Thermion 500 User manual

MANUAL August 24, 2007

OWNER’S MANUAL

(OPERATIONS AND MAINTENANCE)

Thermion Metalizer

Thermion

Thermion Spray Master

Thermion 500

MANUFACTURED BY

SILVERDALE, WASHINGTON, USA

Phone: 360-692-6469 or

1-877-884-3428

FAX: 360-447-8314

Email: [email protected]

file 50115 US 1.098

ARC SPRAY METALIZING SYSTEMS

The US Thermal-Spray Standards Program:

Thermal-spray standards in the United States are developed by several professional

societies that include American Society for Testing and Measurement (ASTM) for test &

measurements methods and composition specifications; American Welding Society

(AWS) for feedstock, equipment acceptance, application process, training &

certification; American Water Works Association (AWWA) for thermal-spray zinc

potable water tank linings; International Association of Corrosion Engineers (NACE) for

corrosion application processes and inspection; and Society of Protective Coatings

(SSPC) for test & measurement methods, application specification & inspection in

regards to protective coatings for the protection of steel.

US Published Standards:

C2.16-92, Guide for Thermal-Spray Operator Qualification.

This guide sets forth recommended thermal-spray operator qualification procedures. It

covers applicable documents relating to thermal-spray equipment, consumables, and

safety. It also contains operator qualification and coating system analysis forms.

AWS C2.18-93, Guide for the Protection of Steel with Thermal Sprayed Coatings

of Aluminum and Zinc and Their Alloys and Composites.This guide sets forth

recommended thermal-spray operator qualification procedures. It covers applicable

documents relating to thermal-spray equipment consumables, and safety. It also

contains operator qualification and coating analysis forms. Note: This standard is being

incorporated into ANSI/AWS C2.18A-XX/SSPC CS 23.00A-XX/NACE TPC #XA, Guide

for the Application of Thermal Spray Coatings (Metalizing) of Aluminum, Zinc, and Their

Alloys & Composites for the Corrosion Protection of Steel, in preparation.

SSPC CS 23.00, Guide for Thermal Spray Metallic Coating Systems.

This guide covers the requirements of thermal-spray metallic coatings, with and without,

sealers and topcoats, as a means to prevent the corrosion of steel surfaces. Types of

metallic coatings include pure zinc, pure aluminum and zinc/aluminum alloy, 85%

zinc/15%luminum by weight. Note: This standard is being incorporated into ANSI/AWS

C2.18A-XX/SSPC CS 23.00A-XX/NACE TPC #XA, Guide for the Application of Thermal

Spray Coatings (Metalizing) of Aluminum, Zinc, and Their Alloys & Composites for the

Corrosion Protection of Steel, in preparation.

ASTM C 633, Test Method for Adhesion or Cohesive Strength of Flame-Sprayed

Coatings.

This test method covers the determination of the degree of adhesion (bonding strength)

of a coating to a substrate, or the cohesive strength of the coating in a tension normal

to the surface. The test consists of coating one face of a loading fixture, and subjecting

this assembly of coating and fixtures to a tensile load normal to the plane of the coating.

iii

US Published Standards:

ASTM D 4541, Test Method for Pull-Off Strength of Coating Using Portable

Adhesion Testers.

This test method covers a procedure for evaluating the pull-off strength (commonly

referred to as adhesion) of a coating by determining either the greatest perpendicular

force (in tension) that a surface area can bear before a plug of material is detached, or

whether the surface remains intact at a prescribed force (pass/fail). Failure will occur

along the weakest plane within the system comprised of the test fixture, adhesive,

coating system, and substrate. This test method maximized tensile stress as compared

to the shear stress applied by other methods, such as a scratch or knife adhesion, and

the results may not be comparable. Further, pull-off strength measurements depend

upon both material and instrumental parameters. Results obtained using different

devices or results for the same coating on substrates having different stiffness may not

be comparable.

MIL-STD-1687A(SH), Thermal spray processes for naval ship machinery

applications, 2/11/87.

This standard covers thermal-spray processes for machinery element repair of ferrous

and non-ferrous substrates. Included are requirements for the qualification of thermal

spray procedures and operators, requirements and guidance for use of thermal spray

material and equipment, quality assurance requirements, and descriptions of applicable

qualification tests. Note: This standard is being revised.

