperture size during spot welding; feeler wire tool was utilized to estimate the clearance among two adjacent wires when meshes were developed. For adequate stability and firmness during plasma spray, meshes were connected on the stainless steel frame.

For mesh coating with bond and ceramic coatings, a rough surface was needed. The coated Hastelloy mesh was heated for two hours at 200oC in an electric furnace to discard the soaked moisture from coating. The Hastelloy mesh offers larger aperture size than molybdenum mesh. The heat processed samples undergo isothermal and cyclic oxidation analyses, the areas of external and internal components were exposed to air. The internal parts were also developed by cutting the specimens in longitudinal and transverse directions. This test analysis is utilized for strengthening and non-strengthening materials that do not crack or failure for the external surface in the limits of a loading analysis.

An effect of static heat exposure on the cracking and damage of the material. To avoid the heat shock to the composites the heating rate of the furnace in the isothermal analyses from room temperature to 1050oC was selected as 1.8 oC per minute. At temperature of 1050oC, the shade of the specimen got orange color and subsequent to each interval two samples, sprayed and one hea processed, were eradicated for metallographic test.

With heat cycling and isothermal tests, the processed ceramic samples were tested to find changes in their appearance. The Hastelloy mesh offered good performance throughout the tests. 

Prevent Electromagnetic interference in electronic devices by Super-Metals

The challenging demand of an enclosure for electronic equipments is the potential to treat as a shield from the electromagnetic interference. EMI is basically the destruction of the electronic equipments or their components by unnecessary electromagnetic disturbance. RFI is also similar to EMI that excels over smaller area of the whole frequency band.

A circuit or equipment that conducts the electric current can develop EMI. An aim in electronic unit design is to attain electromagnetic suitability of components in a configuration and between that system and other equipments that it will face in the service conditions. A barrier is kept between a source and receptor that prevents the strength of interference acts as EMI shield.

Shielding should be performed with extreme care because inadequate use could complicate the conditions. The following shielding choices serve through reflection therefore precaution must be followed to keep the microwaves away in the correct direction from the areas of safety. Wireless equipments for example Wi-FI and phones must not be placed in the place of shielding. In few cases, shielding may cause an increase in local fields, therefore extreme care is needed to keep the conditions under control.

Increased body voltage- Usually the electric fields are not bounced back only in fact are also conducted by the shielding materials, it is extremely crucial to consider the exposure to electric field and microwaves to prevent increased exposure towards you. The wires are configured in the floors or behind the walls.

High dB security-  The shielding material must have adequate security factor to decrease the penetration of the microwaves via the shield. A security factor of 20dB is not sufficient in various situations and the leakage may result into internal reflection. Additionally, the gaps in the shield can widely decrease the shielding efficiency. The distance from the material also affects its efficiency.

The High quality Super Metals such as Silver and Mumetal can be bought from Heanjia. The shielding material can be connected to curtains to decrease the way in of external radiation into home. The shielding components have slight transparency.

Shielded cables can be utilized to decrease the exposure of electrical field. Although they may cause an increase in local intermediate frequencies, therefore it is essential to maintain the distance from the shielded wire.

To decrease the exposure level, it is preferred to ensure that sleeping areas are at some distance from the unshielded wires in the wires and walls, such as power and Ethernet cables. Select the wooden frames rather metallic frames to prevent the exposure of electric field towards you.

Not all metals are fit for magnetic field shielding. You should choose a metal with good permeability rating, like Mu-Metal. Few other materials recommended are nickel based alloys and carbon steel.

Keep in mind that shielding can be a complicated procedure, although as you are necessarily reflecting the magnetic fields. You should completely enclose the source. However this doesn’t become feasible and can be costly as well. So the thing is to either solve the problem or maintain the gap from the source. 

