Decorative Wire Mesh- Providing gorgeous looks & aesthetic appeal to the surroundings

Aluminum Wire Mesh is widely used in a variety of decorative applications including cabinetry, signage, radiator covers, room dividers, automotive grills and lighting fixtures. The use of mesh for decorative purposes is subjective and largely dependent upon the user’s preference and vision. It is necessary to choose a material which is suitable for a particular application and to determine the mesh or opening size. There is a wide range of wire mesh specifications used in various decorative applications. Stainless steel meshes are popular for automotive grills. Copper, brass and bronze are popularly used for cabinetry. Plain steel, Stainless steel and Copper are popularly used for radiator covers and similar applications. Various metal meshes are used for signage, room dividers, light fixtures etc. Wire meshes can be customized to various specifications as per the special decorative applications of customers.

Monel 400 is a uniquely strong and durable material made of copper and nickel. This alloy has high strength and excellent corrosion resistance in a wide range of media including sea water as well as acidic and alkaline environments. Monel 400 wire is drawn to specific diameter wire and woven to certain specifications for fulfilling the requirements of various industries. Monel woven wire mesh is used in marine applications, chemical and hydrocarbon processing equipment. It is also used in valves, shafts, heat exchangers, pumps and fittings.

Aluminum alloys are widely used in the wire mesh industry and these alloys are made of aluminum, copper, manganese, magnesium and silicon. Aluminum woven wire mesh is lightweight and is corrosion resistant in numerous normal environments. Aluminum has numerous benefits including an estimated melting point of 1218°F and a relatively low cost as compared to other meshes. Aluminum woven wire mesh is a popular choice for numerous industries including aerospace, marine, automotive and electrical conductivity applications. The inclusion of magnesium in the Aluminum alloys provides strength and offers excellent corrosion resistance in marine atmospheres.

The utilization of architectural metals offers a unique look with various textures and designs to add beauty and functionality to any facility. Custom designer wire mesh is fabricated for both residential and commercial owners. A stunning designer mesh can be customized to compliment a person’s style and budget. Wire mesh is customized into various wire mesh options including unique architectural wire mesh for the client’s unique requirement.

Decorative Wire Mesh is a step above the ordinary use of a variety of shapes, textures and patterns. It provides style to walls and ceilings by creating a much-appreciated textural appeal. It is used to develop beautiful architectural elements when installed on facades of buildings. Woven wire mesh as decorative mesh is incorporated into signs, railing infills, plant screens and numerous other applications. Woven wire mesh is used to make decorative screens or grilles for various applications. These screens are widely used within radiator cabinets and are also seen in wall units, air conditioning units, loudspeakers or within other products requiring a screen for decorative purposes.

Window Screen Supplier- Elegant & excellent protection against insects, pests & pets

Window screens are customized into various sizes and specifications for use in various commercial and residential applications including homes, hotels, schools, apartment buildings and businesses. Security screens are manufactured with either 0.023 or 0.028 Stainless steel wire of the highest quality. The wire is painted to provide aesthetic appeal and standard framing finishes are white, bronze and mill (bare). Customized colors are also available as per the customer’s request. Window Screen Suppliers manufacture Security window screens which are attached directly to the existing window with a continuous piano hinge. These can be either top hinged, side hinged or middle hinged so that screens are opened for emergency exit or for easy cleaning of windows.

Fixed Panel Security Screens are used to provide security for the apartment buildings, residential homes, college housings and commercial buildings. These panels attach easily over existing windows where there is no need of hinge open. There is a continuous lip for easy installation on the frame. Security screens are used for doors, vandal resistant, windows, storm windows. These security screens are used on Government Housing Agencies to withstand the tough and destructive situations. These screens help in keeping the insects out of the building and reduce the risk of broken glass from rock throwers and constant replacing of screen wire because of tear. Security screens are manufactured from the high quality heavy gauge Aluminum made to the required specifications. These window screens are made from extruded Aluminum frame and Stainless steel 12 x 12 mesh in 0.028 Stainless steel. These security screens are available in a variety of frame options and colors including silver or black Stainless steel mesh.

Hinged Panel security screens are used to provide security for various types of residential and commercial buildings. The hinged security screens latch from inside and hinge open for easy exiting of window in case of an emergency. There are various designs available including hinge from top, side or center. There are various master frame and wire options available. These security screens help in keeping the insects and vandals out while providing the emergency exit where required.

Window screen suppliers also produce pet screens which are resistant to tears and damage caused by household pets. These window screens are available in various colors including black and gray. Pet screen is a heavy duty solution that can allow you to provide protection against six- and eight-legged pests. Pet screens can withstand teeth, claws and other stresses that pets put on screens making it perfect for replacement window screens and screen doors. Pet screens are also ideal for other projects that require heavy-duty structured materials. Pet screens are used for making a hammock, bags, patio furniture, pet beds, hats and more. Pet screens are available in various traditional window screen mesh colors.

Super screens are less durable than pet screens however these screens are tough enough to withstand wear, hail and tear of pets and can reduce solar heat and UV rays. Super screens are available in rolls, complete window screens and unassembled and assembled sliding screen doors.

