Wear protection

In Kapfenberg IMC Extrudertechnology GmbH caters with its range of products to all our customers in our wear protection center.

The following technologies are at your disposal:

Nitration

PTA welding

Thermal spraying

Blasting

Nitration

IMC owns one of the most advanced nitration plants where parts up to 4,300 mm long with a max. ø of 1,200 mm are gas nitrated in a suspended position. Relieving, retrieval, gas-nitro carburization, post-oxidation, annealing, tempering, pre-heating for leveling, welding and heat shrinking complement our services.

piece weight up to max. 6 t

max. furnace temperature +750C

PTA welding

PTA welding is done fully-automatically by a 12-axis robot. Here are the key facts:

max. Ø: 3,500 mm
max. length: 10,000 mm
max. piece weight: 10 t

Inside welding: from ø 50 mm to 3,000 mm length

We also offer any other standardized welding (TIG welding, MAG welding etc.) in our facility.

PTA welding - process description:

During PTA welding the surface of the workpiece is partially melted by a plasma arc used as heat source. The weld consumable is supplied by a carrier gas.

Advantages of this procedure:

Advantages of this procedure are a low fusion degree (ca. 5%) and a small heat affected zone. Machining allowances are considerably lower than in other welding processes. Lamination strength may be very much smaller (> 1mm). Additionally, we offer a wide range of materials including tailor-made powder blends.

Weld consumables are divided into three categories:

·       Iron-based alloys (e.g. 1.4571, 1.4313, Tristell)

·       Cobalt-based alloys (e.g. Stellite, Tribaloys)

·       Nickel-based alloys (with or without tungsten carbides)

Typical applications:

Weld consumable application

·       Guide bushes (Stellite)

·       Moulds for the plastics industry (nickel-based alloy)

·       Forging dies (Stellite)

·       Extruder screws (nickel-based alloy with tungsten carbide)

·       Spherical valves (Stellite)

·       Sealing surface of wedge gate valve plates (Stellite)

·       Diverse parts of the chemical industry (Hastelloy)

Finishing

Finishing layers of resistant materials implies experience therein and special tools. IMC Extrudertechnology accepts any orders from you to entirely finish your work.

Thermal spraying

We offer the following facilities for this technology:

·       Wire and powder flame spraying

·       Plasma spraying

·       HVOF method

Here are the key facts for all methods mentioned above:

max. Ø: 1,400 mm
max. length: 5,200 mm
max. piece weight: 4 t

Thermal spraying - process description:

During thermal spraying the coating material (wire or powder) is fed to an autogenic or plasma flame, partially melts, is accelerated and applied to the workpiece. Lamination strength may vary between 0.1mm and 10 mm but most frequently lies between 0.2 mm and 0.8 mm. Hardness values can be achieved up to >1500 HV 0.3. Particle velocity varies between 80 m/s and 700 m/s according to the method used. Flame temperature also varies according to the method used and usually ranges from 2,800°C to 20,000°C.

Advantages of this technology:

Maximum workpiece temperature is only at 150°C despite such a high flame temperature.

Resulting from this, there is neither warpage nor is any alteration in the microstructure to be found when this method is used. Another advantage of this technology is that any base material (steel, grey cast iron, aluminum, bronze, etc.) may be combined with any coating material (ceramics, carbide, stainless steel etc.).

There are more than 100 different materials at your disposal to be used as coating materials. This method is primarily used with new parts, taking into consideration which coating to apply as early as in construction phase. Our principle is always “A cheap base material & a tailor-made surface”. This method is our choice in repairs and restoration of rejects, too.

Typical applications:

Coating material application

·       piston rods (tungsten carbide, chrome carbide)

·       Turbine components (tungsten carbide)

·       Faces of sealing elements (chrome oxide, chrome carbide)

·       Electrical insulation ceramics (aluminum oxide)

·       Electrically conductive copper, silver

·       Extruder screws (molybdenum)

·       Pump plunger (nickel-based resistant material alloy)

·       Ink ducts ceramics (chrome oxide, aluminum oxide)

·       Bearing surfaces (repair) (a variety of steel grades)

·       Hard chrome replacement (tungsten carbide, chrome carbide)

·       Special blends

Finishing

Finishing layers of resistant materials implies well-versed know-how. Finishing is usually performed by grinding by means of diamond or CBN discs. IMC Extrudertechnology accepts any orders from you to entirely finish your work.

Blasting

We perform blasting jobs of metallic surfaces at our plant designed for aluminum oxide and glass beads. Workpieces of a length of 6,000 mm at the maximum and a maximum piece weight of 10 t are allowed.

Size of blasting chamber : W = 5m, L = 7m