Kennametal UltraFlex Brochure

SURFACE
ULTRAFLEX CLADDING
™
ULTRAFLEX
CLADDING
™
Kennametal is a global provider of
solutions for wear, heat, and corrosion
problems, a world-class manufacturer
of components, and a service
provider to a wide range of industries.
Kennametal is your trusted source
for the most innovative solutions
that deliver productivity, reliability
and extended service life in the most
demanding environments.
Drawing on Kennametal’s expertise
with tungsten carbide-based
materials and incorporating super
alloy-based technologies from the
Kennametal Stellite organization,
UltraFlex™ provides an extensive
portfolio of surface treatments for your
application. Designed to accommodate
even the most complex geometries,
including non-line-of-sight surfaces,
UltraFlex™ covers a variety of
industries and applications, including:
• Oil & Gas Drilling
• Oil & Gas Production
• Chemical Processing
• Power Generation
• General Conveyance
•M
echanical Equipment
UltraFlex™ Cladding Solution
Surface Wear Applications & Benefits
UltraFlex Cladding
™
UltraFlex™, a wear-resistant surface treatment from Kennametal, brings industry-leading performance to components
with complex geometries for power generation, oil and gas, and many other industries. UltraFlex™ is a proven product
for extending component life and increasing productivity. Kennametal’s UltraFlex™ treatment is available in a broad array
of materials, ensuring the optimum solution for the wear environment in your application.
Surface Wear Applications
Benefits
• Abrasion
• Increased component life
• Erosion
• Reduced downtime
• Corrosion
• Reduction in failures
• Metal on metal wear
• Reduced maintenance costs
• Galling
• Reliable performance between
scheduled maintenance
• Fretting
• Consistent product quality
• High temperature environments
• Maintain system efficiency
Productivity in the Most Demanding Environments
THE CHALLENGE
Pumps requiring
impeller replacement
at around 1 month.
A U.S. Gulf Coast refinery had experienced accelerated internal wear of oil
THE RESULT
13 months in service
with no significant signs
of internal erosion.
Working with Kennametal, the company had the inside of closed impellers
pumps, often requiring entire case replacements. Compared to typical industry
pump performance, run lengths were shorter, about a month, and cost per
installed was higher. The application requires pumps capable of withstanding
significant catalyst fines.
treated with UltraFlex.™ The company was particularly impressed by the true
metallurgical bond and a dense, uniform distribution of tungsten carbide
particles throughout the coating, to create excellent erosion resistance
and toughness in complex geometries.
After 13 months in service, a treated oil pump showed no significant signs
of internal erosion.
This technology has also been applied to FCCU fractionator bottoms and
debutanizer reboiler services, with no signs to date of increased vibration or loss
of hydraulic performance.
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UltraFlex™ Cladding Solution
Non-Line-of-Sight & Complex Geometries
Non-Line-of-Sight & Complex Geometries
Parts with complex geometries, inner diameters, and other non-line-of-sight
features may encounter consistency problems with thermal spray or weld
overlay coatings. By comparison, the UltraFlex™ treatment easily conforms to
intricate shapes and reaches remote locations.
Unlike methods such as weld overlay, thermal sprays,
and traditional cladding, Kennametal’s UltraFlex™
treatment accommodates inside diameters and
complex geometries.
Try applying a weld overlay
onto a screen.
From the internal diameters (IDs) of long pipes to the
vanes of closed pump impellers, UltraFlex™ can be
applied to locations that other hardfacing technologies
cannot reach.
In many cases, similar to applying a weld overlay onto a
screen, the area of interest can be reached but the shape
of the surface complicates the welding process.
Welding by hand inherently has a large amount of
inconsistency. Porosity, incomplete fusion, solidification
cracking, heat affected zone (HAZ) cracking,
embrittlement and inclusions are all issues that can
result in the pre-mature failure of the surface treatment.
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With the UltraFlex™ treatment, Kennametal is able to
apply a high quality super-alloy or tungsten carbide
composite onto substrates with complex geometries
without the problems commonly faced with welding.
The UltraFlex™ surface treatment can be applied
in a range of thicknesses. The base thickness
is approximately 0,25mm (0.010"), while typical
applications range from 0,51mm to 0,76mm
(0.020" to 0.030") or more to accommodate your
specific need.
The “as applied” surface is extremely smooth –
especially compared to weld overlay. Depending on the
application, the coating can be used “as applied” or
machined to the desired finish. For example, in some
petrochemical applications, UltraFlex™ alloy formulations
allow for “pigging” of conveyance lines because of the
smooth, crack-free surface.
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UltraFlex™ Cladding Solution
Metallurgical Bond
1000 µm
Metallurgical Bond
Surface treatments with mechanical bonding may not stand up to harsh environments
due to porosity and cracking. UltraFlex™ features a metallurgical bond and other unique
benefits that extend component life.
UltraFlex™ Surface Treatment
Typical Weld Overlay
UltraFlex™ Surface
Required Surface Layer
Minimal Dilution Zone
0,025mm to 0,25 (0.001" to 0.010")
depending on UltraFlex ™ material
1st Alloy Layer
Nickel Buffer Layer
Substrate
Substrate
The UltraFlex™ process metallurgically bonds the wear
system directly to the substrate while minimizing the
dilution zone in comparison to traditional welding
process. This includes several Stellite™ alloy surface
chemistries that are not possible via casting or weld
overlay.
