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‡ Founded in 1996
‡ Pete Castiglione, CEO
‡ Customers in North America, Europe, Asia
‡ Power
‡ Steel
‡ Paper
‡ Petrochemical
Plus
‡ Canada
‡ Steel (Laser)
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‡ Welding and Mechanical Services
‡ Thermal Spray clad applications
‡ Ceramic coating applications
‡ Inspection services
‡ Laser Cladding
 .12/$'(
‡ Full-time Safety Director
‡ Safety Committee
‡ Detailed safety manual
‡ All personnel- 30 hour OSHA course
‡ Annual OSHA and job specific safety training
‡ Job specific safety awards
‡ Site meetings every project including toolbox
and JHA
‡ ISN Network
 3+14"$'(
‡ On-site at every project
‡ continuous quality assurance
‡ QAQC documentation
‡ detailed inspections and reports
‡ NACE certified
‡ Certified Technicians
‡ Metallurgist on staff
‡ Material evaluation and development
Verifiable difference
•  Pre-Inspection

•  Boiler Mapping

•  Documentation

•  Trend Analysis

•  BENEFITS:
Forecast wear rate

Project production increase =

savings

Quality assurance

Verifiable quality
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CFB Boiler Problem Areas!
!  Combustor Water Walls
!  Refractory Interface, Division
Walls, wing Walls, Corners, Gas
Outlets, Ceilings
!  Back Pass Tubes
Utility Boiler Problem Areas!
!  Waterwalls
!  Superheats and Reheats
!  Nose Arch and Slopes
!  Soot Blower Lanes
x Ability to field apply with
lightweight durable HVOF
equipment
x Non-ferrous coating, can be read
with MLO device for accurate
thickness applications
x Repairable
x Very dense HVOF coating with
minimal porosity
x Pre-alloyed powder with spherical
morphology to promote better
flow and deposit efficiency COATING MICROHARDNESS POROSITY TENSILE PROCESS
x Average Production rates of 5-7 LAYER (HV) (%) STRENGTH

square feet per hour at 12 mils Part A 800+ <2% 12,000+ HVOF
average thickness
x Extremely high mechanical bond Part B 1,000+ <4% 13,000+ HVOF

strength
x Nickel Chrome-Chrome Carbide ELEMENT %
makeup promotes superior Cr 68.45

abrasion resistance, high Ni

Ti
25.53
4.8
temperature strength as well as Fe 0.93
low temperature toughness. Si 0.29
Base coat HVOF process. 9 mils of CarbideCladTM HVOF
coating after 2 years in service

Our pre-alloyed powder

provides for a better
coating versus other
competitor options
•  Contains pre-alloyed powder with
spherical morphology to promote
better flow and deposit efficiency
•  Average DE rates of 6-8 square
feet per hour at 12 mils thick
•  High bond strength +12,000 PSI1%
porosity
•  Smooth Surface – less friction in
low angle sliding abrasion
•  High temperature erosion
resistance 845°C
•  Hardness 900 to 1100 Vickers
x Ductile coating that is more
elastic and can dissipate high
impact forces minimizing
gouging
x Coating can be read with MLO
device for accurate thickness
applications.
x Repairable
x Average Production Rates of 10-
12 square feet per hour at 20 mils
thick
x Highly resistant to corrosion and COATING LAYER MICROHARDNESS
(HV)
POROSITY
(%)
PROCESS

oxidation due to chromium

CHROMECLAD 340+ <4% TWIN WIRE ARC
content
x Ceramic sealer can be used on the ELEMENT %
Ni 35.55
single or dual layer system to fill Cr 32.94
in surface voids and prevent Fe 30.32
Mn 0.66
permeation of corrosive gases, Si 0.16
debris and/or liquids.
x ChromeClad E topcoat increases
hardness and longevity of the
ductile ChromeClad base coating
x Contains Boron which significantly
increases the hardness of the coating
x Acts as a case hardener for the more
flexible and ductile base coat
x Readable due to non-ferrous top
coat and dual-phase base coat

COATING LAYER MICROHARDNESS POROSITY PROCESS

(HV) (%)

CHROMECLAD 860+ <5% TWIN WIRE ARC

ELEMENT %
Ni 41.64
Cr 32.48
Fe 24.40
Mn 0.53
Si 0.35
B 0.31
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 Emissivity Testing Results
x 5,000 psi bond strength Coating Thickness (thou) Emissivity
x Very high production rates: 90-150 F-61 Ceramic 5.0 0.80
Carbon Steel - 0.34
square feet per hour
x Slag resistant, slag does not bond
x Endothermic, increases heat
transfer
x Ability to spray tighter areas
x Less surface prep, no spalling
x Cold process, environmentally safe
x Fills voids in thermal spray surface
and becomes part of coating matrix
to prevent permeation
x Much higher emissivity than
carbon steel (a material with
emissivity closer to 1 is said to be
less reflective and allow greater
heat transfer).
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‡ Superheater/reheat tubes
‡ Back pass areas
‡ Burners
‡ Water walls
‡ Nose arch tubes
‡ Kilns and Ducts
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‡ Superior thermal expansion performance
‡ Low conversion temperature 400 F
‡ Vitrification 1060 F >
‡ Can be applied up to .012 thick
‡ Firing procedure ± use normal boiler start
up procedures
‡ For water wash or outside storage- PC-3
pre-cure agent available
• 

• Advantages
• >Powder Process

• >Metallurgical Bond for greater strength

>6-axis CNC accuracy

• >Minimal Heat Affected Zone

• >Less clad thickness = higher conductivity

>50 ft.+ panel length = Less cut lines

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€ CNC controlled process
€ Metallurgical bond
€ High density, void free
€ Can control thickness +/- 5 mils with a
range between 15-120 mils
€ Minimal dilution which maintains alloying
elements and their respective mechanical
properties
€ Very little heat input compared to other
welding processes (i.e. GMAW, GTAW)
€ Minimal distortion
FILLER METAL MICROHARDNESS POROSITY PROCESS
€ Low Heat Affected Zone (40-80% the INCONEL 622 345 <0.5% LASER BEAM
thickness of the coating) WELD
INCONEL 625 320 <0.5% LASER BEAM
€ Wide range of alloys available due to WELD

powder process
ELEMENT %
€ Can manipulate chemistry and hardness for Ni 56.44
higher abrasion resistance or conversely Cr 21.90
for bending capabilities by changing power Mo 14.16
and heat input Fe 3.55
W 3.25
€ Up to 3X the production rate of GMAW and
GTAW
 -High Temperature Erosion Testing

‡ In a simulated High Temperature Erosion Test involving constant media flow,

pressure and a controlled heat source of 800 F, Laser Clad vastly
outperformed Carbide Clad HVOF Thermal Spray by more than 2X the
abrasion resistance
‡ This is due to the ductility and density of the metallurgical bonded Laser Clad
Automated Shop-Applied Thermal Spray CNC Controlled Shop-Applied Laser Clad

Field Automated Thermal Spray Field Automated GMAW Welding

• 

• What’s in it for you?

• No Tube Failures
• No Surprises - Predictable
- Verifiable

• Saves Money - Use less fuel

- Improved service life
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