Innovative mesh production for industrial end use

Metal woven wire mesh is used in almost every industry and regular life both in simple or complex form. Woven wire clothes meet the different needs of application areas such as flow filters in water taps to precision filter elements in space ships. Heanjia is a leading mesh weaver for more than three decades. We develop woven wire mesh for use in filters and fabricated devices meeting the extreme standards. The mesh are used in aerospace, aviation, automotive, electrical, engineering, health, chemicals, water purification, machine construction and plastic processing. We offer tailored solutions for your efficient process, lasting performance and good quality service.

The material shape and function are closely related in filters and produced components from woven wire. We plan, design and develop woven wire mesh from nickel, titanium, copper and corrosion resistant and heat resistant materials such as Hastelloy, Nichrome, Monel, Copper-Nickel alloy, Inconel, Incoloy and other materials. We meet customer demands for end uses, offering innovative solution for your applications and components. It includes woven mesh for automation solutions and dedicated production and testing.

We are regularly extending our technical limits to produce innovative hastelloy mesh productsfor your requirements. A requirement for this is our specialization in manufacturing, finishing and treatment of wire mesh. With our extreme understanding of the whole manufacturing process, we become able to meet customer’s needs precisely and assure the highest product quality.

Heanjia has become a leading manufacturer of mesh products for industry, technology, architecture and medical. With experience in mesh processing and our professional engineers we become able to make long term relationship with our customers.

Our controlled production process begins with our own design and manufacture of machines and extend through our controlled production conditions. It includes clean conditions and regular process control. We have extreme knowledge of our production process that not only ensures high product quality even also allows us to develop special weave types to meet our special customer needs. High production capacities with a wide product range held in stock, offers us the assurance of supply to our customers.

With meticulous process planning and technical studies, we offer quality assurance and accurate matching of products with your requirements. Our team implements the concepts and your requirements by using advanced systems. Your orders are evaluated and ideas are implemented to the end product. It includes production desired tools, devices or machines if needed.

Besides of drawing, our machine and tool designs use data for turning, milling, electric discharge machining of stamping and deep drawing. After processing is performed by using advanced systems and machine technology, high end cutting machines, mechanical and hydraulic presses, welding units and injection moulding method. All types of heat treatment processes are conducted in our production units. Ultra cleaning is ensured by our cleaning units.

We offer wire mesh products for diverse applications such as:

·         Automobile

·         Chemical

·         Casting

·         Machinery

·         Electrical engineering

·         Household equipments

·         Plastic processing

·         Food Industry

·         Aerospace and aviation

·         Medical field

·         Water purification

·         Filtration and Screening

Production process of Hastelloy C-22

Wrought forms of alloy C-22 are delivered in solution heat processed conditions as a standard production. The standard solution heat processing comprising of heating at 2050oF after quick air cooling or by water. Components that have been hot formed or vigorously cold developed must be solution heat processed before further development or installation.

Alloy C-22 offers supreme forming properties. Cold forming is a recommended procedure of forming. Due to its good ductility, it can be easily cold processed. The alloy is normally stiffer than austenitic stainless steels. Hence more energy is needed during cold forming.

Welding

Hastelloy C-22 is readily welded by gas tungsten arc, gas metal arc and shielded metal arc welding methods. It offers welding properties equivalent to Hastelloy C276 and Alloy C4. It is not fit to work with submerged arc welding due to large heat supply to the base metal and slow quenching of the weld. Base metal development includes complete cleaning of joint surface and neighbor area prior to welding. Grease, oil, crayon marks, sulfur compounds and other foreign matter must be eradicated.

Similar composition filler metal is preferred for welding of Hastelloy C22. For gas tungsten arc and gas metal arc welding, Hastelloy C22 filler wire is preferred. For shielded metal arc welding, C-22 covered electrodes are preferred.

Various corrosion damages are connected with welds. Consistent, economical and practical solutions to corrosion weld problems involve the use of Hastelloy C-22 filler metal. Tests were performed in a simulated incinerator off-gas scrub solution for a month. Inconel 625 received vigorous base metal and weld metal corrosion in this condition. Average corrosion of the base metal was noticed on Al-6XN alloy. Hastelloy C22 didn’t receive any corrosion.

A concern about alloy’s sensitivity to intergranular corrosion is the heat affected region of weldments. Welded test coupons of alloy C-276 and C22 were subjected to an oxidizing sulfuric acid process solution. Alloy C276 experienced unusually severe base metal, weld metal and heat affected region corrosion in this specific environment. Actually just 1/3^rd of the sample thickness in the heat affected region could withstand the corrosion. Alloy C276 alloy is nominally corroded to this level in other environment. There was nominal corrosion on the alloy C22 specimen.