MIL-STD-2138A(SH), Metal Sprayed Coatings for Corrosion Protection Aboard

Naval Ships.

This standard covers the requirements for the use of metal-sprayed coatings

(Aluminum) for corrosion control applications on board naval ships. This standards

covers certification of facilities, certification of operators, application procedures, metal-

spray procedures, and production quality assurance (including test procedures and

records). Note: This standard is being incorporated into ANSI/AWS C2.18A-XX/SSPC

CS 23.00A-XX/NACE TPC #XA, Guide for the Application of Thermal Spray Coatings

(Metalizing) of Aluminum, Zinc, and Their Alloys & Composites for the Corrosion

Protection of Steel, in preparation.

MIL-P-85856, Powder Materials, 7 December 1988.

This specification describes three (3 material categories for use in constructing thermal-

spray coatings, consisting of metallic and/or non-metallic components. These powder

materials may be suitable for application using wither plasma arc or combustion gas

(flame spray) techniques.

US Standards In-Preparation

ANSI/AWS A5.33/A5.33M:199X, Specification for Solid and Composite Wires, and

Ceramic Rods for Thermal Spraying, 01/19/99 (ballot to publish).

This specification defines the as manufactured, chemical composition classification

requirements for solid and composite wires and ceramic rods for thermal spraying.

Requirements for standard sizes, marking, manufacturing, and packaging are included.

ANSI/AWS C2.16A, Guide for Thermal-Sprayer Qualification, WD #2, March 5,

1999.

This standard contains the thermal sprayer (operator) performance qualification tests

for thermal sprayers. Qualification tests are included for job knowledge, flame

spraying, arc spraying, plasma spraying, and high velocity oxygen fuel (HVOF)

spraying.

ANSI/AWS C2.18A-XX/SSPC CS 23.00A-XX/NACE TPC #XA, Guide for the

Application of Thermal Spray Coatings (Metallizing) of Aluminum, Zinc, and Their

Alloys & Composites for the Corrosion Protection of Steel, WD-2, February 25,

1999.

This standard is a procedure for the application of metallic thermal spray coatings

(TSC) of aluminum, zinc, and their alloys and composites for the corrosion protection of

steel. Required equipment, application procedures, and in-process quality control (QC)

checkpoints are specified.

ANSI/AWS C2.18B-XX/SSPC CS 23.00B-XX/NACE TPC #XB, Specification for the

Application of Thermal Spray Coatings (Metallizing) of Aluminum, Zinc, and Their

Alloys & Composites for the Corrosion Protection of Steel, WD-2, February 25,

1999.

This standard is a specification for the application of thermal spray coating (TSC)

systems for the corrosion protection specifies procedures for surface preparation and

the application of the TSC with in-process quality control (QC) check points. Annexes

provide amplifying information which include safety, job reference standards and job

control record, selection of TSC’s, TSC operator and inspector qualification, inspection,

material and equipment, and maintenance and repair of TSC’s. This standard may be

used as a procurement document.

ANSI/AWS C2.19-XX, Machine Element Repair with Thermal-Spray Coatings, in

preparation.

This standard covers thermal-spray processes for machinery element repair of ferrous

and non-ferrous substrates. Included are requirements for the qualification of thermal

spray procedures and operators, requirements and guidance for use of thermal spray

material and equipment, quality assurance requirements, and descriptions of applicable

qualification tests. Note: NAVSEA (Charles Null) requested AWS incorporate MIL-STD-

1687A(SH) into an AWS standard, April 1998.

US Standards In-Preparation

ANSI/AWS C2.20-9X, Specification for Thermal Spraying Zinc Anodes on Steel

Reinforced Concrete, Committee Draft #2, February 18, 1999. Ballot CD-205,

Approval to publish. Due 03/31/99.

This AWS standard is a specification for thermal spraying zinc anodes on steel

reinforced concrete. This standard is formatted as an industrial process instruction.

The scope includes: job description, safety, pass/fail job reference standards, feedstock

materials, equipment, a step-by-step process instruction for surface preparation,

thermal spraying, and quality control. There are three annexes: job control record,

operator qualification, and portable adhesion testing.

