ISO 9001 Registered
PH: 716.875.3380

What are thermal spray coatings?

February 6th, 2014
 Quick Links
Our Website

 HFW Services

 

 

 HVOF Robotic Pic Rev

Common

Thermal Spray Applications
Thermal spray coatings are used throughout many industries, from chemical, to power generation, to
steel production to semiconductor.
New applications are constantly developed.
Below lists general areas where thermal spray may be of
significant benefit…
~ Replacement of chrome plating using tungsten carbide thermal spray
~ Life cycle improvements where wear and corrosion lessen the life of your equipment

~ Restoration/ repair of old/ worn components or equipment.

Some common items repaired include…
  • Process Rolls
  • Shafts
  • Valve Components
  • Bearing Housings
  • Gear Boxes
  • Pump Components
  • Agitators
  • Printing Cylinders & Rolls
  • And many more…
HFW Industries, Inc.

ISO 9001:2008 Registered

196 Philadelphia Street

Buffalo, New York 14207-0008

Ph: 716.875.3380

Fx: 716.875.3385

E-mail: sales@hfwindustries.com

What is thermal spraying?
Basically, thermal spraying is when a coating material (in powder, rod or wire form) is heated to a designated temperature and then propelled in a molten state onto a substrate. The result is a mechanically bonded coating that will restore size or protect the substrate in the application.
It’s amazing that the thermal spray process, initially developed over 100 years ago in Switzerland by Max Ulrich Schoop, today uses technology that can spray coatings at supersonic speeds!
What separates HFW from our competition is our 60 years of expertise in thermal spray coating with complementary machining, finishing and assembly capabilities! 
This unique ‘One Source’ capability offers you high quality, timely manufacturing and repair service without the hassle of multiple vendors and blurred lines of responsibility.

 HVOF
How are thermal spray coatings applied?

HFW remains at the forefront of thermal spray technology by using state-of-the-art equipment, including robotics, with our 25 plus thermal spray systems.

The process chosen is based on what is best for each application. That may depend on the material to be sprayed, the substrate and the result desired. HFW has in-house laboratory facilities to qualify and test coatings to customer required specifications.

Thermal spray  processes we perform in-house include:

– High Velocity Oxy-Fuel or HVOF Coatings (pictured above)- dense metal/ carbide coatings

– Plasma Coatings- metal, ceramic and cermet coatings

– Sprayweld Coatings- metal alloys fused to the substrate

– Rokide Coatings- select ceramic coatings

– Metallize Coatings- metal coatings by wire or powder processes

 

HFW can apply any material that does not decompose as it is melted. These materials include pure metals, ceramics, cermets and polymers.

With over 60 years of proven success in extending equipment life, HFW will work with you to develop coatings specific to your application . We have been successful in designing coatings that have extended the life of equipment over ten-fold, savings millions of dollars for our customers! Ask us how our coating technology may be able help in your application!

Consider HFW Industries ‘One Source’ service in helping extend the life and reducing the cost of your application!

 

 

HFW’s Machining complements Coating, Finishing & Assembly Capabilities Providing ONE SOURCE Service

February 3rd, 2014
 Quick Links

Our Website 

HFW Services

 
 

   CNC Machining-Haas-Bowl

   How HFW’s One Source Solutions Help You!

Along with our machining capability, HFW has been providing weld overlays and thermal spray coatings for prolonged life and restoration of equipment used in highly corrosive atmospheres.

By providing one source service, our customers receive the confidence that one proven supplier will handle all the technical issues that come with properly preparing and finishing coated pieces of equipment.

Additional services include…

~ Dynamic Balancing
~ Stress Relieving
~ Precision Grinding
~ Superfinishing
~ Assembly
~ Project Management
 HFW Industries, Inc.

ISO 9001:2008 Registered

196 Philadelphia Street

Buffalo, New York 14207

Ph: 716.875.3380

Fx: 716.875.3385

E-mail: sales@hfwindustries.com

Over the last couple years, HFW has greatly expanded our machining capabilities – from the addition of new state-of-the-art CNC machinery to a growing team of highly skilled machinists.

Known for many years for high quality machining of mostly larger parts, we’ve grown to include CNC machining of a wider range of sizes and complexity, allowing us to expand our in-house capability for production and assembly work.

CNC Machining-Okuma Cell
(Pictured: Above- CNC cell/ Left- programming our Horizontal Machining Center.