For machining of Hastelloy C22 bar, following guidelines should be used. Specific details may vary depending on circumstances of the job.

Drilling- Carbide tools of C2 alloy should be not be used however tipped drills may be significant on rigid setup of moderate depth. The web should be thinned to decrease thrust. Use 135o included angle on point, gun drill can be used.  Oil or water base coolant can be used. Coolant feed carbide tipped drills may be suitable in some processes.

Normal Roughing, Turning or Facing- Grades C2 and C3, negative rake square insert, 45 degree SCEA, 1/32 inch nose radius.

Finishing, Turning or Facing- Grade C2 or C3, positive rake square insert, if feasible, 45 degree SCEA, 1/32 inch nose radius.

Sintered wire mesh for enhanced particle retention in filters

Multi layered sintered mesh are now being widely used to meet the challenges of modern demanding filtration applications. These innovative solutions offer a wide range of benefits that usually more than justify the higher cost price with enhancements in efficiency and durability.

Depending on several years of experience, Heanjia offer a selection of standard products made to meet the needs of a great range of industrial applications. Although specific challenges may opting for a bespoke solution considering the materials and weaving style.

We use only the highest quality raw materials for our products. They are made in dust free, air conditioned plant rooms, by using state of art equipment and highly precise weaving machines that we have made ourselves in-house. When combined with our comprehensive quality control procedures, we can ensure the highest levels of quality, cleanliness and freedom from defects.

Carefully chosen wire clothes are brought together and sintered by heating and pressurizing. This process efficiently combines the benefits provided by every individual layer and offers suitable filtration properties. Sintered wire mesh clothes developed in this way result into the finest filtration results and are also resistant to physical loading, thanks to the robust mesh structure. The smooth surface also offers cleaning processes like back-wash.

The finest sintered mesh filters are particularly suitable for service at high pressure and vigorous service environments. Security layer of square weave mesh, secures the filter mesh against damage. The filtration layer specifies the filter fineness, drainage mesh, distribution layer, inner support mesh, square weave mesh and outer support mesh.

Sintered mesh compensates the reduced rigidity of fine filter clothes. Pairing a filter cloth with a square weave support mesh offers stability at moderate pressures combine with suitable backwash characteristics. A small count of layers refers to decreased pressure loss with suitable backwashing. Sintered mesh filters are fit for separation of solids –liquids, surface filtration for particulate separation, sieve plates, aeration filters, hydraulic filters, backwash filters, cleaning baskets for small components.

Heanjia designs premium quality sintered mesh screens for open hole and closed hole completions with or without a gravel pack. They are produced and tested for robustness, reliability, sand control efficiency and longevity in vigorous production conditions.

Sintered mesh screens are among the top quality mesh screens made with small external diameter. This combination allows operators to evaluate the completion geometry of a gravel pack during the design and execution of the operation and it sometimes permits the selection of larger screen for stand-alone screen completions.

Mesh screens have an internal drainage layer that offers a uniform standoff between the filter medium and basepipe and external drainage layer that offers a uniform standoff between the filter medium and a security shroud. The two drainage layers ensure uniform flow over the surface area of the filter medium.

A premium sintered woven wire mesh offers an efficient performance for filter medium and overall screen production. It is made of multiple layers sintered, that increases particle retention and plugging resistance. Sintering increases strength and mechanical stability of the mesh and locks the engineered pored geometry, ensuring that pore holes do not change during installation or production. A ring separates and secures the mesh from heat during the welding of base pipe.

Success of electric arc spray in Power generation plants

Higher power production with reduced downtime is a major challenge in most power plants. Thermal spray technologies for example arc wire spray are commonly used in the power production repair units. The electric arc spray wire process offers economical and possible coating options that encourage affordability and reliability of power production units that run with maximum capacity for several months.

Thermal spray coatings increase service time and life of a boiler steam based power units. Production water wall tubes and super heater banks that experience attacks of sulfuric and vanadium gases in coal-fired boilers, get extensive increase in their service when sprayed with coatings. When application requirements allow the use of electric arc spray process, the coating significantly increase the service life. Arc sprayed materials are widely in use in global boiler applications including high chromium based nickel alloy for longer life of coal based boiler tubes and Iron-Chromium alloy that has very high hardness is fit for the coal fired boiler condition and a matrix nanocomposite material is used in flu gas component of the boiler.

Introduction and application of thermal spray techniques is fully accepted for service in main tube components of boilers. A venture to extend these benefits to critical systems is now under analysis. By increasing the scope of thermal spray applications, the overall lifecycle of the whole boiler can be enhanced. Boiler systems are made from fly ash handling unit, induced draft fan and fuel handling unit.