ANSI/AWS C2.21-9X, Specification for Thermal Spray Equipment Acceptance

Inspection, WD-4, May 15, 1998.

This standard specifies the thermal spray equipment acceptance requirements for

plasma, arc-wire, flame-powder, -wire, -rod, and -cord, and high-velocity-oxygen-fuel

(HVOF) equipment. Proof of suitability shall be provided by the equipment supplier.

Example inspection reports are provided in four non-mandatory appendices.

ANSI/AWS C2.22-9X, Guide for Metallographic Sample Preparation and Evaluation

of Thermal Spray Coatings. Note: No comparable ISO standard. Inactive

This guide presents the recommend practices for the metallographic techniques and

procedures for characterizing thermal spray coatings. Cutting, mounting, grinding, and

polishing materials and procedures are summarized. Coating analysis covers the

interpretation of the microstructure (percentage of porosity, oxides, and other phases)

and the correlation of that information with the overall properties of the thermal spray

coating by comparison with a standard using the Line-Intercept Method and the Grid

Area Method.

SSPC/NACE/AWS Tri-Society on Corrosion Protection of Steel with

Thermal Spray Coatings (TSTSC)

The SSPC/NACE/AWS Tri-Society on Corrosion Protection of Steel with Thermal Spray Coatings was

formed November 1996, at the SSPC C.1.2.B meeting, Dallas, TX. Membership inducted from the AWS

C2B, SSPC C2.1.B, and NACE T-6H-45 thermal spray committees on corrosion protection of steel. Two

Task Groups were formed:

TG-A, for developing a process specification for the protection of steel with thermal spray coatings of

aluminum and zinc and their alloys. The scope of TG-A is to develop a process specification updating

and merging the content AWS C2.18, SSPC CS 23.00, and MIL-STD-2138.

TG-B, for developing a guide for the inspection of thermal spray coatings on steel. The TG-B

inspection guide is a necessary complement to TG-A process specification.

ISO Standards of TC 107 SC 5, Thermal Spraying

(12 standards issued)

ISO 2063:1991 Metallic and other inorganic coatings -- Thermal spraying -- Zinc, aluminum and their

alloys

ISO/DIS 14231 Thermal spraying -- Acceptance inspection of thermal spraying equipment

ISO/DIS 14232 Thermal spraying -- Powders -- Composition -- Technical supply conditions

ISO/DIS 14916 Thermal spraying -- Determination of tensile adhesive strength

ISO/DIS 14917 Thermal spraying -- Terminology, classification

ISO/DIS 14918 Thermal spraying -- Approval testing of thermal sprayers

ISO/DIS 14919 Thermal spraying -- Wires, rods and cords for flame and arc spraying -- Classification --

Technical supply conditions

ISO/DIS 14920 Thermal spraying -- Spraying and Fusing of thermally sprayed coatings of self-fluxing

alloys

ISO/DIS 14922-1 Thermal spraying -- Quality requirements of thermally sprayed structures --

Part 1: Guidance for selection and use

ISO/DIS 14922-2 Thermal spraying -- Quality requirements of thermally sprayed structures --

Part 2: Comprehensive quality requirements

ISO/DIS 14922-3 Thermal spraying -- Quality requirements of thermally sprayed structures --

Part 3: Standard quality requirements

ISO/DIS 14922-4 Thermal spraying -- Quality requirements of thermally sprayed structures --

Part 4: Elementary quality requirements

ISO 2063:1991, Metallic and other inorganic coatings -- Thermal spraying -- Zinc, aluminum and

their alloys. Edition: 2 (monolingual) -- Number of pages: 10 --Price code: E-- ICS:25.220.40

Descriptors: aluminum plating, classification, coatings, iron and steel products, metal coatings, metal

spraying, protective coatings, specifications, tests, zinc coatings. Last updated on 1998-01-17.

ISO/DIS 14231, Thermal spraying -- Acceptance inspection of thermal spraying equipment. Edition:

1 (monolingual) -- ICS: 25.220.20 Descriptors: acceptability, coating processes, coatings, equipment,

inspection, quality control, specifications, spraying, thermal spraying -- Last updated on 1998-01-17.