 Below- turning of 48″ O.D. turbine shaft)

 Lathe-Turbine   Machining Capabilities Include:    ~ Turning

  • Lathes (13)- to 50″ Dia. Swing x 312″ Long
  • CNC (5)- to 37″ Dia. Swing x 200″ Long
   ~ Milling Centers

  • CNC Vertical Machining Centers (2)-  to 25″ x 60″ Table
  • CNC Horizontal Machining Center (1)- 36″ x 64″ Table
  • Bed Type Mill (1)- 32″ x 78″ Table
  • Horizontal Boring Mills/ Manual (2)- to 62″ x 68″ Rotary Table
  • CNC Horizontal Boring Mill (1)- 55″ x 63″ Rotary Table

   ~ Miscellaneous

  • Planers (2)- to 36″ x 96″ Openside
  • Radial Drill
   Whether it’s the manufacturing or restoration of equipment
or components, one piece or one-hundred- consider HFW
for your upcoming requirements!

Is it possible to improve quality, save money AND reduce downtime by repairing instead of replacing equipment?

January 24th, 2014
Check out the following
“Quick Links”
for additional information 
  
  
 

 

Application Example

(Vacuum Pump)

 * After pump disassembly and cleaning our scope was as follows…

 * Shaft and Rotor Assembly- Machine drive, seal and packing sleeve diameters and machine to prepare cone fits of rotor for coating.  Thermal spray with Hastelloy C and finish.

 * Cones- Thermal spray with Hastelloy C and finish grind to assure proper fit with rotor.

* Heads- Pressure test, machine inboard face and pilot diameter for coating and thermal spray with Hastelloy C and finish.
* Assembly- Assemble complete including bearings, seals, gaskets and packing along with dynamic balancing and painting as required.
The results?
Life of the pump
increased from 9-18 months to 5 years!

Email:  Sales@hfwindustries.com
HFW Industries, Inc.
196 Philadelphia St.
Buffalo, N.Y. 14207
Ph: (716) 875-3380
Fx: (716) 875-3385
Simply… YES! 

How?

By extending equipment life with coatings that rebuild diameters and reduce future wear and corrosion, while having all the work performed under one roof.

HFW has the unique ability to combine thermal spray coatings and weld overlays with precision machining, precision finishing and assembly.

These capabilities give us the capacity to repair and manufacture parts beyond mend.

Typical repair applications include:
  • Centrifuges
    • Scrolls/ Bowls/ Heads

       

  • Pumps (Vacuum / Liquid)
    • Rotors/ Cases/ Various Components
  • Gearbox Covers
    • Repair worn bores
  • Bearing Housings
    • Thrust and Radial, plus Seal Housings
  • Mixers/ Agitators
    • Shafts/ Paddles/ Blades/ Complete Assemblies
  • Valves
    • Guides/ Bodies/ Stems
  • Compressors
    • Reciprocating- Cylinders/ Piston Rods/ Pistons
    • Turbo- Shafts/ Rotor Assemblies

Grinding-Power-Turbo Shaft2

For 65 years we have been partnering as an OEM’s service
arm and working with end-users who have
special engineered equipment.
Let us put our experience to work for you!

Services for the Power Generation Industry

January 20th, 2014
Quick Links
 
 
 
 
 
 
View our profile on LinkedIn

Applications

Typical power related applications include, but are not limited to…

 * Component Reconditioning

* Shafts- Turbine, Turbocompressor (and more)

* Seal & Bearing Housings

* Rotor Components

* Pistons & Piston Rods

* Seals

* Valve Seats & Discs

* Valves and Valve Stems

* Bushings and Couplings

* Gear Box Bore Repair

* Various steam path components

    HFW Industries offers One Source services for the Power Generation industry’s component and assembly manufacturing and repair needs. We focus on solutions that reduce costs, shorten lead times and eliminate hassles of working with multiple vendors.

Check out our robotic HVOF thermal spray coating process, used for a power plant application… 
Power Gen Plant Fan Blade Metallizing.MOV

 

Recent equipment added!

Since 1947 HFW has remained at the forefront of industry innovations with continual investment in thermal spray technologies and our related manufacturing processes.

Recently we have added new equipment that includes…

  • Schenk Dynamic Balancing System
  • Metco Plasma Thermal Spray System
  • HAI HVOF Thermal Spray System
  • Dynabrade Superfinishing Equipment

We have also added to our weld shop to allow for additional in-house fabrication!

