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SIFCO ASC redesigns and rebrands heated flow systems: the TechnoFlow

SIFCO ASC, a Quaker Houghton company, has continued its commitment to improving the selective plating process by revolutionizing its heated flow system. The newly redesigned TechnoFlow can give operators and technicians data logging capabilities as well as improved safety features.

The units are designed to work with SIFCO Process® solutions that are best plated at an elevated temperature. The TechnoFlow 600 can hold over seven liters of solution, while the 1200 unit has a solution capacity of up to 12 liters. Both sizes contain no fuses and have internal circuit breakers as well as 24-volt finger-safe switches meeting UL and CE requirements.

One of the major improvements is the pump adapter plate providing better access to the frame mounting screws, making removing the large 14 GPM pump easier. Improvements have also been made to the pump connector plugs. The new twist lock system guarantees a safe power connection, yet easy removal when needed. Lastly, the TechnoFlow is now equipped with CPVC plumbing lines – providing both sizes a bypass filter – allowing technicians to change the filter mid-operation for large applications.

SIFCO ASC’s Engineering Manager, Derek Kilgore, said: “As well as making the overall electroplating process more efficient and user friendly, we wanted to improve the safety features for operators, such as lids with an o-ring seal to decrease solution splash. The system is now equipped with a PID temperature controller with auto-tuning functions, resulting in less overshoot of the set temperature and has the ability to log temperatures throughout the operation for post plating review.”

The TechnoFlow has recently been incorporated into SIFCO ASC’s new all-in-one plating system featuring dripless technology called the Advanced Solution Control System (ASCS).

As the world leader in selective plating technology, SIFCO ASC has been providing practical, cost-effective brush plating solutions for both OEM components and parts requiring refurbishment in the aerospace, oil and gas, general industry, and power generation sectors for over 50 years.

About SIFCO ASC

SIFCO Applied Surface Concepts provide practical, cost-effective selective brush plating solutions to improve part performance and reduce manufacturing costs through corrosion protection, increased wear resistance, increased hardness, improved conductivity, anti-galling, or slip.

SIFCO ASC surface enhancement technologies and brush plating services have been utilized for over 50 years on both OEM components and parts requiring refurbishment in the aerospace, oil and gas, general industry, and power generation sectors. www.sifcoasc.com

About Quaker Houghton

Quaker Houghton is the global leader in industrial process fluids. With a presence around the world, including operations in over 25 countries, our customers include thousands of the world’s most advanced and specialized steel, aluminum, automotive, aerospace, offshore, can, mining, and metalworking companies.  Our high-performing, innovative and sustainable solutions are backed by best-in-class technology, deep process knowledge and customized services. With approximately 4,700 employees, including chemists, engineers, and industry experts, we partner with our customers to improve their operations so they can run even more efficiently, even more effectively, whatever comes next.  Quaker Houghton is headquartered in Conshohocken, Pennsylvania, located near Philadelphia in the United States. Visit www.quakerhoughton.com to learn more.

Localized Transmission Case Repair Salvages Critical Component

The job of any vehicle’s transmission is to change gears to ensure the engine’s RPM’s are kept low (depending on speed and acceleration). When the vehicle’s transmission is in working order, fuel consumption is decreased, and the turning of the gears does not overload the engine.

With unpredictable environments and severe conditions, off-highway vehicle transmissions are put to the test every day in the mining industry. And when an off-highway vehicle is out for repair, it puts the operation and future revenues in jeopardy.   This unfortunately was the case for the largest coal mining operation in Kalimantan, Indonesia.

While a vehicle was out for repair, the transmission case was dismantled incorrectly causing cracks and damage to the surface. This company could have used spot welding to repair and fill these cracks, but the risk of additional cracks and heat distortion was too high. Familiar with brush plating, they approached PT Rep Sal Indo, a SIFCO ASC partner in Jakarta, Indonesia to determine if the SIFCO Process® of selective plating was an option.

Selective plating, or brush plating as it’s known, is a portable method of electroplating localized areas without the use of an immersion tank. Its portability allows component repairs and OEM enhancements to happen in-situ with minimal masking and disassembly. The process is also 60 times faster than tank plating, allowing for operations to be completed within one working shift.

The area of repair on the transmission case was 356 x 620 mm (14 x 24.5 inches) and required Copper 2050 to fill defected areas, and a cap of Nickel 2080 for wear resistance. First, PT Rep Sal Indo pre-ground the surface to remove any high spots. The cracks were then filled by laser welding, after which a copper topcoat was applied. The copper was then dressed back to ensure it was flat across the entire surface. Finally, the area was capped with nickel.

