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| Spray Galvanizing |
Atomized particles of molten Zinc are projected on to a Grit or Sand blasted steel surface from a special flame or arc pistol fed with Zinc wire. The process is often applied to structural components too large to be dipped in a galvanizing bath, and to structures which are likely to distort during hot dip galvanizing. Zinc coatings for iron and steel provide excellent corrosion resistance in most atmospheres, and in contact with many natural and synthetic substances. Zinc coatings are widely used to protect finished products ranging from structural steelwork for Chemical, Fertilizer, Refinery, Cement, Power plant, buildings, bridges, Pipe lines, etc.
The electrochemical relationship between zinc and steel enables zinc coatings also to protect steel at cut edges and at breaks in the coating by a sacrificial action.
Applications
All steel structures
Transformer Tanks
Radiators
Dairy coils
Communications towers
Steel Tanks
Wind Mill Towers
Electric Poles
Gates
Windows
Building Structures
Gutters in chemical - related industries
Advantages
Proven long term protection
Cold process
No size limitations
Ideal surface for painting
Site jobs possible
No hydrogen embrittlement
Preferred even under alkaline condition
Standards
IS : 5905 IS : 6586
BS : 5493
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| Aluminizing |
Thermal Spraying of Aluminium or Aluminizing involves deposition of Aluminium of 99.5% purity over the prepared surface. The sprayed metal is melted by using Electric Arc that is atomized with compressed air and projected over the substrate, and is prepared using Sand & Quartz Blasting. According to the IS & BS Standards, it would be resistant up to 950ºC temperature.
Thermal Spraying of Aluminum or Aluminizing involves deposition of Aluminum of 99.5% purity over the prepared surface. The sprayed metal is melted by using Electric Arc that is atomized with compressed air and projected over the substrate, and is prepared using Sand & Quartz Blasting. According to the IS & BS Standards, it would be resistant up to 950ºC temperature.
The Aluminizing process is used to protect parts operating in high temperature environments against corrosion and oxidation. As a result, the most common parts coated are high temperature industrial chimney and muffler.
Railway Bridges are aluminum metallized for corrosion protection.
Ship hulls are aluminum metallized periodically for corrosion protection.
Advantages
Site job possible
No size limitation
Better surface preparation
Cold process
Pure aluminum coating
Ideal surface for painting
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| Sand Blasting |
With our vast industrial experience, we have been able to provide value-added sand blasting services to the clients at the competitive prices. Our company is driven by skilled and motivated professionals, who are well-versed with various aspects of glass san blasting and wet sand blasting. We utilize advanced sand blasting equipment and sand blasting machines to enhance the quality of our sand blasting as per the industrial standards.
Our staff use high quality sand blasting abrasive to increase the standard of quality. Wet/ glass sand blasting done by us are well-known for its smooth edges and surfaces. We constantly upgrade our sand blasting machines to keep pace with the set quality norms.
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| Copper Slag Blasting |
We have set a benchmark in the industry by offering reliable and faster copper slag blasting services to the clients. Our professionals undertake every step of copper slag sand blasting smoothly with utmost care. They make use of high quality copper slag blasting media to enhance the quality of copper slag blasting. We have maintained the standard of highest quality level in the best possible manner.
Granulated copper slag blasting is mainly used to remove thick & tough dust and rust from heavy machines and tanks. Copper slag sandblasting undertaken by us is well-known for its fine finishing, smooth edges and accuracy. We assure our clients that copper slag sandblasting are completed within stipulated time frame as per the customized orders of clients.
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| Grit Blasting |
Being a professionally managed company, we are actively involved in providing spectrum of grit blasting services. Fitted with modern in-house grit blasting facilities, we have been able to handle all kinds of sand grit blastingefficiently. Our efforts and experience is directed towards attaining complete client satisfaction by offering effective grit blasting.
The use of ultramodern grit blasting machines and equipment has enhanced the quality of grit blasting as per the industrial standards. Through our qualitative grit blasting services, we have been able to remove large area of paint or gel coat. Our grit blasting is suitable fir cutting back corroded metal surfaces. We have been able to undertake all types of internally and externally blasting.
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| Sealant |
he metal-sprayed coating applied over steel and iron structures is a complete protective system within itself. However, sealant is used in order to enhance the protection level and give the coated metal a pleasing appearance. Among the beneficial characteristics of aluminizing are:
- It perforates and fills the pores, thus reducing the total area of the exposed metal and therefore decreasing the rate of dissolution of the coating.