Various solid fuels are used in power units such as coal. Considering the alternatives to fossil fuels, wood and trash fuel sources are receiving increased popularity. The main trouble with solid fuels such as coal, wood or trash is the large magnitude of particulates that carry flue gas path from the fire box to the exiting stack, causing wide erosion of several components. This factor of the process causes more complications.

A crucial ask in power production facility is to keep up environmental discharges at ideal limits. An example of this emission factor is opacity limit- magnitude of particulate matter that travels through the whole flu path and is released into the atmosphere through smoke stacks. To maintain the opacity level in a specific essential level and reuse as potential energy from the fuel source as feasible , fly ash is re-sent back in the boil before to the induced draft fans through a classifier that separates the exiting char. The re-supplied char moves back to the warmest area of the furnace and moves through the remaining flue gas before it is fully burned to a size beyond the limit of classifier and into the exiting particulate scrubber unit before leading to plant’s exit point.

In wood fire units the resupplied char is very abrasive. It can adversely affect classifier components and cut deep grooves in the re-injection pipes, creating poor flow that causes beyond the acceptable limits of opacity discharge. Users of thermal spray technology in boiler repair field encourages the applications in addition of coating the boiler tubes to increase the life of power production systems. 

Expanded metal sheets for unique and exceptional building designs

Expanded mesh is a featured material for both transparency and shading due to its 3D effects. It helps with the development of advanced screening solutions to control the flow of light in day time. The shade offered is extreme when the sun is at highest point. The frontal opening of mesh increases the magnitude of incoming sunlight while offering an open view to the external world. It makes the building rooms bright and less warm simultaneously.

Sunlight based on position, angle of facade, climate and time during the day describe the extent of light passing through expanded sheet.

People’s safety is the main objective of architectural design that complies with the whole industrial regulations. When the correct fastening techniques are followed, expanded metal sheets provide a safe solution for use and application. This suspended offers a sense of solid security because of durability of the material. So expanded metals are a secured solutions for:

·         Protecting people

·         Isolating risks

·         Prevent Damages

Load handling capacity following the standards for walkable surfaces are certified for technical construction standard. Suitable security is also offered for the stairs. Additionally grating ensures non-slipping.

Aesthetic appearance and durability

Prolong experience with designers and architects has enabled Heanjia to design exceptional quality expanded metal screens with infinite range of possibilities and specifications in addition of protection from corrosion.

Strength

Expanded metal utilized in the construction sector and architecture is made to prevent loads of wind and snow. The open expanded metal is suitable for applications that need ventilation and air flow like car parks, utility rooms and transit areas.

Vertical Elevations

Creativity, prestige and impact. The benchmark project performance is introduced by a choice of unique cladding. Expanded mesh offers excellent aesthetic appearance to buildings in the landscape for which it has earned wide interest of architects.

Versatility

The featured aperture of expanded metal mesh, effects of transparency and light make it fit for showrooms, stands, partitions and trade fair. A functional and beautiful way to divide areas by adding folded panels, customizable sheets. It inspires new ideas regularly.

Comfort and elegance

In office, workshop and everywhere expanded sheet suspended ceilings are installed to meet the project needs. Ceiling solutions enhance the beauty of the room. Attractive colors and quality finishes are perfect for a modern look or to develop a contrast with a classic style. A great range of mesh patterns for an advanced appearance.

Protection and uniqueness

Whether big or small, expanded metal fences are key elements to improve the project design. They also feature engineering projects to protect people and need to be properly designed keeping his characteristic in mind.

Heanjia is specialized in designing and engineering the expanded metals for various projects such as research and innovation with exclusive processing methods. Surface of any mesh shape and size can be made. Expanded mesh can be cut, folded and curved. These are made in standard sizes, customizable sizes are also produced upon order. Expanded mesh catches an eye with geometric perceptions and individualized colors. 

Behavior of Monel 400 bar in Gulf water and NaCl solution

Nickel-Copper alloys are extensively used as corrosion resistant materials in marine industry. The corrosion rates of these materials steeply decreases with increase in nickel concentration. Corrosion performance of Monel 400 in naturally aerated and deaerated Gulf water and 3.5% NaCl solutions was assessed.

Monel 400 is widely used in desalination industry and other marine fields. Since Monel 400 consists of 60 to 70% nickel, 20 – 29% copper and nominal magnitudes of iron, manganese, silicon and carbon. Monel 400 has properties of supreme corrosion resistance, good weldability and good strength. So, it is commonly used in diverse applications for example chemical processing units, gasoline and fresh water tanks, crude petroleum still, valves and pumps, propeller shafts, marine components, electrical and electronic components, deaerating heaters, process vessels and pipes, boiler fed water heaters and heat exchanger.

