Pumps
Pumps
Pumps and plungers are critical components of industrial equipment, and any failure can result in costly production downtime. These components are particularly susceptible to wear and corrosion due to high abrasion and operational stress.
At TSS, we engineer thermal spray coatings to enhance the performance and durability of pump components. From pump casings to wear rings, flanges, pistons, and plungers, we can recoat components indefinitely, extending their service life and reducing the need for replacements.
Impellers and Pump Casings
Applying corrosion- and wear-resistant coatings to impellers and face plates significantly extends component life, improving efficiency and reliability in harsh operating conditions.
Pump Plungers
The plunger is typically the component requiring the most frequent replacement, due to high-speed operation and frictional wear. To extend service life, plungers can be hardened or coated with wear-resistant materials such as tungsten carbide or ceramics. Coatings provide enhanced protection against wear, corrosion, and abrasion.
Material Options for Plungers:
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Ceramic: Ideal for low temperature/low pressure applications, including salt water, chemical, and metering systems. Offers excellent corrosion and abrasion resistance and extends packing life. Recommended max temperature: 180°F, max pressure: 2,000 psi.
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Chromium Oxide: Suitable for amine, glycol, fresh water, gasoline, or other fluids requiring restricted lubrication. Recommended max temperature: 600°F, max pressure: 10,000 psi.
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Tungsten Carbide (TC): Premium coating offering superior wear resistance compared to standard Hard-Co plungers. Slightly less corrosion resistance, but suitable for high-temperature applications up to 500°F and pressures up to 10,000 psi.
Wear Resistance
Coatings on impellers, pump casings, and plungers reduce friction and surface degradation, significantly prolonging component life and enhancing operational reliability.
Corrosion Resistance
Corrosion and erosion are primary causes of metal loss in pumps, especially when abrasion or cavitation is present. Corrosion occurs through electrochemical reactions between the metal and the environment, dissolving anodic metallic ions. Thermal spray coatings act as a protective barrier, dielectrically insulating the metal surface and safeguarding it against aggressive fluids.
With TSS thermal spray solutions, pumps and plungers achieve maximum reliability, extended service life, and reduced maintenance costs across a wide range of industrial applications.
Other contents
Neutral barrier coatings made from materials such as alumina or chromium oxide ceramics offer excellent corrosion resistance by effectively isolating the substrate from the corrosive environment.
Even if the coating is slightly porous, a neutral material generally does not accelerate substrate corrosion, though it is important to avoid any corrosion at the interface to prevent coating delamination.
For optimal performance, sealing or impregnation of the thermal spray coating is recommended. Thicker, denser coatings provide superior barrier properties, ensuring enhanced substrate protection and longer component life.
Cathodic barrier coatings are designed to be cathodic relative to the substrate, providing robust corrosion protection. For example, a stainless steel or nickel alloy coating will be cathodic to a steel substrate.
These coatings are highly effective, but they require a complete barrier between the substrate and the environment. If the substrate is exposed, it will act as the anode, accelerating corrosion and potentially causing coating spalling.
For maximum durability, sealing or impregnation of the thermal spray coating is recommended. Thicker, denser coatings enhance barrier properties, delivering superior protection and extended service life for pump components.
Sacrificial anodic coatings are primarily used to protect iron and steel substrates, typically employing zinc, aluminum, or their alloys. When applied, the substrate becomes the cathode, while the coating acts as the sacrificial anode, corroding preferentially to protect the underlying material.
Even if slightly porous, a standard thermal spray coating of zinc or aluminum largely blocks environmental exposure and provides effective cathodic protection. Where required, organic sealers or protective paint can be applied to the coating, further extending the life of the protective system by enhancing the barrier effect.
This approach is widely recognised as offering superior corrosion protection compared to traditional galvanising, plating, or painting, without incurring significant additional costs.
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