In addition to the small diffusion zone, there is an
inherent benefit of the direct bonding of the surface
layer to the substrate — improving quality and
reducing costs.
Since buffer layers are not required between the
substrate and the UltraFlex™ surface treatment,
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Heat Affected Zone (HAZ)
as is typical with some weld overlays, the result is
a pure alloy surface with minimal dilution.
The UltraFlex™ treatment does not result in a Heat
Affected Zone (HAZ). Unlike a weld overlay process,
hot hardness and wear resistance are not affected
because there is no iron dilution. This results in
improved hardness at higher temperatures.
Direct bonding. Minimal dilution.
Improved hardness at higher
temperatures.
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UltraFlex™ Cladding Solution
Corrosion, Abrasion, & Erosion Solutions
Corrosion, Abrasion, & Erosion Solutions
Coupled with superior material technologies, UltraFlex™ surface treatments can
result in dramatically extended component life, more predictable maintenance,
higher productivity, and reduced operating costs.
For components such as severe service valves, while the
corrosive wear rate is highly dependent on the chemical
composition of the treatment, it is also affected by the
quality of the surface. Most welding, casting, and sprayand-fuse options result in cracking that can penetrate to
the substrate.
More predictable service life
for critical components.
In this case, Kennametal would select the proper
corrosion-resistant Stellite™ alloy-based grade of
UltraFlex™ to ensure that there is no cracking or
de-lamination of the surface to protect the substrate.
For components such as the bottoms pumps in Fluid
Catalytic Cracking units, harsh abrasion and erosion
can destroy components within a matter of months.
While there are several possible methods to treat
steel substrates, none can match the effectiveness
of Kennametal’s tungsten-carbide based solutions to
extend component life.
Using UltraFlex™, Kennametal can deposit a highly
dense layer of tungsten carbide throughout the surface
layer of the component. This has been proven to improve
life by to up to 4 times in such environments.
Velan’s metal-seated
ball valve.
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UltraFlex™ Cladding Solution
Highest Quality Surface Technologies
ULTRAFLEX
CLADDING
Highest Quality
Surface Technologies
When partnering with Kennametal, customers can be
assured that they will have access to the highest quality
surface technologies. The UltraFlex™ product family
has an extensive portfolio of material systems providing
solutions for all of your abrasive, erosive, corrosive,
and galling wear needs.
Wide range of material systems
that offer flexibility and versatility.
Kennametal’s UltraFlex™ portfolio utilizes a wide range
of material systems that offer flexibility and versatility
applicable to your specific wear type and operating
conditions. With the ability to customize thickness
and treat complex geometries and non-line-of-sight
surfaces, we provide access to innovative technologies
that produce longer component life, system efficiency
improvements and reduced operating costs.
™
For customer service or
to place an order contact:
A MER I CA S S A L ES O F F I CES
471 Dundas Street E
Belleville, Ontario
K8N 1G2
Canada
Phone: 1.613.968.3481
Fax: 1.613.966.8269
Email: americasales.stellite@kennametal.com
501 Park East Blvd.
New Albany, IN 47150
USA
Phone: 888.289.4590
Fax: 812.944.3254
Email: k-nalb.cs@kennametal.com
EU R O P EA N S A L ES O F F I CE
Zur Bergpflege 51 – 53
56070 Koblenz
Germany
Phone: 49.261.80.88.0
Fax: 49.261.80.88.35
Email: europesales.stellite@kennametal.com
I NDI A S A L ES O F F I CE
8/9th Mile, Tumkur Road
Bangalore - 560 073
India
Phone: 91.80.2839.4321
Email: bangalore.information@kennametal.com
A S I A – PA CI F I C S A L ES O F F IC E
1799 Bao Jia Road
Shanghai
Jia-Ding District , 201800
China
Phone: 86.021.39523860
Fax: 86.021.39523810
Email: asiapacsales.stellite@kennametal.com
www.kennametal.com
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UltraFlex™ Cladding Solution
Subheader
W O R LD HE AD QU ARTE RS
Kennametal Inc.
1600 Technology Way
Latrobe, PA 15650
USA
Tel: 800.446.7738 (United States and Canada)
E-mail: ftmill.service@kennametal.com
EUR O PEA N HE AD QU ARTE RS
Kennametal Europe GmbH
Rheingoldstrasse 50
CH 8212 Neuhausen am Rheinfall
Switzerland
Tel: 41.52.6750.100
E-mail: neuhausen.info@kennametal.com
A SIA -PA C IFIC HE AD QU ARTE RS
Kennametal Singapore Pte. Ltd.
ICON@IBP #01-02/03/05
3A International Business Park
Singapore 609935
Tel: 65.6.2659222
E-mail: k-sg.sales@kennametal.com
INDIA H EA D QU ARTE RS
Kennametal India Limited
8/9th Mile, Tumkur Road
Bangalore - 560 073
Tel: 91.80.2839.4321
E-mail: bangalore.information@kennametal.com
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©2013 Kennametal Inc. l All rights reserved. l B-13-03160