HVOF Thermal Spraying with Tungsten Carbide

January 17th, 2014
Quick Links
 
 
 
 
 
 
View our profile on LinkedIn
 

 

 

 WC/ Co/ Cr

Coating Properties

 * Microhardness:  

 1,000-1,350 DPH (300g)

  * Bond Strength (per ASTM C633):

 10,500+ PSI

 * Porosity:

 < 1%

  * Est. Max. Service Temp.:

 1,000 deg. F

 * Est. Surface Roughness as Sprayed:

 150-250 Ra

 * Possible Surface Roughness as Finished:

 1-5 Ra

 
 HFW Industries has been providing thermal spray coating solutions since 1947 and High Velocity Oxy-Fuel (HVOF) coatings for over 20 years.
 
 In addition to the HVOF process, HFW also applies thermal spray coatings using flame spray, electric arc metallizing and plasma spray processes. 
 
 During the 1980’s the HVOF process was developed to be an accessible market alternative to Union Carbide’s D (detonation) gun process.
 
 HVOF uses the internal combustion of fuel gases (ex: propylene, propane, hydrogen or kerosene with oxygen) to produce a hypersonic gas stream into which the coating material is fed. The powder is heated and propelled by the gas stream at hypersonic velocities against the workpiece where molten coating particles impact and form a homogenous coating structure.
 

 Tungsten Carbide/ Cobalt/ Chrome coatings can be used for abrasion and sliding wear resistance when some corrosion protection is required. Typical applications include piston/ compressor rods, sleeves, fan blades, mechanical seal faces, process rolls, and at times as a replacement for chrome plating.

Photomicrograph Image of 
Tungsten Carbide (86%) with Cobalt (10%) and Chromium (4%) using 
HFW’s HVOF Thermal Spray Process
  

86-10-4 WC-Co-Cr 

 HFW Industries offers ISO 9001:2008 registered services for manufacturing and repairing equipment used in demanding applications that can utilize our expertise in combining our coating technology with our precision machining, finishing and assembly capability. 
 
 We focus on One Source solutions that reduce costs, shorten lead times and eliminate hassles of working with multiple vendors.

 

 HFW Industries, Inc.

 (716) 875-3380

Send us an email

   

Check out our CNC Machining capabilities

August 15th, 2011
 

Expanded CNC Machining Capabilities

Specializing in:

Conventional and CNC Machining of All Metals 

 
 

 

Check out the following “Quick Links” for additional information 

 

 

 
 

We appreciate the opportunity to keep earning your business!!

 

Over the last two years, HFW has greatly expanded its CNC machining capabilities – from the addition of new state-of-the-art machinery to a team of highly skilled CNC specialists.  Known for many years for high quality machining of mostly larger parts, we’ve grown to include CNC machining of a wider range of sizes, while still maintaining our industry leading reputation for quality. 

Our single source solution to your manufacturing or repair needs is still what separates us from our competition. From CNC machining, to service life enhancements – like ceramic or carbide coatings, we have the experience to put it all together – all from one location – all aimed at making your life easier. 
 
Whether it’s one piece or a hundred, we’re ready to help! 

  

 

CNC capabilities include:

  • Turning to 40″ diameter x 200″ centers
  • Horizontal Boring Mill- 55″ x 67″ Rotary Table   X=78″  Y=59″  Z=57″   60 Tools
  • Horizontal Machining Center- 30″ x 80″ Table with 30″ Built In Rotary Table    
  • Vertical Machining Centers- To 25″ x 60″ Table
  • Rotary Tables & Indexing Heads

  

 

 

Let us know of your upcoming needs.

 Sincerely,

Ronald Jurewicz, Mfg Mgr. – rjurewicz@hfwindustries.com

Matt Watson, Vice Pres. – mwatson@hfwindustries.com

HFW Industries, Inc.

Phone: 716-875-3380

Fax: 716-875-3385 

 

 
 

Maybe you can improve print quality and lower costs by repairing your cylinders too?

July 27th, 2011

    Can you reduce  your cost of quality by repairing your offset-web press cylinders?

 

 

 Engineered Services for Print Cylinders include: 

  • Complete Plate & Blanket Cylinder reconditioning
  • Journal repairs
  • Bearer changes
  • Dynamic balancing

 

 Journal Repairs  Maybe you don’t need to repair the whole cylinder? 

Over time, journal diameters can wear and cause a reduction in production quality and efficiency.

