Spraywelder™ System Demonstration

Back by popular demand, UK Technical Manager Warren Lewis demonstrates the #Spraywelder™. Designed to produce a consistent coating for circular parts, the Spraywelder™ is ideal for seal areas on shafts, motor body shafts, and glass industry parts such as narrow neck press, blow plungers, and plugs.
Warren takes us through the process of applying powder to a plug using the Spraywelder™. Learn how to achieve a consistent deposit with step-by-step instructions.
Watch the video to hear more about the history, advantages, and applications of Spraywelder™.
Watch how the final product should look when successfully coated here: • Spraywelder™ System - ...
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View our other Thermal Spray Demonstration video - Fusewelder™ Torch: • Fusewelder™ Torch - De...
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[@richardjones-sl2zd]

Came here from a TH-cam channel called Abom79, where an industrial manual machinist called Adam Booth went over full time to pursue his TH-cam channel further.
He uses the Eutectic Terodyn 2000 spray welding system which although similar to yours does not have the final fusion stage using the acetylene torch for a long period. He uses this system on bearing surfaces and highlights its benefit of much lower temperatures ( compared to welding as the alternative) thus not altering the base metal temper and avoiding shaft distortions and the like. Your system having to use the acetylene torch at the final stage would seem to put itself at a disadvantage wrt that.
The system he uses has been around for many decades. and although it might have decreased in popularity over the years ( probably due to comebacks), he swears by it provided preparation and consistency is good and it's used for the right application. He says he has done loads of these at his previous employ, without any failure comebacks.

[@warrenlewis9883]

Sorry for the late reply. I believe the Terodyn 2000 was sold in the USA. The European version was called the Castodyn 2000. They had a blue handle and lots of valves. Good kit be quite expensive. No longer available. For resurfacing bearing areas, two-stage or single stage "cold" spray powders are preferred because as you mention, there is no secondary fusing stage so the shaft remains "cold". This is often referred to as "metallising". Wall Colmonoy also manufactures a small range of metallising powders which can also be used with the J3 Spraywelder.

[@spyroskopitsas6088]

Hallo Mr. Lewis, congratulations for your excellent videos. I would like to ask you at what distance and what rpm you are using when you are adding powder on an turning axle. Thank you in advance. S.Kopitsas Athens Greece.

[@WallColmonoy]

Hello S. Kopitsas,
The distance and rotational speed can vary depending on the powder being used, nozzle selection, and the diameter of the part. The RPM is usually taken between 9 and 15 linear meters per minute. Could I ask if you have a Spraywelder? If so, do you need a manual?
Cheers
Warren

[@spyroskopitsas6088]

@@WallColmonoy hallo Warren, thanks for your reply. I do not have a Spraywelder, and of course i need a manual and some more info on that subject
(like: powder types and prices,
welding temperatures, pastes, etc.) Usual i am working with ck45, ck65, and inox axles (1-3 inches diameter).
Thanks again.
Spyros

[@WallColmonoy]

@@spyroskopitsas6088 Thank you for your response. For more information about our Spraywelder™, including a link to download the manual, you can visit www.spraywelder.com. Also, if you would like to contact me directly, you can email me at [e-mail].

[@abhaychoraria4310]

Generally the blow and blow plungers are about 10 to 15 millimetres, and it is very difficult to coat those small diameter s with the spray welder( there will be a lot of over spray and while fusing the fusing torch heat will be too high for the b&b plug diameter), I think that is why the fuse welder is used commonly thorough out the glass industry

[@WallColmonoy]

Hi Abhay. If the overspray is too high, perhaps the incorrect nozzle is being used. As can be seen in the post, we used a J3C nozzle which, as you can see, has a very small, narrow spray pattern and so overspray should be kept to a minimum. Then, if during fusing, the part is becoming overheated, perhaps the fusing torch is too big or the technique being used needs to be re-assessed. The Sprayweld™ process was commonly used for both BB plugs and NMPB plungers during OEM manufacture before HVOF. This process should not be a problem. Thanks for your comment! Regards - Warren Lewis- Technical Manager

[@migueldelacruz9826]

Alguien de México que desee tener en su taller una pistola J -3

[@WallColmonoy]

Para mas informacion visite www.spraywelder.com o pueda enivarnos un mensaje a [e-mail].

[@evilgrin123]

Do you offer spray service or just the equipment?

[@WallColmonoy]

Hi! Yes, we do coatings from our UK Aerobraze facility (in Pontardawe Wales) and in Cincinnati (USA). More details are here:
www.wallcolmonoy.com/products-capabilities/aerobraze-engineered-technologies/high-performance-high-value-hardsurfacing-wear-resistant-coatings/
Or contact us at [e-mail] for a quotation.
Thank you!

[@defnecicegi8451]

Why acetylene rather than LPG?LPG should burn hotter than acetylene from my memory. Can it be used with lpg oxy?

[@WallColmonoy]

Hello Defne,
LPG & oxygen is about 2800deg C whilst Acetylene & oxygen is 3200deg C.
The Spraywelder™ will work using LPG (propane) but fusing is always better and quicker using oxy-acetylene due to the higher temp.
Cheers,

Warren

[@defnecicegi8451]

@@WallColmonoy overall, 2800 celcius will be enough for the alloys to fuse?

[@WallColmonoy]

@@defnecicegi8451 Hi- the answer depends on a number of factors including base material, pre-heat and duration. If you email [e-mail] we can talk you through it. Generally we always recommend using oxy-acetylene.

[@albatista4309]

What you need to run that gun air oxygen and propane?

[@warrenlewis9883]

This runs using oxygen and just about any fuel gas. In the demo, I use propane.

[@rommelolpato5359]

Good day...what kind of powder will recommend for Cast Iron?

[@WallColmonoy]

Hi, almost any of our powders will work on cast iron when deposited using the Spraywelder™or Fusewelder™. It largely depends on what hardness the customer wants to achieve. We also need to know what equipment will be used so we can suggest the correct particle size range. Thanks - Warren

[@rommelolpato5359]

@@WallColmonoy we used wallcolmonoy 21A PTA in plasma transfer arc welding is this applicable for spray welding ?

[@WallColmonoy]

@@rommelolpato5359 Hi. Colmonoy®21A is self fluxing powder suitable for deposition using the PTA welding process and the Fusewelding process. It appears to not be made in the appropriate sieve range for deposition using Sprayweld™equipment. What type of equipment do you have? Please feel free to also reach out to me directly with any further queries. My email is [e-mail]

[@WallColmonoy]

@@rommelolpato5359 Hi. Colmonoy 21A is self fluxing powder suitable for deposition using the PTA welding process and the Fusewelding process. It appears to not be made in the appropriate sieve range for deposition using Sprayweld™equipment. What type of equipment do you have? Please feel free to also reach out to me directly with any further queries. My email is [e-mail]

[@jamesweber7001]

This is great, for sure, but it is unfortunate that they named it a “Spray Welder”, as this often confuses and leads people to believe this is a welding process. It is actually the flame spray powder process, which is great and widely used for >100 years. Because of this name, when helping clients and students, I need to continuously enforce that “Spray Welding”, a generic term that many people use to describe thermal spray, is not welding and the unfused coating is not welded to the substrate. If secondary fusing is used, then the coating is bonded to the surface more like welding, but not the same as welding and there is a gigantic heat affected zone due to the glowing hot fusing temperature needed. Again…all great! Just remember that this is thermal spray and not welding.