- It smoothes the surface texture preventing the retention of grime and other contaminants, thus reducing still further the rate of surface attack.
- By smoothing the surface texture the appearance of the coating will remain cleaner and more attractive than without a sealant, and may more readily be maintained in a clean condition.
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| Advantages |
Process
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Surface of steel structural is blasted by compressed air pressure with abrasives to remove all traces of rust or any foreign contamination and thus facilitate exposure of the base metal, within a few hours; the blasted surface is coated with zinc or aluminum. This is done by melting a zinc or aluminum wire in an electric arc or flame and atomizing the molten particles. These particles are then propelled by compressed air on to a blasted surface.
.Advantages
| Advantages of Aluminizing and Spray Galvanizing in comparison to ordinary painting |
All metals have properties that cause them to react as an anode or a cathode when coupled to another material in a corrosive environment. The application of zinc / aluminum (anodic coating) to iron substrates forms a protective layer and results in corrosion protection referred to as cathodic protection or sacrificial protection.
Aluminizing or Spray Galvanizing provides good mechanical interlocking based on quality abrasive blasted pre-treatment. Coating thickness of up to 500 microns can be applied though the industry standard is 100 - 150 microns. Aluminizing process is ideal in high temperature environment to prevent oxidation and corrosion. Coating with sealant provides a base for paints for longer life to structures.
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| Testing Process |
| The advantages of our services can be understood by the following |
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Every coating process is tested for adherence to IS & BS standards .We carry out the job of spray galvanizing / aluminizing to the coating thickness of 175 - 200 microns to be confirmed by the thickness measurement gauge before and after the coating process
The brief details of the test carried out on Zinc or Aluminized coating surfaces are:
THICKNESS OF COATING : This test is carried out to ensure that the coating provided is to the accepted standards. A self calibrated coating thickness gauge with test pieces is used for testing the thickness of Zinc/Aluminum Coating as per IS: 3203:1982.
PURITY TEST : Purity of Zinc / Aluminum wire used is tested in an external laboratory ascertain which should 99.95% pure be as per IS: 209.A certificate to this effect can be provided to the customer along with our test certificate if desired.
BOND TESTS : This test indicates the mechanical bonding of Zinc/Aluminum coating to the substrate. This is carried out by using an special Bond Tester as per ASTM-D 4541-1985. A dolly is fixed on a sample piece using an adhesive material and by forcing it to be pulled out by using the Bond Tester. The load at which this dolly gets separated from the test piece indicates the bonding strength in terms of PSI (Pound per Square Inch). Secondly by using a scriber, several lines at close intervals are drawn on the coated surface as per IS: 5905. The coating along the lines should not peel-off.
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| Stress Relieving |
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Machining induces stresses in parts. The bigger and more complex the part, the more the stresses. These stresses can cause distortions in the part long term. If the parts are clamped in service, then cracking could occur. Also hole locations can change causing them to go out of tolerance. For these reasons, stress relieving is often necessary.
Typically, the parts that benefit from stress relieving are large and complex weldments, castings with a lot of machining, parts with tight dimensional tolerances and machined parts that have had a lot of stock removal performed.
Stress Relieving is the controlled heating and cooling of metals to alter their physical and mechanical properties without changing the product shape. Stress relieving is sometimes done inadvertently due to manufacturing processes that either heat or cool the metal such as welding or forming. Stress relieving is done at about 650°C for about one hour or till the whole part reaches the temperature. This removes more than 90% of the internal stresses. Alloy steels are stress relieved at higher temperature. After removing from the furnace, the parts are air cooled in still air.
Stress Relieving is often associated with increasing the strength of material, but it can also be used to alter certain manufacturability objectives such as improve machining, improve formability, restore ductility after a cold working operation. Thus it is a very enabling manufacturing process that can not only help other manufacturing process, but can also improve product performance by increasing strength or other desirable characteristics. Steels are particularly suitable for heat treatment, since they respond well to heat treatment and the commercial use of steels exceeds that of any other material.
At Mythri Metallizing (P) Ltd., we are rather proud to boast that we are equipped with the state-of-the-art ,a 5x3x2.5 meters furnace for the purpose of Stress Relieving at our works in Peenya Industrial Area, Bangalore.
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