Sometimes plate or blanket cylinders require complete reconditioning, but sometimes a simple repair to the journal, or a re-stubbing of journals may be all it takes to keep your press running effectively.

The cost of repairing a journal, versus replacing or reconditioning an entire cylinder equals reduced maintenance costs.

Replacing and repairing journals has been an important part of how we save money for our customers every day.

Let HFW help you find ways to minimize your repair costs, while maximizing production!

 

  HFW Industries, Inc.

ISO 9001:2008 Registered

196 Philadelphia Street

Buffalo, New York 14207-0008

Ph: 716.875.3380

Fx: 716.875.3385

E-mail: sales@hfwindustries.com

 

High quality print is imperative in today’s environment. The cost of scrap and press downtime due to poor quality can cost you money or even a customer!

For over 40 years, HFW Industries has worked with offset-web press OEMs, rebuilders and print facilities to keep production running profitably by repairing press cylinders. Better running cylinders equals better running presses.

 

It all starts with a detailed inspection of your worn cylinders to determine the work scope involved. See below for details…

 

 Going from worn to new

Every print cylinder that comes into HFW for reconditioning goes through the exact process outlined below, resulting in the same outcome – highly satisfied customers!

Step 1: Detailed Inspection

  • Disassembly and cleaning
  • Preliminary inspection of cylinder
  • Received condition (Diameter, TIR and surface condition)
  • Review parts for condition

Step 2: Engineered Services Manager Review

  • Analyze condition and establish work scope
  • Review with customer (If desired)
  • Prepare quotation (Or work scope summary)
  • Submit to customer

Step 3: Customer Approval

  • We will not initiate work until our customer fully approves and understands the work scope entailed

Step 4: Remanufacture

  • Prepare for coating
  • Establish Duragap® protective edge (If desired)
  • Thermal spray (Via metallize, plasma spray, or HVOF processes)
  • Proof finish
  • Precision machine slot (gap) to required width and radii
  • Dynamic balance and make necessary weight corrections (If required)
  • Assemble and install new bearers, bearings, and component parts
  • Finish grind to specifications
  • Final assembly
  • Inspection / documentation
  • Packaging

 

To learn more, please visit us at www.reconditionedprintcylinders.com.

Sincerely,

Matt Watson, Vice President- mwatson@hfwindustries.com

Ron Jurewicz, Manufacturing Mgr.- rjurewicz@hfwindustries.com

 

Can thermal spray improve your uptime and lower costs?

July 27th, 2011

   What are thermal spray coatings?

Can they help you increase equipment service life and save cost by salvaging worn parts?

 

   Common Thermal Spray ApplicationsThermal spray coatings are used throughout many industries, from chemical, to power generation, to steel production to semiconductor. New applications are constantly developed.

Below lists general areas where thermal spray may be of significant benefit…

 

~ Replacement of chrome plating using tungsten carbide thermal spray

~ Life cycle improvements where wear and corrosion lessen the life of your equipment??

 

~ Restoration/ repair of old/ worn components or equipment.

Some common items repaired include…

  • Process Rolls
  • Shafts
  • Valve Components
  • Bearing Housings
  • Gear Boxes
  • Pump Components
  • Agitators
  • Printing Cylinders & Rolls
  • And many more… 

 

 

HFW Industries, Inc.ISO 9001:2008 Registered196 Philadelphia StreetP.O. Box 8Buffalo, New York 14207-0008Ph: 716.875.3380Fx: 716.875.3385

E-mail: sales@hfwindustries.com 

 

 
What is thermal spraying?

Basically, thermal spraying is when a coating material (in powder, rod or wire form) is heated to a certain temperature and then propelled in a molten state onto a substrate. The result is a mechanically bonded coating that will restore size or protect the substrate in the application.

It’s amazing that the thermal spray process, initially developed over 100 years ago in Switzerland by Max Ulrich Schoop, today uses technology that can spray coatings at supersonic speeds!

What separates HFW from our competition is our 60 years of expertise in thermal spray coating with complementary machining, finishing and assembly capabilities! 

This unique ‘One Source’ capability offers you high quality, timely manufacturing and repair service without the hassle of multiple vendors and blurred lines of responsibility.