With the use of selective plating, the company was able to salvage the part, saving a considerable amount of cost that would come with replacing the transmission case. What’s more, is the repair was completed within its regular maintenance schedule and the vehicle was back in operation without any additional downtime.

Desafíos de operación y mantenimiento en PowerGen

Extracto de “Brillo selectivo: el uso de placas de cepillo en la industria PowerGen”, descargue el documento técnico aquí.

La mayor parte de la producción de energía eléctrica industrial y municipal en los EE. UU. es producida por generadores accionados por turbinas de vapor o de gas, con una potencia sustancialmente menor porcentaje producido por turbinas eólicas. En esencia, una turbina consiste esencialmente en una serie de álabes giratorios, la mecánica normal de los equipos giratorios es uno de los factores que contribuyen a una variedad de desafíos de mantenimiento.

Algunos problemas son más comunes en turbinas de gas donde la corrosión de los componentes de acero forjado de alta resistencia y alto costo puede ocurrir con el tiempo. La corrosión puede atacar el eje de la turbina u otros componentes en áreas críticas y, eventualmente, debilitar el eje. Dentro de una turbina, la corrosión y la posterior erosión del metal dan como resultado lo que se denomina “roca de cubo”. Esto ocurre porque las palas dentro de la turbina no están perfectamente equilibradas hasta que la turbina está funcionando a RPM máximas. Por lo tanto, cuando una turbina arranca o se apaga, las palas se balancean hacia adelante y hacia atrás hasta alcanzar la velocidad máxima o detenerse por completo. Este balanceo provoca raspaduras y rozaduras en el eje, lo que desgasta el metal y crea un área denominada cubeta, un espacio libre fuera de tolerancia entre las áreas del eje y las cuchillas. Los grupos electrógenos de carga máxima, sistemas de generación distribuida ubicados cerca del usuario final, están particularmente sujetos a tensiones adicionales debido a la frecuencia de los ciclos del servicio en línea al fuera de línea. Durante los períodos fuera de línea de rotación del engranaje de giro a baja velocidad, se produce el problema del desgaste de la roca del cucharón debido al impacto y la erosión de las tolerancias de precisión del ajuste del cucharón a la rueda.

Otros factores que afectan tanto a las turbinas como a los generadores son altos calor y corrosión continua. Se pueden producir daños por desgaste o rayado en los muñones de los cojinetes o en las áreas del sello del eje debido a una lubricación deficiente, contaminación o sobrecalentamiento. Diversos contaminantes atmosféricos y el potencial galvánico de metales diferentes pueden causar problemas de corrosión que a menudo pueden acelerarse con el calor o una variedad de superficies desgastadas.

Según un informe de la consultora GlobalData, se espera que el gasto mundial en mantenimiento aumente de 9.250 millones de dólares en 2014 a 17.000 millones de dólares en 2020, un crecimiento impulsado por el aumento del número de instalaciones y el envejecimiento de las turbinas.

Revestimiento selectivo es una forma de ofrecer propiedades anticorrosivas y proteger contra el desgaste y la fricción. Puede ayudar a proteger, mejorar y optimizar el rendimiento de los componentes y equipos críticos y puede ayudar a mejorar el rendimiento operativo, la expectativa de vida, la confiabilidad y el costo total de propiedad.

Para el OEM, los generadores plantean una variedad de desafíos únicos en el diseño, la producción y el mantenimiento, ya que las conexiones de la barra colectora transportan enormes cargas de corriente y la conductividad y la integridad a largo plazo de estas conexiones son esenciales para la eficiencia de producción. Los conductores de cobre y aluminio y otras ubicaciones críticas de conexión a tierra suelen galvanizarse con plata o estaño y, en ciertas aplicaciones, con níquel.

