Industrial machinery

Thermal processing extends the lifetime and operational efficiency of a wide range of industrial machinery components used throughout the machine building industry.

Pumps and valves

Pumps and valves are used throughout industrial machinery, such as forestry and agricultural machinery, mining machines and winches, as well paper and chemical machines. Many of the harsh operating environments in which this equipment can be expected to work demand significant strength and durability. Additionally, the reliance on the equipment to perform, and avoid downtime is often critical to the operation being performed. Through nitriding and case hardening the components we are able to reduce the wear and galling that would otherwise reduce the lifetime and reliability of these parts.

Designers of pumps and valves requiring corrosion resistance often chose stainless steel as a material solution. Issues of wear, galling, and erosion can create design challenges or the need to move to costly specialty steels. Bodycote’s proprietary S³P processes applied to common stainless steel grades provide excellent resistance to galling, wear, and erosion for pumps and valves, decreasing costly downtime and increasing the life of the component.

Gears

Gears are a feature of all machines and equipment that include transmission and have to be processed to exacting standards to ensure safe operation of the machine and a long working life. Thermal processes provide the necessary methods to create the correct properties needed. Often, finished machined gears need to be heat treated and, in this instance, no or minimal distortion can be tolerated.

Bodycote can meet these strict requirements utilising the low pressure carburising (LPC) or press quench process. Low pressure carburising (LPC) is a case hardening process carried out in vacuum. Besides its environmental friendlier characteristics, it allows for dimensional control and precise control of case depth, microstructure and hardness. Typical treated parts include:

• Spur gears
• Helical gears
• Sun gears
• Ring gears
• Bevel gears
• Pinion gears

Rolls

Rolls used within aggressive environments, such as those found in steel-making, paper and printing industries, suffer severe wear and corrosion problems resulting in high replacement costs, reduced performance, impaired quality and excessive downtime.

With the use of high-pressure high velocity oxy-fuel (HP/HVOF) thermal spraying techniques, a durable engineered surface, with high micro hardness and excellent wear and corrosion resistant properties, can be applied to the roll face and journals. This coating can be either textured or ground/superfinished, giving the required characteristics which enhances the performance of the roll and extends service life.

Benefits:

• increase cycle life
• improved performance
• re-coating at the end of the life cycle, increasing life expectancy indefinitely
• thick coating capability (over 2.5mm for certain materials)
• cost effective three step process compared to minimum eight steps for chromium plating
• HP/HVOF offers the versatility of selecting a number of different coating chemistries for specific application requirements
• damaged rolls can have original dimensions restored, reducing roll replacement
• on site/in situ coating application where transportation of the roll is not viable or production down time is vital

Typical applications

• correcting rolls – steel galvanising
• sink rolls – steel galvanising
• flattener rolls – steel
• pinch rolls – steel
• anilox rolls – printing
• winder rolls – paper
• finishing rolls – printing
• bridle and deflector rolls
• yankee dryer rolls
• guide rolls
• hydraulic rams
• pump shafts