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1.9.1.2-106MXC 011206 010928

Praxair and TAFA Arc Spray Cobalt Alloy 106 MXC®

Material Review:

This material produces coatings which resist wear from abrasive particles, hard surfaces and fretting in high ® temperature environments. A coating of 106MXC material can also be used to resist heat and restore parts made of cobalt or cobalt alloys. The coating is machinable, and significantly harder than Praxair and TAFA's ® 76MXC . This material can be sprayed with any Praxair and TAFA Arc Spray gun. Praxair and TAFA 106MXC is being evaluated at several major manufacturers of aircraft engines as a cost-effective alternative to plasma sprayed materials that conform to PWA 1316 and PWA 1318. CAUTION: All Praxair and TAFA wires have been optimized for arc spraying. Use of alternate wires may cause problems such as excessive tip wear, spitting and feeding problems. Please use only Praxair and TAFA certified wires.

Application Review:

Praxair and TAFA 106MXC is used to produce wear resistant coatings, resist particle erosion at temperatures from 1000-1550°F [540-840°C], and is suitable for exhaust valves and seats. Forging tools and hot crushing rolls are also protected with 106MXC since it is very resistant to indentation from hard surfaces. Mismachined or worn parts may be rebuilt with 106MXC and remachined. Turbine air seals and turbine vanes coated with 106MXC withstand fretting in high temperature environments. Other applications include heat treating fixtures, and any manufacturing equipment that has temperature and erosion environments.

MXC® is a registered trademark of TAFA Incorporated, Concord, NH

Typical Composition:

Nickel Chromium Tungsten Carbon Cobalt 10 percent 25 percent 8 percent 1 percent 56 percent

Coating Physical Properties:

Wire Size Deposit Efficiency Melting Point Bond Strength Coating Texture Macrohardness Coating Density Finish Machined: Ground: 1/16" (1.6 mm) 64 Percent

1

2300°F (1260°C) (approx.) 6700 psi (46 MPa) Variable (see next page) 58-68 Ra 7.4 g/cc

3 1 2

40-60 (microinches) Ra 10-30 (microinches) Ra 6.7 lbs/hr/100 amps (3.0 kg/hr/100 amps) 0.9 oz/ft /0.001" (1.1 kg/m /100 microns) ArcJet parameters with primary air at 60 psi (413 kPa) and secondary air pressure at 50 psi (345 kPa) and a 3" (7.6 cm) standoff produce the smallest spray pattern. 116 ft. (35.4 m)

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Spraying:

Spray Rate Coverage (wire consumption) Spray Pattern

Length of wire per lb

1 2 3

Depends on air pressure, standoff, nozzle cap and target size. Depends on air pressure - fine with high psi, average with medium psi, and rough with low psi Depends on atomizing air pressure and the use of ArcJet.

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Spraying Procedure: Coating Type

Atomizing Air Pressure:Primary Secondary Nozzle Cap Nozzle/Positioner Arc Load Volts b Amps Standoff Inches Coating Thickness/Pass-mils Coating Texture-microinches aa

a

Standard 8830/35 4 50 --Blue Short Cross 30-32 100-200 3-5 5 200-350

ArcJet 8830/35 50-60 40-50 ** ** 30-32 100-200 3-5 5 150-250

Standard 8850 60 --Green Long Cross 32-34 100-200 3-5 4-5 350-600

ArcJet 8850 60-75 50 Green Long Cross 32-34 100-200 3-5 5 250-400

Standard 9000 60 --Green Long Cross 31-33 100-200 3-5 5 150-250

ArcJet 9000 4 60 60 Green Long Cross 31-33 100-200 3-5 5 200-350

Using excessive voltage reduces quality of coating. Voltage should be adjusted to give minimum noise and smooth arc operation. Excessive voltage causes larger particles and poor spray pattern. Too low a voltage will cause popping. Be sure not to overheat substrate even if this means stopping to allow cooling, use air jet cooling if greater speed is required. NOTE: Standard air caps and positioners can be used in 8830 or 9000 systems. * ** P/N 450729 P/N 620074 8830 Arc Jet Air Cap Arc Jet Modified Short Cross (8830 & 9000)

-------------------------4 For finer finish, raise air pressure at point of finish. 5 When using power lead extensions other than the normal 12 foot furnished, the voltage must be increased by approximately 3.4 volts per 50 foot extension; i.e. add 3.4 volts to the recommended voltage setting for a given wire if the extension is increased to a 50 foot length. 6 Can vary between 50-300 depending on size of the part and traverse speed.