Tungsten Mesh- Excellent material for electronic applications

High purity uniform shapes Tungsten Mesh and Chromium plated Tungsten Mesh is widely used as screen or gauze. Standard size ranges from 0.75 mm to 1 mm to 2 mm diameter with strict tolerances and alpha values (conductive resistance) for uses such as gas detection and thermometry tolerances. Custom wire alloys and gauge sizes can be fabricated upon customer’s request. Crystallization, solid state and other ultra high purification processes such as sublimation are used to produce materials. Custom compositions are produced for commercial, research and new proprietary technology applications. Rare earth metals and most other advanced materials are cast into various forms including bar, rod or plate through processes such as nanoparticles and in the form of solutions and organometallics. Tungsten is also produced as ingot, pellets, granules, powder, pieces, discs and compound forms such as oxide. Other shapes can be customized as per request.

The slow positron yield has been measured for various tungsten moderator samples from a 22Na radioactive source. Investigation of multi-folded tungsten mesh, W(100) single crystal foil and W polycrystalline foil samples was performed. It was observed that the fast to slow conversion efficiency of the tungsten mesh moderator depends upon the annealing pretreatments, the number of folding layers and the chemical etching duration. An optimal efficiency of 1.2 x 10-3 was achieved with 5 min etching duration and a folding number of 12 layers with the raw tungsten mesh material having a wire diameter of 20 μm and transmission efficiency of 92.5%.

Tungsten wire mesh has high physical stability and print repeatability. This mesh has high tensile strength, lower elongation and consistent quality to fulfill various technical demands of screen printing applications in the electronics and photovoltaic markets. Tungsten has high melting point and high corrosion resistance. Tungsten has high tensile strength at temperatures over 3410°C and is environment friendly.

Study was done of the structural and phase transformations in tungsten-containing functional coatings of carbon steels obtained in high-energy processes of implanting tungsten carbide micropowders by the method of complex pulse electromechanical processing. It is observed that an intensive austenization of steel occurs with the dissolution of a powder of tungsten carbide with the subsequent formation of composite gradient structures as a result of the decomposition of supercooled austenite supersaturated with tungsten both by the diffusion mechanism and by the spinodal decomposition mechanism during thermoforce action in the deformation zone. It was found that individual zones of the tungsten-containing phases of the alloy were in the liquid-phase state and underwent spinodal decomposition with the formation of highly disperse carbide phases of globular morphology.

A study was done of the metallic meshes for space antenna transformable reflectors. Optical characteristics of four metallic meshes (15 micron tungsten, 15 micron gold-plated tungsten, 20 micron molybdenum, and 50 micron Ni-coated steel) were investigated with the Nikolet IS50 spectrophotometer. The spectral optical characteristics of these metallic meshes in the range from 0.4 to 2.5 microns were required for thermal design of space antenna reflectors.

Thermal Spray Wire- Excellent material for boilers

The nickel alloy coatings produced have high structural integrity, are dense and can tolerate elevated temperatures and oxidizing atmospheres. The addition of chromium enhances high-temperature corrosion resistance. These wires are used as bond coatings and for machine element restoration. Nickel-based alloy thermal spray wires are used for bond coatings under ceramic top coatings and exhibit particle erosion resistance at high temperatures. These thermal spray wires are suitable for oxidation and hot gas corrosion at elevated temperatures. These wires provide salvage and build-up of machinable carbon steel and corrosion-resistant steels. Nickel-based alloy thermal spray wires are used as salvage and restoration materials for nickel-based superalloy components. These wires are suitable for corrosion resistance in oxidizing and reducing environments such as for use in boilers. These thermal wires are used on digesters.

Coatings have high bond strength and ideal in bond coat applications. Coating properties vary significantly as these are dependent on the chosen equipment, coating parameters, gun hardware and coating thickness. These coatings have resistance to ionic corrosion and deposit efficiencies of 65% or higher can be achieved when correctly sprayed. These coatings are machined or ground when dimensional control or a smooth surface finish is needed. The SmartArc PPG gun is advised when electric arc wire coatings with the lowest possible oxides are needed due to its ability to use other types of atomizing gases such as nitrogen.

The investigation of corrosion behavior of high velocity combustion wire sprayed coatings was conducted. 

The investigations on thermally sprayed Hastelloy C276 and stainless steel 316L showed that the applications of cathodic coatings for corrosion protection was limited and needed an additional sealant to decrease the amount of pores and cracks. Differences could be revealed with respect to spraying conditions by comparing coatings processed with a variety of spray systems. Finer microstructures with less interconnecting pores or cracks were achieved using high velocity spray systems such as HVCW and HVOF, therefore these coatings showed a better corrosion resistance than coatings produced by conventional flame spraying or arc spraying. All coatings showed a significantly less noble corrosion potential compared to the respective bulk material which could be attributed to compositional changes during spraying. The oxygen contents notably differed (ranging from about 2 to 7 wt. %) with respect to spraying conditions and had minor influences on the corrosion potentials of detached or sealed coatings. Thermal sprayed cathodic coatings showed a smaller corrosion resistance and higher corrosion current than respective bulk materials. It was observed that the corrosion protection by passivation was less effective than for bulk material. On comparison of sealed coatings achieved by various spray methods, the results showed that a sealant in case of very high porosity couldn’t avoid under-corrosion. Therefore, dense coatings produced by high velocity processes such as HVOF and HVCW spraying were needed for improved corrosion protection.

Thermal Spray Wires are mainly used in the Electric Arc Spray Process and the Flame Wire Spray Process. Hastelloy C276 thermal spray wire has excellent high temperature oxidation and corrosion properties. It is good for repair and build-up of similar chemistry super alloy components.

