1. Easy to operate.
  2. Portable and usable width 100 to 220 volt outlet.
  3. On-site repair work which requires no dismantling of large machines.
  4. Extremely low heat input eliminates distortion, pits, shrinkage,and internal stress.
  5. Requires no pre and post heat treatments.
  6. Provides excellent bonding by the formation of diffusion layer.
  7. Rotating consumable electrode gives high deposition efficiency and produces excellent coating.
  8. High power output allows thick coating and retains its property for extended period.
  9. Very smooth as-coated surface is obtained with a vibrating applicator.
  10. Inert shield gas (Ar, He, etc.) produces excellent thick coating.
  11. Repeatable coating thickness and surface roughness can be obtained by adjusting the level of power output and frequency.
  12. Finishing stock of the overlay can be kept to the minimum,reducing finishing time.
  13. Repeated overlays possible over worn out coating.
  14. Environmentally safe. Produces no toxic gas, liquid, or unpleasant odor and noise.
  15. Application of "DiaCoat", fine spherical diamond particles, over the coating reduces the coefficient of friction.
Repair by overlay (lost wax aluminum die)



Part Name: V-Roll, Date: June 22.1994, Developed by: S.Aoshima
Machine Name: Pipe Transfer Unit
Problem Solved: SparkDepo coating eliminated slippage of small pipes due to worn roll surface.
Roll Materials, Size, Hardness,and Cost:
S45C (1045 Carbon Steel), 160 to 233 mm Dia. X 60 to 66 mm L, approximately 30kg (22 lb.), HQI Hs 69 to 65, and a total cost reduction by 80%.


Coating in Progress


Electro-spark Deposition (ESD) Process: Coating, Overlay, SparkDepo, SparkCoat
Applicator Used: Standard, Miniature, Vibratory
Electrode No. and Size: WTC-90, 5.0 mm Dia. X 100mm L
Coating Parameter Settings: O/P=1+2+3 (High), F/A=9
Caution:
Apply rough but thin coating approximately 100 µm. (The spec. called for 1 mm thick thermal spray coating but it was smoother and less hard than the SparkDepo coating, WTC-90.)
Advantage of ESD:
Required 4.5 hours and a total cost of Yen 54,000 vs Yen 300,000 for thermal spray coating; however, the service life was similar.
Note: This is one of the active applications and a periodic order is continuously received.