Repair of Two SUS Cast Iron Valves | Innovative Repair with Kanmeta Cold Spray

Cold spray was applied for the repair of corrosion and material loss in SUS cast iron valves at a petrochemical plant.

Customer's Challenge:

There were several concerns with existing repair techniques for material loss in SUS cast iron valves:

　 1)High heat input from welding could cause adverse effects due to sensitization.
　 2)The base material was already significantly degraded, and welding heat could propagate further cracking.
　 3)In some environments, anti-corrosion thermal spraying was not applicable.
　 4)If metal loss had already occurred, thermal spraying could not build up the metal.

Kanmeta Engineering's Proposal:

Kanmeta Cold Spray was adopted due to the following benefits:

1)No high heat input, preventing damage to the base material.
　2)No limitation on coating thickness, with environmental barrier capabilities even in harsh corrosive environments.
　3)Flexible application that allows it to be used on existing equipment.
　4)Post-processing (facing) can be performed even on gasket surfaces.

 Results:

1)The material loss areas were repaired with a thick, high-environmental-barrier cold spray coating, providing three-dimensional restoration.
2)Even on SUS materials, which are sensitive to heat, the cold spray could be applied without adverse effects.
3)High-performance coatings were applied over the existing equipment, eliminating the need for component replacement.