Arc Spray Wire- Excellent adhesive and bond strength

The module of elasticity is an essential mechanical property defining the strength of a material which is a prerequisite to design a component from its early stage of conception to its field of application. Mechanical properties of the deposited layers differ from the bulk material due to the anisotropy of the highly textured coating microstructure when a material is to be thermally sprayed. The overall performance of the coated component is influenced by the mechanical response of the deposited layers. Therefore the evaluation of the effective module of elasticity of the coating is necessary. Various conventional experimental methods have been investigated and their results vary due to inhomogeneous characteristics of the coating microstructure. 

An alternative method to determine the coating anisotropic elastic behavior dependence on crystallographic orientations is the synchrotron radiation coupled with a tensile test rig. Inconel 718 HVOF coatings sprayed on IN718 substrates were investigated. A deeper understanding of the nature of the HVOF coating Young’s modulus is yielded by a combination of these experimental techniques and thus a tool for Design Practice for repair applications.

Wire spray offers low cost, high porosity, unmelted particles, oxides and low to moderate bond strength. Arc spray wire has high adhesive and bond strength. It involves formation of a quasi alloy coating by using two pieces of dissimilar metal and alloy wire rods. It offers high spraying efficiency and spraying by all metals which can be wire rods possible. There is no deterioration and changes found on the materials to be sprayed due to low temperature spraying. It has excellent oil retaining property and sliding wear characteristic due to pores within coatings.

The properties of arc-sprayed aluminum on alloyed armor-grade steel were examined. EuTronic Arc Apray 4 wire arc sprayer was used to conduct a thermal arc spraying. Dense, abrasion- and erosion-resistant coatings approx. 1.0 mm thick with and without nickel/5% aluminum-buffered subcoating were produced using an aluminum wire 1.6 mm in diameter. Aluminum coatings were characterized according to ASTM G 65-00 abrasion resistance test, ASTM C 633-01 adhesion strength, ASTM G 76-95 erosion resistance tests, HV0.1 hardness tests and metallographic analysis. Results showed the properties of arc-sprayed aluminum and aluminum-nickel material coatings that are especially promising in industrial applications where erosion-, abrasion- and corrosion-resistant coating properties are required.

Combustion with energy recovery of post-recycling municipal solid waste (MSW), also known as waste to energy (WTE), is the only proven alternative to landfilling. WTE avoids landfilling and methane emissions to atmosphere and reduces the volume of MSW by 90%. Corrosion on the superheater tubes is a major concern in the WTE industry which is related to the relatively high concentration of chlorine (0.47-0.72 wt %) in the flue gas and the formation of alkaline salts and sulfates. The operation of WTE plants is affected by the corrosion due to the cost and time needed to repair or replace the superheater tubes. High temperature corrosion (HTC) is prevented inside the WTE boilers by applying numerous coating techniques including laser claddings, thermal spray coatings, weld overlays and fused coatings.

China Insect Screen- High protection & aesthetic appeal to the surroundings

316 Stainless Steel Insect Screens are used in HVAC systems to provide a barrier against the migration of insects either into or out of a controlled space. These screens are commonly known as “thrip screens”. Stainless steel insect screens are used as a biosecurity measure in AQIS regulated facilities or laboratory spaces requiring physical containment or barrier protection against insects, specifically those that will burrow through existing filter media such as mites and thrips. Stainless steel insect screensare used in various applications including insectariums, hospitals, quarantine facilities and research laboratories. These insect screens are manufactured using 250 micron, 316 stainless steel mesh and a 316 stainless steel holding frame. Another holding frame material option is 304 stainless steel. Stainless steel insect screens offer easy installation using holding frames that embody mounting studs. The insect screens are fixed directly to the studs in the holding frame and secured with stainless steel wing nuts. The insect screens are also mounted to the holding frame using a holding tab mechanism that utilizes studs and clamps.

Stainless steel insect screens are used for windows in homes, offices and other buildings. These insect screens are made with innovative designs so that these match the décor of the homes and other buildings. These insect screens offer security, archtitectural appeal and unobstructed views. These screens are made of stainless steel wire mesh compressed and secured with 15000 pounds of force in heavy-duty aluminum frame, especially for security. These security screens are powder coated 0.28″ diameter wire with 12 weaves per square inch for long lasting durability. These stainless steel security screens are made as per industry impact force standard with tensile strength of 800 lbs. per linear inch. Screen mesh filters out harmful sun rays so that home stays cool and doesn’t fade. These screens can also have emergency escape release system that is safe and easy to use. These security screens can be easily installed over existing window and have an overlap mount for the best protection. These insect screens are tamper-proof and provided with 1-way installation screws.

There are insect screens made of 304 stainless steel screen mesh and cage mesh with PVC body. These screens have flow area equal to 100% of pipe area and adapts to existing vent pipes. These insect screens are helpful in preventing bugs, birds and small animals from nesting in vent pipes. These insect screens also prevent malicious introduction of liquids and other matter. The wafer design of these insect screens minimizes space requirements. These insect screens provide 100% flow area and have an excellent corrosion resistant construction. These insect screens are available in sizes 4″-12″ and are installed in vault or reservoir vent pipes.

