ООО «Gefest ximremstal montaj»
Installation and repair of technological equipment
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LLC "GEFEST HIMREM STALMONTAZH"
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Highly qualified certified engineering and technical staff
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Workers with extensive experience in the construction of complex facilities
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Individual approach to each customer
OUR SERVICES
CONSTRUCTION AND ASSEMBLY WORKS
INSTALLATION OF TECHNOLOGICAL EQUIPMENT
INSTALLATION OF PROCESS PIPING
INSTALLATION OF TECHNOLOGICAL AND BUILDING METAL STRUCTURES
CONSTRUCTION AND ASSEMBLY WORKS FOR EXPLOSIVE PRODUCTIONS
CHEMICAL
PETROCHEMICAL
AND OTHER OBJECTS ASSOCIATED WITH THE USE OR STORAGE IN THEM OF TOXIC SUBSTANCES
CONSTRUCTION AND ASSEMBLY WORKS AT:
REPAIR
OVERHAUL
RECONSTRUCTIONS
MODERNIZATIONS
PERFORMANCE OF CONSTRUCTION AND ASSEMBLY WORKS ON:
INDUSTRIAL FACILITIES
HOUSING AND CIVIL OBJECTS
OBJECTS OF THE SOCIAL SPHERE
OPERATING PRODUCTIONS
OPEN AREAS
TECHNOLOGICAL PROCESS
TECHNOLOGIES AND EQUIPMENT FOR GAS-THERMAL SPRAYING AND SURFACING
is an innovative company with highly qualified
a team of specialists in the field of gas-thermal technologies and surfacing with more than 10 years of experience in the application of coatings in various industries.
The main focus of solutions is concentrated on surface modification using the following technologies:
- Flame spraying
- High-speed flame spraying using liquid fuel (kerosene)
In order to perform work on hardening surfaces by surfacing, a semi-automatic wire surfacing installation is used. In addition, a small coating booth is provided for test work with the required auxiliary
equipment.
a team of specialists in the field of gas-thermal technologies and surfacing with more than 10 years of experience in the application of coatings in various industries.
The main focus of solutions is concentrated on surface modification using the following technologies:
- Flame spraying
- High-speed flame spraying using liquid fuel (kerosene)
In order to perform work on hardening surfaces by surfacing, a semi-automatic wire surfacing installation is used. In addition, a small coating booth is provided for test work with the required auxiliary
equipment.
Our installations include:
- coating installation (gun with control modules)
- soundproof chamber
- forced ventilation system with required filters
- gas supply system
- compressed air supply system (including for cooling parts)
- coating installation (gun with control modules)
- soundproof chamber
- forced ventilation system with required filters
- gas supply system
- compressed air supply system (including for cooling parts)
APPLICATION (REPAIR) OF BABBIT INSERTS/BEARINGS
1. Insert with damaged babbit layer
2. The liner after removing the babbit layer before coating
3. View of the liner with a cylindrical surface (without dovetail)
4. Application of the babbitt layer on the liners assemblies
5. Insert after spraying
6. Finishing the coating in size
Coating must be carried out with the condition
providing the required enforcement system
ventilation - an exhaust hood with an air duct system that provides a reduction in potential harm from particles of the sprayed material.
2. The liner after removing the babbit layer before coating
3. View of the liner with a cylindrical surface (without dovetail)
4. Application of the babbitt layer on the liners assemblies
5. Insert after spraying
6. Finishing the coating in size
Coating must be carried out with the condition
providing the required enforcement system
ventilation - an exhaust hood with an air duct system that provides a reduction in potential harm from particles of the sprayed material.
SEALING COATINGS
This type of coating provides the ability to create a gap
controlled value between the movable and fixed parts of the unit assembly.
A coating of this type is applied with a sufficiently large thickness (up to 2 mm or more), which, taking into account the loose structure, provides protection against potential damage to the assembly parts
in case of their contact during the operation of the unit.
The part is installed in the protective equipment of the required configuration, which provides protection against sandblasting and coating of adjacent surfaces
parts not intended for coating. The part is removed from the tooling after coating.
controlled value between the movable and fixed parts of the unit assembly.
A coating of this type is applied with a sufficiently large thickness (up to 2 mm or more), which, taking into account the loose structure, provides protection against potential damage to the assembly parts
in case of their contact during the operation of the unit.
The part is installed in the protective equipment of the required configuration, which provides protection against sandblasting and coating of adjacent surfaces
parts not intended for coating. The part is removed from the tooling after coating.
Detail of the "sleeve" type after applying the sealing coating Compositions of the most commonly used materials for this type of coating:
• Composites of aluminum-silicon alloy + graphite
• Nickel-graphite composites
• Composites of nickel, chromium, aluminum and boron nitride
• Composites of aluminum-silicon alloy + graphite
• Nickel-graphite composites
• Composites of nickel, chromium, aluminum and boron nitride
PROTECTIVE COATINGS FOR COPPER MOLDS OF BLAST FURNACES
This type of coating should provide protection from two main factors affecting the lance during its operation:
- Contact of the surface of the lances with splashes of molten metal
- Erosive wear resulting from contact with a hot gas stream, incl. with its impurities in the form of solid particles.
