TPT July 2011

C oating , P iCkling & g alvanising

Zinc spraying on tube seam A ROLL forming machine draws hot or cold rolled steel through successive stations and shapes the material into a tube. Electric resistance welding closes the seam left by the butted edges. Although no filler metal is added that would change the chemical compositions, the welding process applies temperature high enough to sacrifice some corrosion resistant properties of the base metal. The process may also vaporise

alloy materials to reinstate the corrosion resistance properties of the tubing. Applying the spray material while the weld seam is still hot assures a metallurgical bond of the substrate, improves both the deposit efficiency and density of the sprayed material, and allows the coating to blend, thereby helping the weld seam. Arc spray is, in terms of operating cost, the least expensive of the thermal or metal spraying processes used for applying metal coatings to base materials. Any electrically conductive material in wire form can be arc sprayed. The wire pulling system is powered by an AC motor fitted in the gun, which ensures precision wire feed speed. The wires meet at the head of the gun and melt in the electrical arc, and the molten mass is atomised and blown on to the substrate with compressed air. The particles cool to ambient temperature and coalesce into a high quality metal coating. Metallizing Equipment Co Pvt Ltd has supplied this system to tube mills throughout the world. Metallizing Equipment Co Pvt Ltd – India Fax: +91 291 2746359 $25,000 saved in rework over an 8-month period); receive regular technical service visits from Quaker, resulting in increased worker morale because the operations staff felt taken care of by their management team; and increase its own market image and as a result gain new business. To learn more about Quaker Chemical and its full product line offerings, including its UV-curable series of coatings, please visit quakerchem.com Quaker Chemical Corporation is a global provider of process chemicals, chemical specialities, services, and technical expertise to a wide range of industries – including steel, aluminium, automotive, mining, aerospace, tube and pipe, coatings and construction materials. Quaker’s products, technical solutions, and chemical management services enhance customers’ processes, improve product quality, and lower costs. Quaker’s headquarters is located near Philadelphia in Conshohocken, Email: sales@mecpl.com Website: www.mecpl.com

aluminium or galvanised coatings previously applied to the rolled steel. A contoured scrafing tool or smoothing mandrel removes welds pattern or excess material from the outer diameter of the tube surface. Many tube makers install a two-wire electric arc spray process directly down line from the scrafing tool or smoothing mandrel. The spray process applies coatings of aluminium, zinc or their

The Metallizing Equipment machine applies cooatings to aluminium and zinc or their alloy material

Flexible UV coatings help to build business

Quaker used its integrated knowledge of steel manufacturing, metalworking fluid processes and coatings chemistry to recom- mend an appropriate solution that would not only increase the flexibility of the tube coating, but also offer superior corrosion protection and increase the cosmetic appearance of finished tubes. The resulting elimination of rejects/returns and improved quality not only decreased costs, but also opened new sales opportunities for the manufacturer. Quaker’s customised QUAKERCOAT ® product is a high-gloss, 100% UV-curable, permanent protective coating. This product offers a lower total applied cost, because the formulation chemistry provides balanced properties for flexibility, hardness and corrosion protection. In addition, this eco- friendly line contains zero-VOC emissions, has virtually no overspray and very limited discharge, and is available in different colours. By switching toQuaker’sQUAKERCOAT ® UV product, the tube manufacturer was able to: eliminate the premature corrosion issues, which resulted in significant cost savings ($85,000 saved in lost claims and

WHEN a US tube manufacturer repeatedly experienced premature corrosion on pipes, end-user warranty claims and unanswered service requests to their coatings supplier, management realised it needed serious help from industry experts. They took action and contacted Quaker Chemical Corporation. Quaker is a leading global provider of process chemicals, services and technical expertise to a wide range of industries. It offers a complete “front-to-back” product portfolio for the tube & pipe industry, including lubricants, coolants, cleaners, rust preventives and coatings – including UV coatings.

Pennsylvania. Quaker – USA Website: www.quakerchem.com

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