Retractable pleated insect screens made of stainless steel are made in innovative designs so that these screens fit into large openings. These insect screens are made considering the functional aspects as well so that these screens provide protection against various kinds of intruders including insects.

Mesh Cathode- Highly useful for producing wires

The objective of this work is to produce electrolytic Copper powders by electrorefining and electrowinning techniques in a new cathode basket is the aim of this work. Different cathode materials such as Copper, Aluminum and Stainless steel in the form of baskets were subjected to pure lead anodes for electrowinning process and pure or industrial Copper anode plates for electrorefining process. It was observed that Aluminum cathode basket is the most preferable basket material for deposition of Copper powder using both electrowinning and electrorefining techniques. Major drawback of Aluminum basket is the contamination of Copper powder with Aluminum after a long period of electrolysis process. As per the indication from scanning electron microscope analysis, pure and fine Copper powders with dispersive shapes from electrorefining process and dendritic shape from electrowinning process were obtained.

 Copper and its alloys are highly useful due to various properties including high thermal conductivity and high electrical conductivity. It also offers ease of casting, rolling, extrusion and drawing to produce tubing, wire and strip. It has low corrosion rate of copper when used for food preparation. It has high aesthetic appeal, excellent alloying characteristics and low toxicity to humans. Copper is used for making ornaments, coinage, tools and pots for cooking. Copper and brass, a copper-zinc alloy is used to make ornaments. Copper is highly used in an electrical conductor and about 50% of the current demand is for electrical uses. Copper has a very high electrical conductivity per unit volume and can be drawn readily into single or multifilament wires bent readily and repeatedly without excessive work hardening. Copper is readily tinned and has good soldering characteristics. It has resistance to corrosion at contact points.

Wires can be produced from copper mesh cathodes. An admiralty brass is an alloy with 71% copper, 28% zinc, and 0.75-1.0% impurities has resistance to salt water corrosion therefore is extensively used in ships. Fire-refined copper is used for noncritical applications such as bar stock, water tubing and ingots for alloying. Copper is produced by electrorefining or electrowinning techniques for use in electrical applications. All copper produced from ore receives an electrolytic treatment at some stage via electrorefining from impure anodes or electrowinning from leach or solvent extraction liquors. Electrorefining produces the majority of cathode copper ca. 95% as opposed to ca. 5% from electrowinning. 

The electrorefining process eliminates unwanted impurities. Cathode copper has purity greater than 99.9% wt Cu, with less than 0.005% total metallic impurities. Electrorefining process separates valuable impurities which can be recovered in other processes. The main technical factors in electrorefining are the cathode purity, the production rate and the specific energy consumption. The anode quality, electrolyte conditions and cathode current density affect these factors. The process for electrorefining copper is typical of those carried out in aqueous solution. The electrolyte is copper sulfate (0.7 molar) and sulfuric acid (2 molar). Metals that are likely to be found as impurities are considered in order to see how copper is purified. Ag, Au and Pt are noble than copper and therefore will not dissolve anodically but will be found as metals in the anode slime.

Inconel 718 wire- Excellent corrosion resistance and tensile strength

Inconel 718 is an alloy of nickel-chromium-niobium- molybdenum that has high corrosion resistance, strength and excellent fabrication characteristics. This alloy has high tensile strength and excellent yield & creep-rupture properties at high temperatures. This alloy can operate at cryogenic temperatures up to 1200°F. Inconel718 wire has applications in valves, springs, aircraft and land-based turbine engines. This alloy is used by various industries including nuclear, automotive, oil, nuclear, gas, defense and aerospace.

Nickel-based superalloys such as Inconel 718 are used in nuclear, aerospace and chemical industries due to their excellent mechanical and chemical properties at elevated temperatures. Nickel-based superalloys compose over half of the materials used in the aerospace industry, in particular for the hot section of gas turbine engines for components such as blades, turbine disk, combustors etc. Inconel 718 has low thermal conductivity that increases the thermal effects during machining. Inconel 718 often exhibits strong work-hardening behavior, high adhesion characteristic onto the tool face altering cutting process parameters completely when machining. This alloy may contain hard abrasive particles and carbides that create excessive tool wear and hence the surface integrity of the end products can be disappointing.

Electrical discharge machining (EDM) is a competitive alternative process to machine Inconel 718 as compared to mechanical cutting. EDM can machine titanium alloys, hardened steels, cemented carbide and conductive ceramics regardless of their strength and hardness. It allows machining of complex part geometry. The tool electrode does not rotate for material removal, holes with sharp corners and irregular contours can be conveniently machined by EDM unlike mechanical cutting and grinding. The low force nature in the EDM gap also allows the machining of thin and flexible parts, deep grooves and holes that otherwise are difficult to machine by milling. The machining accuracy and surface finish are high especially at trim cutting conditions despite the low machining efficiency of EDM. These unique process characteristics make EDM an enabling technology in aerospace, medical device, tool and automotive industries.

Wire-EDM is widely used as it can be fully automated and flexible in making complex geometrical shapes in one setup. This process capability is particularly essential for aero-engine manufacture. 