Protection of the most loaded part of the lance (snout) can be provided by applying the following coatings:
- Coatings based on Al (aluminizing)
- Various ceramic coatings
- Ceramic coating with impregnation, which includes ceramic inclusions (particles of fine fraction)
All of the above methods are acceptable methods for protecting lances, however, it is the last solution that provides
the most significant increase in the life of the lances.
- Contact of the surface of the lances with splashes of molten metal
- Erosive wear resulting from contact with a hot gas stream, incl. with its impurities in the form of solid particles.
Protection of the most loaded part of the lance (snout) can be provided by applying the following coatings:
- Coatings based on Al (aluminizing)
- Various ceramic coatings
- Ceramic coating with impregnation, which includes ceramic inclusions (particles of fine fraction)
All of the above methods are acceptable methods for protecting lances, however, it is the last solution that provides
the most significant increase in the life of the lances.
FLOW SPRAY COATING
Reflow spraying is one of the best solutions for protecting the surfaces of a part, when, under its operating conditions,
impact loads and various types of wear are presented.
In this case, maximum adhesion rates are provided, taking into account the formation of a metallurgical bond between the coating and
of the main part Ni-B-Cr-Si based coating composition provides high
indicators of wear and corrosion resistance of the surface with the appropriate coating. If the WC solid phase is included, the wear resistance index increases significantly.
impact loads and various types of wear are presented.
In this case, maximum adhesion rates are provided, taking into account the formation of a metallurgical bond between the coating and
of the main part Ni-B-Cr-Si based coating composition provides high
indicators of wear and corrosion resistance of the surface with the appropriate coating. If the WC solid phase is included, the wear resistance index increases significantly.
The main limitation of the process is the absence of unacceptable changes to the part (1) when heating to a level of 900-1000 C.
The surface of the part after the coating melting operation has a sufficiently low roughness, which in some cases is acceptable and does not require additional processing.
If necessary, mechanical processing is applied to achieve the required dimensions and roughness of the working surface.
The surface of the part after the coating melting operation has a sufficiently low roughness, which in some cases is acceptable and does not require additional processing.
If necessary, mechanical processing is applied to achieve the required dimensions and roughness of the working surface.
HIGH VELOCITY FLAME (HVOF-LF) COATING
The main application is the application of wear-resistant coatings based on carbides - WC-Co, Cr3C2-NiCr.
Taking into account the use of a selected sublayer, as well as specialized impregnations, a significant improvement in the corrosion resistance of coatings is provided.
This technology (HVOF) involves its implementation exclusively in a noise barrier with the highest possible degree of process automation.
The part is installed in the rotator to ensure its fixation and rotation in the process
coating.
Taking into account the use of a selected sublayer, as well as specialized impregnations, a significant improvement in the corrosion resistance of coatings is provided.
This technology (HVOF) involves its implementation exclusively in a noise barrier with the highest possible degree of process automation.
The part is installed in the rotator to ensure its fixation and rotation in the process
coating.
Refurbishment/repair and maximum durability
working surfaces of rollers, shafts, rods of equipment of various units (printing, rolling mills, oil and gas equipment units, etc.) is the most common use of this type of coating.
working surfaces of rollers, shafts, rods of equipment of various units (printing, rolling mills, oil and gas equipment units, etc.) is the most common use of this type of coating.
APPLICATION OF COATINGS BY THE METHOD OF GAS FLAME SPRAYING
Flame spraying is one of the most cost-effective methods of repairing various work
surfaces of parts. At the same time, in the case of using appropriate materials, a certain level of required
indicators of wear-, erosion-, corrosion resistance can be provided.
Unlike the HVOF method, where higher coating flame jet velocities are expected,
the possibility of using a wide range of different materials for masking and protecting non-sprayed surfaces of parts.
The main materials used for this technology:
- Alloys based on Ni-, Cr-, Fe
- Alloys based on Mo-, Al-, Zn
When coating is applied, a sufficiently bright spray jet flame is formed, which requires the use of protective welding goggles.
After coating, final machining is required to achieve the required size of the coated surface.
surfaces of parts. At the same time, in the case of using appropriate materials, a certain level of required
indicators of wear-, erosion-, corrosion resistance can be provided.
Unlike the HVOF method, where higher coating flame jet velocities are expected,
the possibility of using a wide range of different materials for masking and protecting non-sprayed surfaces of parts.
The main materials used for this technology:
- Alloys based on Ni-, Cr-, Fe
- Alloys based on Mo-, Al-, Zn
When coating is applied, a sufficiently bright spray jet flame is formed, which requires the use of protective welding goggles.
After coating, final machining is required to achieve the required size of the coated surface.
HARDENING / SURFACE
A semi-automatic welding machine is a necessary equipment for any center for applying gas-thermal coatings.