ISO/DIS 14232, Thermal spraying -- Powders -- Composition -- Technical supply conditions.

Edition: 1 (monolingual) -- ICS: 25.220.20 -- Descriptors: certificates of conformity, chemical composition,

chemical properties, classification, coating processes, coatings, delivery condition, designation,

microstructure, physical properties, powdery materials, size classification, specifications, spraying, thermal

spraying -- Last updated on 1998-01-17.

ISO/DIS 14916, Thermal spraying -- Determination of tensile adhesive strength.

Edition: 1 (monolingual) ICS: 25.220.20 Descriptors: adhesion tests, adhesive strength, coating

processes, coatings, determination, spraying, tension tests, tests, thermal spraying

Last updated on 1998-01-17

ISO/DIS 14917, Thermal spraying -- Terminology, classification. Edition: 1 (monolingual) -- ICS:

01.040.25, 25.220.20 -- Descriptors: classification, coating processes, coatings, spraying, thermal

spraying, vocabulary -- Last updated on 1998-01-17.

ISO/DIS 14918, Thermal spraying -- Approval testing of thermal sprayers. Edition: 1 (monolingual) --

ICS: 25.220.20 -- Descriptors: coating processes, coatings, instructions, personnel, procedure,

qualification, qualification approval, spraying, thermal spraying -- Last updated on 1998-01-17.

ISO/DIS 14919, Thermal spraying -- Wires, rods and cords for flame and arc spraying --

Classification -- Technical supply conditions. Edition: 1 (monolingual)--ICS: 25.220.20 -- Descriptors:

certificates of conformity, classification, coating processes, coatings, cordages, delivery condition,

designation, diameters, dimensions, marking, metal bars, packaging, properties, specifications, spraying,

thermal spraying, wire -- Last updated on 1998-01-17.

ISO/DIS 14920, Thermal spraying -- Spraying and fusing of thermally sprayed coatings of self-

fluxing alloys. Edition: 1 (monolingual) -- ICS: 25.220.20 -- Descriptors: coating processes, coatings,

melting, specifications, spraying, thermal spraying -- Last updated on 1998-01-17.

vii

ISO Standards of TC 107 SC 5, Thermal Spraying

ISO/DIS 14922-1, Thermal spraying -- Quality requirements of thermally sprayed

structures -- Part 1: Guidance for selection and use. Edition: 1 (monolingual) -- ICS:

25.220.20 -- Descriptors: coating processes, coatings, quality, rules (instructions),

specifications, spraying, thermal spraying -- Last updated on 1998-01-17.

ISO/DIS 14922-2, Thermal spraying -- Quality requirements of thermally sprayed

structures -- Part 2: Comprehensive quality requirements. Edition: 1 (monolingual)

-- ICS: 25.220.20 -- Descriptors: coating processes, coatings, inspection, personnel,

qualification, quality, specifications, spraying, thermal spraying -- Last updated on 1998-

01-17.

ISO/DIS 14922-3, Thermal spraying -- Quality requirements of thermally sprayed

structures -- Part 3: Standard quality requirements. Edition: 1 (monolingual) -- ICS:

25.220.20 -- Descriptors: coating processes, coatings, inspection, personnel,

qualification, quality, specifications, spraying, thermal spraying -- Last updated on 1998-

01-17.

ISO/DIS 14922-4, Thermal spraying -- Quality requirements of thermally sprayed

structures -- Part 4: Elementary quality requirements. Edition: 1 (monolingual) --

ICS: 25.220.20 -- Descriptors: coating processes, coatings, inspection, personnel,

qualification, quality, specifications, spraying, thermal spraying -- Last updated on 1998-

01-17.

viii

Important Safeguards

Means Warning! Watch out!

There are possible hazards with this procedure! The possible hazards are

shown in the below symbols. Your end user (applicator, operator or helper)

should read and understand these safeguards. The operator should read

and understand the operating and installation instructions provided with this Thermion

Arc Spray System.

The arc spray process and Thermion Arc Spray equipment share similarities with

welding processes and equipment. Improper use or maintenance may cause serious

injury or death. Your end user should have training or experience in safe practices for

the arc spray process before operating the arc spray equipment.