Resistance to oxidation by austenitic stainless steels

High focus is given to the feasibility of stainless steels with air or oxygen. However trends in the design of steam and other forms of power production have grown more interest in the oxidation in carbon monoxide and water vapor.  Subjecting to the nominal conditions to the leads of the development of security layer as mentioned earlier, however when conditions are severe, layer damage may occur. The beginning of this variation is unpredictable and sensitive to alloy’s chemistry.

Although, the reaction mechanisms are identical to in air, oxygen, water vapor and carbon dioxide reaction rates may vary considerably. For instance, identical scaling behavior has been found in air and oxygen except that scale damage occurs faster in oxygen.

Because, the results occurred in air could be implemented carefully while considering service in pure

oxygen. An increased corrosion rates can be in the presence of water vapor that creates an effect of damped air on the oxidation of stainless steel 330. The higher nickel magnitude in steel type 330 is less prone to the moisture effects therefore it is noticed that higher chromium and nickel content offers greater service temperature in damped air. The steel types 330 service supremely at temperatures above 1800oF and services at temperatures about 2000oF. The addition of moisture to oxygen significantly improves the corrosion rates of SS 304 and 316, the temperature limits can be maintained at the nominal levels.

It is hard to mention the maximum operation temperatures for steam operation, a reason is the sensitivity of corrosion rate because of surface condition, the smooth cold treated surfaces reduce the corrosion effects in the steam services. The austenitic stainless steel grades can serve at temperatures about 1600oF or 871oC at the higher temperatures.

The steel types 304 and 321 are used in the mild pressure steam units at temperatures around 1400oF or 760oC. The security layer on type 304 and 316 exfoliate at the high temperatures. The oxidation of steel grades in carbon dioxide and carbon monoxide media at 1100 – 1800oF due to their service in the gas quenched nuclear reactors. Wide evaluation on the steel oxidation in availability of carbon dioxide at temperatures above 1200oF to 1800oF were performed, the outcomes describe the oxidation in steel type 304 in Carbon dioxide at 1 atm at the different temperature limits.

The steel type 406 provides supreme resistance to corrosion by carbon dioxide at 1700oF or 927oC, specifically because of aluminum concentration. Moreover, it appears that the higher magnitude of nickel improves the oxidation resistance in carbon dioxide media. For services in CO2, the scaling temperature limits for steel types 302, 321, 347, 410 and 430 should be adjusted about 100 to 200oF or up to 93oC, although the chromium-nickel grades like concentrated stainless steel 310 and SS 330 can be utilized at temperatures for service in air.

The austenitic stainless steels offer average service in the high temperature oxidizing media. Commonly used steel grades are stainless steel 304, steel 309, steel 316 and steel type 330.

Nichrome Mesh heating applications-Dehydrator and powder sintering

Dehydrator

Domestic dehydrator is used to preserve different types of fruits, vegetables, meats etc to maintain the supply of fresh products. These contain safe heating elements such Nichrome wire mesh heating elements  with equal total wattage. The drying trays are made with metal mesh such as aluminium mesh for use as trays.

Powder sintering

Selective inhibition of sintering is essentially based on preventing the selected powder particles from sintering. Each layer development includes four steps:

a.       Laying thin powder layer: It is performed by a roller that sweeps a horizontal surface nominally above the earlier layer and takes the powder material in the front while moving in a way that its front surface creates an upward motion.

b.      Accumulation of sintering inhibitor- This step by using raster printing by a standard multiple  nozzle inkjet or vector printing with a single printing nozzle with fine orifice, sintering preventor liquid is accumulated on the chosen regions of each layer.

c.       Reducing radiation frame- It is used for transformation of powder material by reflective plates that show the essential part of every layer to radiation. Without these plates, the whole powder base is sintered.

An alternative to use masking plates is use of a passing heating bar, a radiation panel that is made from a relatively small count of discrete heating elements such as nichrome mesh that can be activated like a chosen region of the powdered layer is sintered.

Another method is sintering by a heater that is adequate to scan the needed areas of every layer with a good small and is adequate to reduce wide powder sintering.