High temperature has significant impact on the process-induce surface integrity including microstructure change, microhardness, surface topography, residual stress and element distributions as EDM is a thermal dominant process. The heat affected zone (HAZ) with a white layer is associated with high tensile residual stress, porosity, microcracks, grain growth and alloying from the tool electrode or dielectric fluid. As per a recent study, wire-EDM is highly detrimental to surface integrity compared to hard turning and grinding. However, this is not necessarily true since the degree of thermal damage depends on not only process conditions but also EDM generators. Thermal damage in main cut can be removed or minimized by subsequent multiple trim cuts at reduced discharge energy. Relaxation pulse with low energy has been tried to improve surface quality in EDM of silicon carbide. It has shown that machining sequence with trim cut and polishing technology is necessary to guarantee surface integrity. Thermal damage by EDM may be minimized with the development of low energy generators and EDM strategy.

Hastelloy wire- High corrosion resistance for various chemical processing applications

Hastelloy alloys are widely used by chemical processing industries as these are corrosion resistant. These are used in the areas of solar energy, pharmaceutical, geothermal, oil and gas due to their reliable performance. Hastelloy process equipment has high localized corrosion resistance, high resistance to uniform attack and high resistance to stress corrosion cracking. This alloy is easy to weld and has excellent fabrication. Hastelloy C22 alloy is resistant to pitting and crevice corrosion. It is used to protect against corrosive FGD systems and sophisticated pharmaceutical reaction vessels. Hastelloy C276 is used as shell & tube heat exchangers and bleaching vessels. Hastelloy C2000 is highly versatile and corrosion resistant alloy. It has high resistance to uniform corrosion in oxidizing or reducing environments. It has higher resistance to stress corrosion cracking and localized corrosion as compared to Hastelloy C276.

Hastelloy alloys are used in numerous applications in various industries including petrochemical, pharmaceutical, seawater, biomass, utilities, chemical process, oil & gas, geothermal, water desalination, mining, liquefied natural gas, nuclear power and solar power. Hastelloy bar alloys are fully resistant in various environments including Acetic Acid, Acetic Anhydride, Potassium Iodide, Potassium Nitrate, Potassium Oxalate, Potassium Permanganate, Potassium Sulfate, Pyrogallic Acid, Acetic Vapors, Fatty Acids, Ferric Chloride, Ferric Hydroxide, Ferric Nitrate, Ferric Sulfate, Ferrous Ammonium Citrate, Aluminum Acetate and Aluminum Chloride to name a few.

Oxidized Hastelloy X (Hx) fiber braid was demonstrated to work excellently as a good electric insulation of Ag-sheathed Bi2Sr2CaCu2O8 (Ag/Bi2212) wires. A test coil employing 45m long Ag/Bi2212 square shape wire with 50µm Hx fiber braid was fabricated in order to develop a wind-and-react processed Ag/Bi2212 superconducting magnet with a high coil current density. A test coil of size as 73mm outer diameter, 64.5mm inner diameter and 74mm coil winding height consisted of 4 layers and 210 turns and was heat-treated at around 890˚C in oxygen gas. The critical current Ic of the test coil was 245 A at 4.2 K in a self-field, corresponding to a 67% value of the short sample Ic heat-treated at the same time for comparison. Coil inductance was calculated to be 1.9mH, and as a result, the same inductance value was obtained in the test coil. It was found that Hx cloth knitting method allows to insulate sufficiently between wires in Ag/Bi2212 square shape wire.

Hastelloy is used in the manufacture of hot gas filters used to optimize the process. These filters can tolerate higher temperatures and offer greater throughput. These filters provide higher back pulse efficiency with no measurable product bleed through resulting in an optimized chemical process system. Hastelloy is also used to produce filter media made from multiple layers of woven wire mesh sintered together into a rigid, porous and durable structure. Each wire mesh layer is chosen for a specific engineering purpose that is, filtration (particle size removal), strength or flow drainage. Filter media are sintered in porous panels which are then formed and welded into strong & self-supporting filter tubes.

Monel wire- Excellent material for hydro-carbon processing

Monel is a family of nickel-copper alloys with high tensile strength and high resistance to salt water, atmospheric corrosion and various acid & alkaline solutions. Monel 400 can be magnetic depending upon the composition and previous work history. Monel K500 contains aluminum and titanium for age hardening. This alloy is fully nonmagnetic and spark resistant. Monel K500 is used for gyroscope application and anchor cable aboard minesweepers. It is used for propeller shafts on a wide variety of vessels and exhibits high fatigue strength in seawater. This alloy is also used in chemical process applications for handling of organic acids, dry chlorine and caustic. Monel 400 is used for marine engineering, hydrocarbon processing equipment, shafts, fasteners, valves, fittings, heat exchangers and chemical processing equipment.

Monel 400 has high strength and high corrosion resistance in a wide range of acidic and alkaline environments. It is especially ideal for reducing conditions. Monel 400 has excellent ductility and thermal conductivity. This alloy is ideal for seawater applications and has high corrosion resistance in a wide range of acidic & alkaline environments. Monel 400 has applications in chemical processing, pumps, marine engineering, hydro-carbon processing, valves and heat exchangers.

Monel 400 is used for handling sulfuric acid solutions under reducing conditions. There is an effect of aeration in 5-6% acid concentration on the corrosion rate of Monel 400 at various temperatures. The rate is very low at all temperatures in air-free solutions. Aeration increases the corrosion rate of Monel 400. 