Las uniones dinámicas, que están sujetas a fricción, también pueden ser candidatas para procesos especiales de galvanoplastia, particularmente cuando se consideran metales diferentes y potencial galvánico en el diseño. Los disipadores de calor presentan un conjunto diferente de desafíos y, según la geometría, es mejor galvanizar áreas específicas del disipador de calor con plata, estaño o níquel, mientras que el resto del área de la superficie permanece desnuda o se le aplican recubrimientos tipo pintura.
Otras áreas en las que la galvanoplastia ofrece una solución eficaz son los anillos colectores y los componentes del excitador que pueden tener requisitos de diseño en los que los componentes electrochapados o las superficies específicas del componente requerirán una conductividad mejorada y una vida útil prolongada. Los diámetros interiores del anillo de retención del generador y el área de acoplamiento de ajuste por contracción en el forjado del rotor/campo a menudo requieren tratamientos superficiales mejorados para garantizar la integridad a largo plazo de la unión eléctrica, la capacidad de corriente y las dimensiones de ajuste adecuado.

Existe una variedad de métodos comúnmente utilizados para la reconstrucción de tolerancias mecánicas y la mejora y protección de superficies portadoras de corriente, algunos de los cuales incluyen recubrimiento de soldadura, metal/rociado térmico y polvos de metales plastificados, y revestimiento de tanques de inmersión fuera del sitio. Si bien todos tienen sus nichos, ninguno ofrece las claras ventajas del enchapado selectivo.

Significativamente más rápido que el revestimiento de tanques, el revestimiento selectivo minimiza el enmascaramiento, el desmontaje y el tiempo de inactividad, depositando soluciones que resisten el desgaste, el contacto eléctrico y la corrosión. Es rápido, rentable y adaptable para todo, desde la aplicación de productos OEM hasta reparaciones únicas, y puede llevarse a cabo en el sitio, en cualquier lugar.

In-situ Repair Maintains Critical Alignment

As with many machines, alignment of gears and components is critical. So, when even one component becomes out of round or out of tolerance, it can jeopardize not just the machine, but the entire operation with the threat of downtime and costly repairs.

Unfortunately, the largest coal mining operation in Kalimantan, Indonesia, experienced just this situation when a differential bearing housing became out of round from the relentless production required by the mining industry. But repairing this bearing housing isn’t as easy as it seems. They could build up the area with thermal spray, however this process is time consuming and comes with a high risk of mis-machining due to the critical alignment of the differential gear during assembly.

So, this coal mining company reached out to PT Rep Sal Indo, a SIFCO ASC partner based in Jakarta, Indonesia, specializing in the SIFCO Process® of selective electroplating. The SIFCO Process® is a portable method of electroplating localized areas without the use of an immersion tank. The use of handheld anodes allows technicians to mask off the specific areas to be plated, and apply the deposit in-situ, with minimal disassembly. Such was the case with the Differential Bearing Housing. By using selective plating, the repair was able to be completed with the gears installed, fully preventing the risk of misalignment. PT Rep Sal Indo fully repaired 2 internal diameters within 0.025mm – meeting the customer’s required specifications and significantly reducing potential downtime.

Restoring Tolerance to Wheel Hub Bolt Holes

Off highway vehicles face demanding environments. And every component of that vehicle is essential.

For the largest coal mining operation in Kalimantan, Indonesia, that critical component was a wheel hub assembly. The wheel hub assembly allows the vehicle to steer freely, and is critical to the anti-lock braking and traction control systems. But when a tire is changed, often multiple times as in the mining industry, the bolt holes become worn and oversized – not allowing the bolt shank to retain its position.

So, when 18 bolt holes of the wheel hub assembly needed resized, there was only a couple of options – electroplating or welding and machining. Build up by welding and machining, however, requires complex equipment, extensive downtime, and potential heat distortion and mis-machining. Electroplating, on the other hand, has no risk for heat distortion and can be plated to size. But, since tank plating was not an option due to the masking required to protect the rest of the component, they decided to contacted P.T. Rep Sal Indo, a SIFCO ASC partner in Jakarta-Indonesia who specializes in the SIFCO Process® of selective plating.

Selective plating is the portable method of electroplating and is used to apply electroplated deposits and anodized coatings in localized areas of a part without the use of an immersion tank. By using the SIFCO Process®, P.T. Rep Sal Indo was able to restore dimension to 18 bolt holes, by first building up the area with Copper 2050, then capping the holes with Nickel 5644 for wear resistance. The total internal dimension of bore was plated within 0.02mm of the required thickness.

Mining companies will continue to face the everyday challenge of wear and tear on their machinery, therefore forcing them to reduce costs through rebuilding and remanufacturing their critical components. With the use of the SIFCO Process® these components can be restored to their OEM standards with superior adhesion and minimal downtime – helping mining companies move forward towards more continuous, cost-efficient and sustainable operations.