Online Zinc Spray System
G. I. Tubes and pipes produced from Tube Mills generally lack corrosion resistance property at weld portion, throughout the entire seam length (due to removal of galvanized layer while welding the seam) resulting in poor corrosion resistance and subsequent rusting. Metal coat has analysed the problem and developed chemically non-hazardous thermal spray systems for continuous on line zinc spray coating on G. I. Tubes and Pipes on seam. Such systems have been demonstrated and supplied to various leading tube mills where these systems have been performing satisfactorily. The Zinc spray is 20 to 30 Microns. However 10 to 100 micron can be deposited (depending upon tube/pipe traverse speed) on Tubes and Pipes ranging from 15mm N.B. to 125mm N.B. Size without interrupting Tube Mill speed. The average output can be of 10 pipes per minute with an approximate 25 microns coating thickness. The System package consist of dry spray booth (Spray Chamber), Twin Cyclone, Exhaust Fan with motor along with ducting.
The Spray Booth is installed just after welding Work Station. The Arc Spray Gun is positioned inside the Spray Booth. The distance of the spray gun from the tube / pipe is adjusted depending upon size of tube / pipe and spray pattern required to minimize spray wire losses. The Hot Weld seam is sprayed with zinc wire resulting in dense coating with strong metallurgical bond over weld seam. The fumes and fine Zinc dust generated in spray booth is sucked into cyclone dust collector due to suction created by exhaust fan. Due to cyclonic action the zinc particles are trapped at the bottom of cyclone dust collector and clean air is discharged from outlet of blower into atmosphere keeping The Arc Spray Gun System consists & of Arc Spray Gun with two wire feeding arrangement DC/AC Power source built in with control console with wire spool stand having spool capacity 15Kgs each. The Wire feeding mechanism is by pull process powered by electric motor. The wire feeding speed is adjustable through motor. The zinc spraying is cool process producing fine and dense quality coating having high bonding strength and minimum porosity.
Arc Spraying
The arc spraying process involves melting of two like or unlike wires (the coating material) in an arc and accelerating them towards the prepared work surface by means of an atomising gas such as compressed air. Arc spraying is a high-performance wire spraying process, but the coating material must be electrically conductive.
Twin wires are fed either electrical driven motor.
Twin wires are fed either electrical driven motor.
ONLINE ZINC SPRAY SYSTEM LAYOUT
The equipment layout is flexible and minimum space required for installation of zinc spray coating system is 18′ Length x 8′ Breath x 12′ Height (size in feet).
CONSUMABLES
ZINC SPRAY WIRE
Wire Dia -1.6 mm / 2 mm.
CHAMICAL COMPOSITION
The average chemical composition of ZINC WIRE
| GRADE | 99.99 ZN | 99.95 ZN |
| ZINC(%) | 99.99%MIN | 99.95%MIN |
| Impurities(%) | Lead(Pb) | 0.002 max | 0.020 max. |
| Cadmium (Cd) | 0.003 max | 0.020 max |
| Tin (Sn) | 0.001 max | 0.002 max |
| Iron(Fe) | 0.003 max | 0.005 max |
| Copper(Cu) | 0.001 max | 0.003 max |
| Total Impurities | 0.01 max | 0.05 max |