The rate decreases until the boiling point is reached at higher temperatures in aerated acid when the corrosion rate is the same as in air-free acid. The acid becomes oxidizing and the corrosion rate undergoes a sharp increase that is only slightly affected by aeration above 85%. Monel 400 is attacked by boiling 25% acid, the reduction of the cation releasing hydrogen sulfide, attendant sulfur and sulfur dioxide from their interaction. Monel 400 has excellent resistance to boiling sulfuric acid solutions up to about 15% concentration. Monel 400 has excellent resistance in the storage of 80% acid at room temperature but is not used continuously with pure acid of higher concentration without preliminary tests. The maximum concentration for the use of Monel 400 in pure acid solutions is reduced to about 65% at elevated temperatures. Concentrated acid (93 to 98%) is added to large proportions of organic materials and is progressively diluted to lower concentrations in some organic processes. 

In such cases Monel 400 has excellent resistance due to dispersion of the acid and the film-forming or inhibiting action of some organic materials. The actual corrosion rate of Monel 400 is close to the air-free rate because continuous air saturation is uncommon in most sulfuric acid applications. A high degree of aeration would be expected only when air is bubbled continuously through the solution or when the solution is sprayed or poured through the air or churned up with considerable air in pumping. The rate at which air may be replenished at a quite solution-air interface is small compared to the rate at which oxygen can be removed by corrosion. Consequently, a high degree of aeration would be expected only at the liquid line and, if this level is constant, corrosion would be accelerated at this line. The presence of organic materials such as foods, sugars and fats limit the degree of aeration because these materials will react with dissolved oxygen and remove it from solution.

Hastelloy Bar- Excellent performance in highly oxidizing environments

Hastelloy C22 offers excellent longevity in numerous corrosive environments and boasts a quick lead time. This alloy is used in high temperatures and chloride environments as it resists crevice corrosion, pitting and stress corrosion cracking. Hastelloy C22 has excellent resistance in oxidizing and reducing environments. It has excellent performance when exposed to strong oxidizers such as chlorine, ferric chlorides, cupric chlorides, organic & inorganic hot contaminated solutions, acetic anhydride, formic & acetic acids, seawater and brine solutions.

Products that use acidified solutions are exposed to a high risk of corrosion. 

Hastelloy C22 is widely used in various corrosive environments including phosphoric acids, sulfuric acids in active pharmaceutical ingredients (APIs), chlorides, acetic acids, buffer solutions and any other beauty or health product where contamination due to corrosion is a concern. Hastelloy Bars are widely used in chemical process industry, oil & gas industry and automotive industry. 

The welding characteristicsof the Hastelloy Bar are similar to the austenitic stainless steels and exhibit no special welding problems due to its corrosion resistance. Development and qualification of welding procedure specifications is suggested in order to achieve quality production welds. These procedures are needed for code fabrication and should consider parameters including base & filler materials, joint design, preheat/interpass control, welding process, electrical characteristics and postweld heat treatment requirements. Any modern welding power supply with adequate output and controls can be used with the common fusion welding processes. Welding heat input is controlled in the low to moderate range and wide weave beads are not advised. Stringer bead welding techniques with some electrode/torch manipulation are preferred. 

Hastelloy exhibits both sluggish welding and shallow penetration characteristics. Therefore, care must be taken with respect to joint design and weld bead placement to insure that sound welds with proper weld bead tie-in are achieved. Hastelloy has a tendency to crater crack so grinding of starts and stops is advised. Cleaning is considered an essential aspect of welding of the corrosion-resistant Hastelloy. Contamination by corrosion products, sulfur, greases, lead, oils and other low melting point elements can lead to severe cracking problems.

Welding can be performed on base materials that are in the solution annealed condition. Materials with more than 7% outer Fiber Elongations of cold work should be solution annealed before welding. The welding of materials with huge amounts of residual cold work can lead to cracking in the weld metal and the weld heat affected zone. Various welding processes that are commonly used with Hastelloy are Gas Tungsten Arc Welding, Shielded Metal Arc Welding, Manual and Machine. It is essential to select the welding filler material in the design of a corrosion-resistant welded structure. 

Various types of corrosion-resistant alloys are used at various locations in the same structure. It is also important to select the welding filler materials for dissimilar metal joining applications. There are two methods of welding filler material selection such as selection of overalloyed filler materials and selection of matching filler materials.

Arc Spray Wire- Highly cost-effective coating alternative for Industries

High wear and corrosion of parts result in increase of operating costs at thermal power plants. The arc spraying of protective coatings is an effective solution to this problem. The wear & heat resistance of the coatings were tested via a two-body wear test accompanied by microhardness measurement and the gravimetric method respectively. Cored wires of the base alloying system Fe-Cr-C were used as a feedstock. Rise of wear resistance and heat resistance of the coatings was achieved by additional alloying with Al, B, Ti and Y. A high temperature corrosion test was performed at 550°C under KCl salt deposition. The porosity and adhesion strengths of the coatings were also evaluated. The microstructure was investigated with a scanning electron microscope (SEM) unit equipped with an energy dispersive X-ray (EDX) microanalyzer and the phase composition was assessed by X-ray diffractometry. The test results showed the positive influence of additional alloying with Y on the coating properties. A comparison with commercial boiler materials showed that the coatings have the same level of heat resistance as austenite steels and are an order of magnitude higher than that of pearlite and martensite-ferrite steels. The coatings can be applied to wear-resistant and heat-resistant applications at 20°C-700°C.

