Thermion BRIDGEMASTER User manual

File: c:\msoffice\winword\thermion\manuals\bridgemaster 2005

MANUAL July 19, 20075

Patent # 4512513; 4624410; 5791560; 6683271 B2

OWNER’S MANUAL

(OPERATIONS AND MAINTENANCE)

MANUFACTURED BY

SILVERDALE, WASHINGTON, USA

Phone: 360-692-6469

Toll Free: 877-884-6428

Fax: 360-447-8314

Web Site: www.thermioninc.com

SERIAL #

________________________________________

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.

vii

ISO Standards of TC 107 SC 5, Thermal Spraying

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.

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

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 Inc. arc spray system.

The arc spray process and Thermion Inc. 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, guarantee 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. Please

specify your machine serial number.

This manual is divided into nine sections:

Section 1: Introduction

Section 2: Safety Measures

Section 3: System Assembly

Section 4: Controls

Section 5: Operation (General)

Section 6: Principles of Operation

Section 7: Liner Replacement

Section 8: Parts Required for Various Wire Sizes

Section 9: Components Section

The information contained in this manual represents our best judgment; however, Thermion

Inc. assumes no liability for its use.

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