Low corrosion rate in running brackish or seawater combined with corrosive media encouraged the use of Nickel-Copper alloys in marine applications, oil, chemical processing industries such as non-oxidizing chloride solutions.

The corrosion of copper-nickel alloys in natural seawater and chloride environments in different conditions has been evaluated. It is found that corrosion rate of Copper-Nickel alloys significantly decreases with increase in Nickel concentration in alloy. Although corrosion resistant Monel 400 bar contains 70% nickel and has the potential to withstand vigorous media, it should not be used in stagnant salt water.

Seawater is a combination of inorganic mixtures, gases, solids, organic materials and creatures. Gulf seawater contains salts of sodium, magnesium, potassium, calcium and strontium and has high concentration of chlorine and sulfate ions. Oxygen dissolved in water also increases its corrosive nature however in desalination and oil well plants, the seawater is not much vigorous to many application materials.

Experiment

Monel 400 bar and sheet were used for analysis. An electrochemical cell with triple electrodes was used for measurements. Monel rod was used as an electrode, it was grinded and polished and then washed with double distilled water, degreased with acetone, washed again with distilled water and dried.

In deaerated media, Monel 400 electrode was kept after the solution was purged with pure nitrogen for 60 minutes and the cell was placed purged above the solution before the analysis ends. It was followed for the entire deaerated experiments to prevent oxygen penetration in AGW and NaCl solutions during the tests.

Results

Monel 400 was placed in solution for 60 minutes in naturally aerated solution of gulf water and NaCl solutions. Anodic reaction of alloy 400 is a selective dissolution of nickel, specifically at high potential points. Increase in applied potential value decreases the development of passive oxide layer or the accumulation of corrosion products on the surface of electrode.

Pitting corrosion on Monel in both seawater and NaCl solutions was due to chlorine ion and selective dissolution of nickel caused the development of pits. It is found that Gulf seawater is more vigorous than 3.5% NaCl and deaeration process reduced the corrosion of Monel in both environments. Pitting corrosion of Monel in AGW was faster than in NaCl solution.

Aerospace functional alloys for stiffness and wear resistance

Aerospace and space industry has been traditionally known for development and introduction of latest material systems and development techniques. The main driving factors for materials development are weight loss, application oriented function enhancement and decreased costs. Application of latest engineering materials has wide impact on both economical and ecological problems.

Aluminum alloys basically cover cryogenic and moderate high temperature range applications. Material strengtheners are used where high stiffness and wear resistance are needed. Titanium alloys are used in the temperature limit of about 500 to 550oC.

Aerospace industry always demands for the advanced materials for challenging performance needs of a component that is often a integral part of a complex technical system. The major issues to be fixed by advanced material development are material characteristics, fabrication and costs. Component performance in this sector is basically determined by mechanical characteristics for example strength, stiffness and damage tolerance and physical and chemical characteristics like density, corrosion resistance at ambient and high temperatures. Using suitable development methods have a special role with regard to material properties and costs and may hence eventually determine whether an advanced material will find application. Nowadays life cycle costing has been referred as an essential tool to determine the economic feasibility of the material.

The major driving forces for engineering materials development in aerospace and space industry are weight loss and high temperature capability. Weight loss is effectively done by decreasing density. Additionally weight loss of a specific component can develop a snowball effect if the airframe and engine of aircraft allow using less stringers, a downsized engine, small wing and more. For aircraft, similar benefits related with a loss of fuel consumption are achieved by improving the efficiency of engines through higher turbine inlet temperatures. However a large count of additional criteria is stressed for every application, materials are usually categorized according to their properties. Aluminum and titanium based alloys are the recommended lightweight aerospace alloys.

Aluminum alloys are utilized at room temperature and in cryogenic applications, enhancing the high temperature properties and the corrosion resistance of these alloys. Titanium alloys are used when lighter weight aluminum alloys do not fit in the needs of strength, corrosion resistance and high temperature needs. For use at temperatures of about 800oC Nickel base alloy Inconel 718 wire are used as the prime materials in aeroengines in a condition where high temperature capability and high strength are needed. Single crystal turbine blades show state-of-art technology. Besides of their use in high temperature applications, they are continuously finding new applications in structural parts.

Normally the material characteristics can be tailored to the required component application by change in processing. Certainly no other metal is more closely connected with aerospace industry than titanium. Titanium alloys offer supreme corrosion resistance and excellent strength to weight ratio. In addition of strong efforts to increase the part in general industrial market the largest part of produced titanium still goes into aerospace industry.