Thermal spray coating is a suitable method to improve corrosion resistance of low carbon steels. The corrosion behavior of wire-arc-sprayed coatings on C35 steel was undertaken. Characterization techniques including metallographic and corrosion resistance of different coatings were investigated. Electrochemical tests of arc sprayed stainless steel, Inconel and composite coatings were performed in 3, 5% NaCl solution. The results comparison showed an excellent corrosion resistance of the stainless steel coating.

Nickel-basedalloys are used for Arc Spray Wire in numerous applications due to their outstanding wear and corrosion resistance at high temperatures and their relatively low cost. These alloys have high strength, hardness and excellent corrosion resistance due to addition of chromium.

The oxidation and sulfidation can cause problems for the materials exposed depending on the local activities of oxygen and sulphur in coal fired boilers used for power generation. Burning fuels with significant amounts of chlorine or elements such as potassium, zinc, sodium, vanadium and lead can cause the formation of ash & salt deposits with very low melting points. Corrosive conditions develop with the molten salts fluxing the protective oxide scales or directly dissolving the metal if the temperature of the metal surface is above the melting point of the salt’s eutectic composition. This corrosion mechanism is often encountered in waste incinerators, fluidized bed boilers burning fuels with higher chlorine contents (e.g. solid waste), black liquor recovery boilers in the pulp & paper industry and engine exhaust systems when oils with higher amounts of vanadium are burnt.

There are numerous countermeasures that are developed to avoid excessive material damage corresponding to the variety of corrosive environments. Alloy selection is an essential factor wherein a large number of Fe-, Co- and Ni- based alloys exist today specially designed for excellent resistance to sulfidation, oxidation and corrosion by ash/salt deposits. Designs aspects improve temperature distribution (avoid hot spots), avoid excessive deposition of ash and slags by use of soot blowers, rapping, screens. Chemical additives such as neutralization of corrosive components in the flue gases by injecting additives such as dolomite or limestone. Shielding  such as SiC tiles in waste incinerators and other types of refractory linings. Different coating techniques are applied to protect critical surface areas from corrosive gases including co-extrusion, weld overlay, chromizing and thermal spray coatings.

Metallic Storm Window Screen Factory- Excellent protection against insects & long lasting performance

Window has been a product for cold climate regions with small producers providing custom unit sizes. Adding a storm window unit to an existing window provides several improvements. A storm window is a product of window screen factory that dramatically reduces air infiltration and increases the thermal performance of a single-pane window while reducing the impact of weather on the prime unit. Available options such as low-e glazing will further reduce energy consumption while available tilt-in sash allows for ease of maintenance. High performance storm windows are also ideal for noise reduction.

Aluminum is the material that provides high strength with a narrow profile. The poor conductive properties of aluminum can be mitigated by existing wood windows that serve as a thermal break. Storm windows are typically not ideal for installation on vinyl prime units as the elevated temperatures between the units escalate the expansion and contraction of the frames. Storm windows have a similar effect on windows joined with lead caming. Aluminum windows benefit from the addition of storm windows but the differential movement between the windows must be accommodated with material such as a double-sided adhesive cork tape.

Storm windows are installed either on the interior or exterior of the prime unit and are typically available as sliding units operating vertically or horizontally or as a fixed unit ideal for removal. Units are available in sizes large enough for sliding glass doors. Operable units available in double- and triple-track configurations allow air circulation and self storage of a screen. Fixed units are ideal for picture windows however they need seasonal maintenance when used in conjunction with operable prime units.

The performance of a storm unit is evaluated as a complete assembly. The design and material of the frame, its assembly, the installation, and the weatherstripping details all contribute to performance that can vary from model to model. Steel windows by window screen factory are excellent candidates for storm windows to compensate for their high level of conductive heat loss. A storm unit reduces transfer through the individual lites of a steel window sash. Storm windows are applied to existing steel sash frame with fasteners, magnetic trim or adhesive tape or can be affixed to material adjacent to the steel frame. Storm windows are usually available with screen units. The aluminum screening material provides strength but is subject to denting and corrosion. Aluminum will not dent but can stretch. 

A screen’s primary purpose is providing protection to insects although some new screening materials have been developed that improve energy performance. Various screens are now available that reject unwanted heat gain in warm climates but reduce ventilation and natural day-lighting. The energy savings of such screening can be significant and some utilities subsidize their cost in hot climates. These screens are effective on east and west elevations where the sun is at a low inclination, and passive solar control strategies such as awnings and overhangs are not generally effective

Hastelloy Bar- Highly anti-corrosive & weldable

Hastelloy is a family of alloys such as C-22 & C-276 that is widely used for its high corrosion resistance. Hastelloy C-22 alloy is a nickel-chromium-molybdenum-tungsten alloy that is highly versatile due to its high resistance to both uniform and localized corrosion along with various mixed industrial chemicals. Hastelloy C-22 alloy has excellent weldability and is used as overalloy filler wire and weld overlay consumables to increase resistance to corrosion.