 

 
 
How are thermal spray coatings applied? HFW remains at the forefront of thermal spray technology by using state-of-the-art equipment, including robotics, with our 25 plus thermal spray systems.   The process chosen is based on what is best for each application. That may depend on the material to be sprayed, the substrate and the result desired. HFW has in-house laboratory facilities to qualify and test coatings to customer required specifications.   Thermal spray  processes we perform in-house include: 

  – High Velocity Oxy-Fuel or HVOF Coatings (pictured above)- dense metal/ carbide coatings 

  – Plasma Coatings- metal, ceramic and cermet coatings 

  – Sprayweld Coatings- metal alloys fused to the substrate 

  – Rokide Coatings- select ceramic coatings 

  – Metallize Coatings- metal coatings by wire or powder processes 

  HFW can apply any material that does not decompose as it is melted. These materials include pure metals, ceramics, cermets and polymers.  

  

 

With over 60 years of proven success in extending equipment life??, HFW will work with you to develop coatings specific to your application . We have been successful in designing coatings that have extended the life of equipment over ten-fold, savings millions of dollars for our customers! Ask us how our coating technology may be able help in your application!

Consider HFW Industries ‘One Source’ service in helping extend the life and reducing the cost of your application!

Sincerely,

Matt Watson, Vice President- mwatson@hfwindustries.com

Ron Jurewicz, Manufacturing Mgr.- rjurewicz@hfwindustries.com 

Mark Sherman, Sales Engineer- msherman@hfwindustries.com

 

Could repair or re-stubbing of journals be all you need to fix your roll or cylinder?

May 24th, 2011

Over time, journal diameters can wear and cause a reduction in production quality and efficiency.

Sometimes production rolls or print cylinders require complete reconditioning, but sometimes a simple repair to the journal, or a re-stubbing of journals may be all it takes to keep your production line running effectively.

The cost of repairing a journal, versus replacing or reconditioning an entire roll or cylinder equals reduced maintenance costs.

Replacing and repairing journals has been an important part of how we save money for our customers every day.

Let HFW help you find ways to minimize your repair costs, while maximizing production!

What is Hardfacing? Can Hardfacing Reduce Your Costs Due to Corrosion, Wear and Down-time?

May 10th, 2011
The total cost of wear and corrosion on industrial equipment each year is so high it’s incalculable. There’s a lot of opportunity to increase your process up-time by improving your wear and corrosion resistance by using hardfacing!
  
Mechanical properties of many substrates don’t include inherent corrosion resistance and thus require hardfacing to enhance their performance.
  
Ask us how we help our customers with hardfacing technology when we combine it with our machining, finishing and assembly capabilities!
 
So What Is Hardfacing? Hardfacing, or hardsurfacing, is a term used when a layer of weld overlay is applied over a base material in order to prolong the life or restore dimensions of the component. The bond formed between the overlay and base metal is metallurgical.

Methods for applying hardfacing include (but are not limited to):

  • Plasma Transferred Arc
  • Oxy-Acetylene Torch
  • TIG/ MIG/ Sub Arc

 Typical base materials that are hardfaced include:

  • Low & Medium Carbon Steels (ex: 1020/ 1030)
  • Alloy Steels (ex: 4140, 8620)
  • Stainless Steels (ex: 304/ 316)
  • Super Alloys
When to Consider Hardfacing?
  
~ When a component needs to be replaced and repair may be a low-cost option
  
~ When your application is in a highly corrosive atmosphere
  
~ When wear on a component becomes an issue over it’s life cycle
  
Think about your equipment’s life cycle, up-time requirements, part inventory cost and cost to replace versus repair a process component…
  
Common Hardfacing Applications
 
Steam valve components Compressor rods and sleeves
Pump cases and components
Mixing equipment
Extruder screws
Process rolls
Centrifuge screws
Seals
Fan blades
Molds
Dies
Plungers
Mining equipment
… and many more!

Every application is different. Reasons vary as to what will be the best method for hardfacing and what materials should be used. Typical materials are noted below.

 Commonly applied materials for reducing wear: 

(Includes wear via combinations of abrasion, impact, metal-to-metal, heat, etc.)

  • Tungsten carbide
  • T420 Stainless Steel
  • Cobalt based materials
  • Nickel based materials
Commonly applied materials for reducing corrosion:
 
 

 

  • T316 Stainless Steel
  • Hastelloy ‘C’ 276
  • Cobalt based materials
  • Nickel based materials

Our extensive in-house manufacturing and repair capabilities with almost 65 years experience give us the ability to offer you high-quality and timely services without the hassles of multiple vendors and blurred lines of responsibility.

Let HFW Industries quote our ‘One Source’ service for your upcoming project!