Alternative Sintering: An alternative to sintering every layer is bulk sintering where no sintering is conducted after inhibitor use to every layer and as soon as the entire layers are processed with inhibitor liquid, the whole powder magnitude is sent to a sintering oven.

Benefits of Sintering

1.       SIS is an economical process as heating element is used. The process is quick as the whole layer is sintered simultaneously. The liming factor in speed is the inhibitor deposition process that nowadays can be performed by multi-jet print heads at good speed.

2.       The size accuracy and surface quality of the fabricated components is superior to the SLS.

It needs less inhibitor liquid to prevent sintering.

3.       Multi-color components can be developed by using the proposed process.

Many liquids that fully prevented sintering were analyzed for compatibility with heat and piezo pump

inkjet printers. An array of tests has also been conducted to evaluate the influence of time and temperature on sintering.

The inhibition process has a significant role in sintering. The process control is needed to develop extractable components with fine geometric factors.

SIS is a supreme technique to fabricate precise and dense metallic components. Different chemical inhibitors and mechanical inhibitors are used for different types of metals including super alloys. The technique depends on bulk sintering of the processed powder volume. The use of this method in manufacturing components has given rise to several studies and its future use in the industries.

Effect of hot processing on microstructure of Inconel alloy 625

The hot processing of metals and alloys results into complicated material movement in them. To evaluate their ultimate mechanical characteristics, microstructural control is essential. It is found that during hot deformation the work hardening, dynamic reclamation and dynamic recrystallzation are usually noticed in the materials with small stacking-fault energy.

Dynamic crystallization is not just an essential softening mechanism, in fact it is also a supreme method to process the crystal grain size. So, in the nickel base alloys that have high strengths at the elevated processing temperatures, resulting in to high rolling loads.

Hot rolling

The samples are initially heated up to 1200oC and soaked for half hour to receive the uniform temperature distribution of above limit prior the test. The process is repeated until the uniform temperature is received. During the repeated processes, the rolling loads were measured .

Results

However the extents of deformation were very high, but there were no cracks or damages were noticed at the edges of the hot processed samples. Meanwhile the temperature reduction after every roll pass was discovered to be noticeable. The end temperature of the first rolling pass was 1130oC and reduced to only 840oC at the 5^th pass.

Nickel alloys attain work hardening at large strains. When compared the hot rolling of the nickel alloy Inconel 625 to the superaustenitic steel 904l performed in the earlier work, the nickel alloy 625 describes a supreme resistance to deformation. Therefore the initial extent of deformation during the commercial processing of nickel super alloy slabs has to be nominal. Meanwhile the ductility of nickel alloys is supreme and doesn’t show any worry.

Inconel 625 offers good resistance to deformation that improves with each roll pass. It is caused by reduced temperature, enhanced strain rate and accumulated strain. Microstructure of alloy 625 prior hot deformation. The sample was annealed at 1200oC for half hour, then water cooling, utilized to receive a fine, uniform gamma phase with carbides solute in the matrix. It is evident that the microstructure comprises of equiaxed grains with a mean grain size of 80 micro-m and a big count of annealing twins in the austenite grains, generally for  nickel based super metals with a small stacking-fault energy.

The beginning of the recrystallization process is feasible. The recrystallization proceeds by enhancing in count and reducing in size of the new grains, developing around the boundaries and eventually showing a crucial part of the microstructure and regularly appearing at the deformation double boundaries.

Larger grain boundary mobility results in the nucleation of the twins, that treat as the main activate nucleation mechanism of crystallization for nickel superalloys deformed at the elevated temperatures. The magnitude of double boundaries improves with higher strain. During the hot deformation of small-stacking fault energy metals, the plastic deformation results into a serration of the grain boundaries. For the adequate deformation level, the serrations can results into development of new grains by bulging from the already present grain boundaries.

It is evident that structural changes occur during hot rolling of Inconel alloy 625 super alloy. The misoritentation in the deformed grains improves with the reduced rolling temperature of the deformation and increased strain rate.