The main modes of its use:
- MIG/MAG for hardfacing
- TIG for tacking / fixing samples on the surface of a model / sample of a complex part
- Rough cleaning of the surfaces of the part with a carbon electrode.
The main modes of its use:
- MIG/MAG for hardfacing
- TIG for tacking / fixing samples on the surface of a model / sample of a complex part
- Rough cleaning of the surfaces of the part with a carbon electrode.
In the case of aggressive operating conditions of parts (impact load, abrasive wear, etc.), surfacing is an excellent solution to increase the life of parts. It is important to understand that only an experienced welder will ensure the performance of the required work, taking into account the specifics of the impact on the part (HAZ, possible temperature floods) and the formation of a high-quality deposited layer (potential hot, cold cracks in the layer, etc.)
Main Applications:
- Crowns/borans of agricultural machines
- Feed augers for various media (clay, rock, etc.)
- Wear-resistant plates, knives
The most acceptable solution is without the need for subsequent machining with a simultaneous wide tolerance in coating thickness (±2-3 mm).
Development of surfacing modes.
- Crowns/borans of agricultural machines
- Feed augers for various media (clay, rock, etc.)
- Wear-resistant plates, knives
The most acceptable solution is without the need for subsequent machining with a simultaneous wide tolerance in coating thickness (±2-3 mm).
Development of surfacing modes.
SURFACE PREPARATION BEFORE COATING
One of the most important aspects of the coating technology is the correct and high-quality preparation of the surface of the part to be coated.
The surface of the part must be:
- cleaned of dirt, oil and other traces of contaminants
- the surface profile must match
the intended method of coating, as well as the thickness of the applied coating.
The most widely used surface preparation method is ALD. It is necessary to pay special attention to the condition and particle size of the abrasive material used when performing surface preparation work.
The surface of the part must be:
- cleaned of dirt, oil and other traces of contaminants
- the surface profile must match
the intended method of coating, as well as the thickness of the applied coating.
The most widely used surface preparation method is ALD. It is necessary to pay special attention to the condition and particle size of the abrasive material used when performing surface preparation work.
If thicker coatings are required, it is preferable to use a combination
ASO and "torn thread" profile
The following techniques are used to prepare the surface:
- machining (turning) to achieve the required profile
surfaces - "torn thread"
- abrasive blasting (ASO)
- cutting "torn thread" + ASO
ASO and "torn thread" profile
The following techniques are used to prepare the surface:
- machining (turning) to achieve the required profile
surfaces - "torn thread"
- abrasive blasting (ASO)
- cutting "torn thread" + ASO
PREPARATION OF SAMPLES FOR PERFORMANCE OF METALLOGRAPHIC INVESTIGATIONS
The assessment of the quality of the applied coatings is carried out by the method of metallographic examination either of the segments of the part itself, or on witness samples. Sample preparation for
research in this case involves the following operations:
sample cut on an accurate cutting machine up to
required sizes; then the sample is installed in the mold and further fixed by pressing in a specialized resin. The final measure is the grinding and polishing of the surface of the pressed sample, provided for further research.
research in this case involves the following operations:
sample cut on an accurate cutting machine up to
required sizes; then the sample is installed in the mold and further fixed by pressing in a specialized resin. The final measure is the grinding and polishing of the surface of the pressed sample, provided for further research.
It is important to ensure detailed control in the implementation of all activities and, if possible, the maximum degree
automation of these processes.
After all the preparations have been completed, the sample is examined on an optical microscope for the ratio of qualitative and quantitative parameters with the provided standards and specifications for a specific type / type
coatings.
automation of these processes.
After all the preparations have been completed, the sample is examined on an optical microscope for the ratio of qualitative and quantitative parameters with the provided standards and specifications for a specific type / type
coatings.
ADDITIONAL METHODS OF CONTROL OF GAS AND THERMAL COATINGS
Together with metallographic studies, additional measures are taken to assess the quality of the applied coating.
Express test for coating adhesion by bending
coated plate/sample.
Checking the geometric dimensions of the surface with coatings to assess the thickness of the applied coating.
Inspection using penetrating liquids (capillary inspection) to detect possible, invisible to the naked eye cracks/damages in the coating after final machining
Surface roughness check
- after performing ASO
- after coating
- after the final machining
Express test for coating adhesion by bending
coated plate/sample.
Checking the geometric dimensions of the surface with coatings to assess the thickness of the applied coating.
Inspection using penetrating liquids (capillary inspection) to detect possible, invisible to the naked eye cracks/damages in the coating after final machining
Surface roughness check
- after performing ASO
- after coating
- after the final machining
INSTALLATION WORKS ON SUCH OBJECTS AS
OJSC "MAXAM CHIRCHIQ" REPUBLIC OF UZBEKISTAN,
G. CHIRCHIK
OJSC "FERGANAZOT" REPUBLIC OF UZBEKISTAN, FERGANA CITY