Hastelloy C-22 alloy has applications in various fields such as

·        Acetic Acid/Acetic Anhydride

·        Cellophane Manufacturing

·        Complex Acid Mixtures

·        Expansion Bellows

·        Geothermal Wells

·        Incineration Scrubber Systems

·        Pesticide Production

·        Pickling Systems

·        Selective Leaching Systems

·        Sulfonation Systems

·        Weld Overlay-Valves

·        SO2 Cooling Towers

·        Tubular Heat Exchangers

·        Plate Heat Exchangers

·        Phosphoric Acid Production

·        Nuclear Fuel Reprocessing

·        HF Furnace Scrubbers

·        Flue Gas Scrubber Systems

·        Electro-Galvanizing Rolls

·        Chlorination Systems

·        Acid Etching

Hastelloy C-22 alloy is available in various forms such as strip, bar, pipe, plate, covered electrodes, tubing, wire, billet, and sheet. Wrought forms of this alloy are furnished in the solution heat-treated condition. Hastelloy C-22 alloy's performance against crevice corrosion, pitting and stress corrosion cracking is excellent. It also has high resistance to oxidizing aqueous media including wet chlorine and mixtures containing nitric acid or oxidizing acids with chloride ions. This alloy has high resistance to environments where reducing and oxidizing conditions are encountered in process streams. It can be used in multi-purpose plants and where upset conditions occur. It has high resistance to various chemical process environments including strong oxidizers such as ferric and cupric chlorides, hot contaminated solutions (Organic and Inorganic), chlorine, acetic anhydride, brine solutions, formic & acetic acids and sea water. This alloy resists the formation of grain-boundary precipitates in the weld heat-affected zone thus making it appropriate for numerous chemical process applications in the as-welded condition.

Hastelloy C-22 alloy is used in papermill as it passes extensive testing in the actual bleach washer environment for corrosion resistance. It has high resistance for the hydrofluoric acid prescrubber and for the clamshell bellows. It is used in a steel finishing manufacturing line in the form of Sleeved electrogalvanizing finishing rolls. This alloy helps in reducing the defects on the rolls that is essential to manufacture defect-free galvanized steel for the automotive industry. Acid pump strengthened with Hastelloy C-22 alloy is suitable for use in a continuous stainless steel pickling operation. This acid consists of 2 percent hydrofluoric acid, 20 percent hydrochloric acid and 40 gm/liter of iron at 170°F. Hastelloy C-22 alloy is effectively used in severe conditions such as in C-stage bleaching operations in a mill. This alloy is used as a thin-sheet lined for exposure in a utility flue-gas desulfurization plant. It is used as a fan to handle the incineration of radioactive and hazardous wastes due to its durability and corrosion resistance. Hastelloy C-22 alloy filler metal is a cost-effective, reliable and practical solution to corrosion weld problems.

Hastelloy Wire- Ideal for use in highly corrosive environments

Hastelloy Wire is made of various alloys of Hastelloy such as Hastelloy C276 and Hastelloy C22. Hastelloy C276 alloy has excellent corrosion-resistance to both oxidizing and reducing media. It also has excellent resistance to localized corrosion attack. Hastelloy C276 alloy is used in numerous industries as it works in aggressive and corrosive environments. Hastelloy C276 alloy is a versatile corrosion-resistant alloy that doesn’t need to be solution heat-treated after welding and has excellent fabricability. It has resistance to formation of grain boundary precipitates in the weld heat-affected zone that makes it suitable for numerous chemical process applications in the as-welded condition. 

Hastelloy C22 alloy weld filler materials are considered for environments where attack of Hastelloy C276 alloy weld joint is experienced. Hastelloy C276 alloy has excellent resistance to localized corrosion and to oxidizing & reducing media. It is used in environments where “upset” conditions can occur. It is also used in multipurpose plants. It has high resistance to various chemical process environments including strong oxidizers such as ferric and cupric chlorides, chlorine, acetic anhydride, brine solutions, hot contaminated media (organic and inorganic), formic & acetic acids and seawater. It is used in flue gas desulfurization systems due to its high resistance to sulfur compounds and chloride ions encountered in numerous scrubbers. This alloy has high resistance to pitting and stress corrosion cracking. It can withstand the corrosion caused by wet chlorine gas, hypochlorite and chlorine dioxide.

Hastelloy C276 alloy is hot-upset, forged and impact extruded. Although this alloy has a tendency to work-harden, it can be deep-drawn, punched, spun and press-formed. Hastelloy C276 alloy can be welded using common welding methods except the oxyacetylene and submerged arc processes which should not be used when the fabricated item is to be used in corrosive environment. Excessive heat input is avoided by taking special precautions.

In a test of oxidizing NaCl-HCl solution, the solution temperature was varied in 5°C increments to determine the lowest temperature at which pitting corrosion initiated after an exposure of 24 hours in pitting testing and the lowest temperature at which crevice corrosion initiated in an exposure of 100 hours of crevice corrosion testing. The lowest temperature at which pitting corrosion initiated was 150°C and the lowest temperature at which crevice corrosion initiated was 80°C.   

In the crevice-corrosion test with 6% ferric chloride solution, the solution temperature was varied in 2.5°C increments to determine the lowest temperature at which crevice corrosion initiated in an exposure of 24 hours. The lowest temperature at which crevice corrosion initiated was 95°C.

In the pitting corrosion test with oxidizing H2SO4-HCl solution, experiments were performed in increments of solution temperature of 5°C for an exposure of 24 hours to find the critical pitting temperature. The lowest temperature at which pitting corrosion initiated was 110°C.

Additional uses of HastelloyC276 wire include welding the clad side of joints on steels in various industries such as petrochemical, chemical and petroleum. Typical applications of Hastelloy C276 alloy are in marine industries, pickling systems, chlorination systems, chemical processing and nuclear fuel reprocessing.