Extreme Industrial Coatings

Our 6-Axis Linear Robotic Welder

admin — Fri, 24 Dec 2010 08:09:59 +0000

We have recently received a 6-axis linear robotic welder designed specifically to integrate with our plasma-welding systems. When fully installed, this system will allow us to produce:
* High-quality tungsten carbide plate—including “chunky carbide” plate and wear pads.
* Tungsten carbide cylinders and pipe fittings.
* Stellite-type and SuperNickel coatings with entrained tungsten carbide.

With this integrated robotic system, we will be able to provide our customers with some of the most advanced wear surfaces available in the western U.S. for plate, pipe fittings, and cylinders.

Why should our customers care?
* In-house quality control of all plasma welding from plate manufacture to final on-site installation.
* Robotic welding precision and repeatability.
* Customized coating chemistries.
* Greatly increased coating thicknesses.
* Lower costs.

Some of our 2008 acquisitions include two Plasma Transfer-Arc welders, a Diamond Belt grinder, a 32” x 168” monster lathe, and upgraded dynamic balancing analyzer and software.

Wear Protection for Combines

admin — Fri, 24 Dec 2010 08:03:30 +0000

So how does RocketCoat carbide compare to hard chrome?

RocketCoat carbide is three times more abrasion resistant than hard chrome, and rock chip damage can be repaired with basic spray fuse equipment. Many parts we have coated will probably outlast the combines in which they have been installed.

Wear Protection for Potato Harvesters

admin — Fri, 24 Dec 2010 08:01:56 +0000

The knives on this two-ton-per-minute potato harvester are normally completely worn out at the end of a season—largely due to the destruction of the leading edges.

We coated the leading edges on all the knives with 60% plasma tungsten carbide. We then chromed half of them and coated the other half with 88% tungsten carbide RocketCoat. The plasma carbide took all the major impact wear and allowed even the hard chrome to finish the season with little appreciable wear. The RocketCoat carbide did not even polish in service.

Wear Protection for Potato Seeders

admin — Fri, 24 Dec 2010 08:00:14 +0000

Potato air seeders have multiple, expensive wear points, including the air valves, fan, fan housing, and planting shoes. Our tungsten carbide RocketCoat and thermoset polymer coatings can help prevent catastrophic fan failures, such as you can see at the lower left.

The set of six air valve bodies on this seeder costs approximately $4500 and lasts one season. The RocketCoat on this valve body shows no wear at the end of the 2005 planting season. UPDATE: End of 2010 season, still no sign of wear! For more information on our services for the Lockwood Air Cup Potato Seeder, click this link.

Wear Protection for Tillers

admin — Fri, 24 Dec 2010 07:58:17 +0000

Tillers present some brutal abrasion issues for exposed wear parts. Pulleys and rollers on these machines coated with RocketCoat tungsten carbide will likely never need replacing; this, in turn, will extend the life of the $1400 set of belts.

Wear Protection for Rotary Mowers

admin — Fri, 24 Dec 2010 07:56:48 +0000

We coated 84 mower blades for the largest grass seed producer in Oregon with 60% plasma tungsten carbide. The inserted photo shows one of these blades at the end of the 2005 harvest season. The plasma carbide shows virtually no wear.

Wear Protection for Log Loaders

admin — Fri, 24 Dec 2010 07:54:57 +0000

The front fork tips on this log loader in St. Maries, Idaho, used to wear out in as little as two weeks. The 3/8” of plasma tungsten carbide we applied to the fork tip protector plates will provide as much wear resistance as 7-1/2” of AR400 steel.

Wear Protection for Earth Scrapers

admin — Fri, 24 Dec 2010 07:52:32 +0000

Earth scraper chain rollers suffer from extreme wear due to grinding abrasion.

Wear Protection for Hammermill Fans

admin — Fri, 24 Dec 2010 07:50:43 +0000

Fans coated with RocketCoat tungsten carbide, which is 50 times more abrasion resistant than mild steel. We spot repaired the fan on the far left with spray fuse carbide.

We coated the worn upper-left fan with RocketCoat, which lasted longer than a brand new fan.

The plasma carbide at the lower left provides the ultimate in wear protection.

Wear Protection for Pumps

admin — Fri, 24 Dec 2010 07:26:10 +0000

We used 2-1/2 pounds of plasma nickel to repair the suction end at the top left, which suffered severe cavitation damage. The thermoset polymer we then applied is both cavitation and corrosion resistant. The RocketCoat tungsten carbide we applied to the other unit is extremely resistant to abrasion and corrosion.

Due to severe abrasion, the worn out impeller located in the middle of the picture lasted only nine days. In contrast, the RocketCoat tungsten carbide coated impeller directly right of it shows no drop in pressure after five months in service.

Corrosion can take a terrible toll on certain industrial pump systems. The uncoated impeller, shown on the bottom far left, lasted 30 days. The RocketCoat version next to it has been in service for five months and counting. This same coating has been approved for a direct contact with extremely corrosive nuclear material.