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Finishing:

An exceptionally good finish can be achieved by turning: Surface Speed Traverse Speed Depth of Cut 110 fpm (0.08 m/s) 0.002-0.003" (.05-.08 mm) per rev. 0.015-0.025" (.4-.6 mm) for first few cuts then 0.001-0.005" (.03-.13 mm) to finish

Coated tungsten carbide and ceramic tools can be used to obtain a finish of 32 microinches Ra. Grinding can also be used to obtain a good smooth finish. Dress frequently and do not permit coating to overheat. Cutting oil is not required. On the hardest coatings, pull out may be a problem if a cutting tool is used, but it is easier to produce a 20 microinch Ra finish using the correct grinding wheel and grinding technique. A 15 microinch finish can be obtained with care. Secondary finishing is required below 10 microinches. Use grinding wheels that meet the following specifications:

· · · · · Silicon carbide 37 C I hardness 8 porosity Vitrified open wheel

Typical Grinding Setup:

· · · · Wheel rpm: Shaft rpm: SFPM: Amount removed per pass Med/High Low High with the work running opposite the wheel 0.0005 (.013 mm)

Use very light pressure and clean wheel. Super finishing with either silicon carbide or diamond cloth using a mineral base (non-sulfur) 5 to 10 weight hydraulic oil or kerosene can produce finishes below 10 microinches Ra by starting with 240 grit paper and progressing to 320, 400 600, 1200, and even 4000. If diamond cloth is selected, use a 9 to 15 micron particle size. The objective is to use the 240 cloth to completely remove the grinding marks from the 37 C wheel. Then, use the 320 cloth to remove the marks from the 240 cloth. Each successive cloth is used to remove the marks from the previous one. If one switches to the finer cloths too soon, a high polish will result on the "high spots", but many of the original deep grinding marks will remain.

Speeds & Feeds Wheel Speed SFPM Work Speed SFPM Wheel Traverse IPM In Feed (inches) Coolant

Dry Grinding 6000 (30 m/s) 60 (.3 m/s) 7 (3 mm/s) rough 2.5 finish (1 mm/s) 0.001 (.025 mm), rough 0.0005 (.013 mm) finish --

Wet Grinding 6000 (30 m/s) 70 (.36 m/s), rough 12 (5 mm/s) 0.001 (.025 mm) 0.0005 (.013 mm) Water Soluble, 1 part coolant to 50 parts water

Hazards:

Observe normal spraying practices, respiratory protection and proper air flow pattern advised. For general spray practices, see AWS Publications AWS C2.1-73, chapter 11, "Recommended Safe Practices For Thermal Spraying" and AWS TSS-85, " Thermal Spraying, Practice, Theory and Application." Thermal spraying is a completely safe process when performed in accordance with proper safety measures. Become familiar with local safety regulations before starting spray operations. DO NOT operate your spraying equipment or use the spray material supplied before you have thoroughly read the Praxair and TAFA Instruction Manual. DISREGARDING THESE INSTRUCTIONS IS DANGEROUS TO YOUR HEALTH.

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A Material Safety Data Sheet will be sent with each initial purchase and updated as required. The Information provided herein is believed to be accurate and reliable; however, results may vary with workpiece preparation and operator technique. Praxair and TAFA warrants only that the wires are free of defects in material and workmanship. No other warranty is expressed or implied.

Copyright 2000 Praxair Technology, Inc. All rights reserved www.praxairthermalspray.com [email protected] Telephone: 1-317-240-2650 Fax: 1-317-240-2596 Praxair, the Flowing Airstream design and Making our planet more productive are trademarks or registered trademarks of Praxair Technology, Inc. in the United States and/or other countries. Other trademarks used herein are trademarks or registered trademarks of their respective owners. Printed in the United States of America 05-2000

www.tafa.com [email protected] Telephone: 603-224-9585 Fax: 603-225-4342 TAFA is constantly improving its products, therefore specifications are subject to change without notice TAFA Incorporated is a Praxair Surface Technologies company.

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