WARNING-ELECTRIC SHOCK MAY KILL

DO NOT touch bare conductors or terminals when energized. DO NOT work in

wet or damp areas. Wear dry insulated gloves and dry protective clothing. Remember

that when the power source is on, the electrode (wire) is electrically hot. DO NOT touch

the wire with bare skin while touching the electrical ground. Install and maintain your

electrical equipment using the correct electrical code standards appropriate for your

requirements, a certified electrician should always hook primary leads to the electrical

grid source with the appropriate safety disconnects.

WARNING-ARC RAYS MAY INJURE EYES AND BURN SKIN

The arc spray process produces extreme heat and strong ultraviolet rays.

Never try to arc spray without a welding helmet equipped with the proper lens. Protect

helpers, observers and bystanders. Failure to protect may cause permanent damage to

eyes. Also, protect skin from both arc rays and burns from heat. Always where

protective clothing which does not allow skin to become exposed.

WARNING-FUMES AND GASES MAY BE DANGEROUS TO YOUR HEALTH

Follow the precautions specified by the wire material manufacturers.

Breathing any fumes created by the arc spray process may cause illness or death when

there is not proper ventilation and protection. Keep your head out of the fumes. If

ventilation is not adequate, wear approved respiratory protection.

WARNING-WIRE FEED ROLLS CAN INJURE

Keep clear of wire feed rolls, these gears are hazardous during operation.

Keep clear of all moving parts, moving wire and rolling wire spools.

WARNING-NOISE CAN BE DAMAGING TO YOUR HEARING

Wear ear protection at all times. In some conditions double ear protection

may be required.

Warranty Information

A. Limited Warranty

1) Subject to the terms and conditions hereof, Thermion Inc. warrants to the

user that all new and unused equipment furnished by Thermion Inc. is free

from defect in workmanship and materials as of the time and place of delivery

by Thermion Inc. or its agent. With respect to trade accessories or other

items manufacture by others, such items are sold subject to the warranties of

their respective manufacturers, if any.

2) Thermion Inc. will honor an original user's warranty claim on warranted

equipment in the event of failure resulting from a defect for a period of 90

(ninety) days from date of purchase.

3) Thermion Inc. will honor an original user's warranty claim on component and

any defects in workmanship on the wire feed unit for a period of 90 (ninety)

days from date of purchase.

B. Express Warranty

Any express warranty not provided herein and any implied warranty, guaranty or

representation as to performance, and any remedy for breach of contract which,

but for this provision, might arise by implication, operation of the law, custom of

trade or course of dealing, including any implied warranty of merchantability or of

fitness for particular purpose, with respect to any and all equipment furnished by

Thermion Inc. is excluded and disclaimed by Thermion Inc..

C. Consumer

Except as expressly provided by Thermion Inc. in writing, Thermion Inc. products

are intended for purchase and use by commercial/industrial users and for

operation by persons trained and experienced in the use and maintenance of

Thermal Arc Spray equipment and not for domestic use. Thermion Inc.

warranties do not extend to, and no reseller is authorized to extend, Thermion

Inc. warranties to any consumer.

Preface

This manual has been designed for experienced Thermal Arc Spray operators

and must be read completely before using the equipment. If you lack experience

or are unfamiliar with the practices and safe operation of welding equipment,

please consult your foreman. Do not attempt to install, operate, or perform

maintenance on this equipment unless you are qualified and have read and

understood this manual. If in doubt about installing or operating this equipment,

contact your distributor.

For the safe and successful use of this equipment, be sure the information

contained in this manual reaches the operator. Extra copies of this manual are

available upon request. Specify Part Number 51088 and your machine serial

number.

This manual is divided into nine sections:

Section 1: Introduction

Section 2: Safety

Section 3: System Assembly

Section 4: Controls and Their Functions

Section 5: Operation (General)

Section 6: Principals of Operation

Section 7: Liner Replacement

Section 8: Parts for Various Wire Sizes

Section 9: Parts Diagrams

The information contained in this manual represents our best judgment;

however, Thermion Inc. assumes no liability for its use.

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