CERABEAD

CERABEAD is a Ceramic Bead filled Pully lining compound incorporating a blend of Ceramic Beads and Powders. It exhibits outstanding abrasion resistance, adhesion and toughness.

APPLICATION: CERABEAD is used where maximum abrasion resistance is needed. It offers toughness to withstand impact of heavy rocks and ores. Possesses resistance to wet acidic and alkaline conditions. Typical applications include wood chip conveyors, mining operations, cyclones, sand & gravel conveyors, waste disposal facilities, hoppers, lining large pump housings in coal & wood fired power plants and paper mills.

PROCEDURE: A clean, dry surface free of loose rust or scale is necessary. Abrasive blasting to "near white" is preferred for general use. For severe immersion condilions or elevated temperature exposure, blast to "white metal".

For Concrete - Remove heavy grime by wire brushing or mechanical abrasion. Degrease wih detergent followed by waler rinse. Allow to dry fully. All delerioraled and weak concrete musl be removed to expose a sound surface.

MIXING: Mix volumes of 'Base' and 'Activator' which are supplied in contrasting colors, on a dean flat surface. Mix with spatula until a uniform blend free of streaks is obtained.

APPLYING: When spreading, take care to work the material into indentations and over rough surfaces before building up desired thickness. CERAMETAL 2 Or DIFFGLASS PRIME Priming is Highly Recommended for optimum perfonnance of lhe product. Smooth surface can be obtained by patting the material wih spatula evenly. Care should be taken to maintenance compactness of the Beads. If a coaling is to be applied over CERABEAD, the recommended recoat times may be followed. If these are less than 6 hours, the CERABEAD should be lighlly abraded, then wiped wih solvent and clean clolh. If it is more than 6 hours, abrade wih mechanical abrader & Cure according to the given schedules.

CERAMETAL 2

CERAMETAL-2 is a solvent free, fluid grade poly-ceramic coating and surfacing compound for fluid flow environments. Easily applied by brush, it is the finest material available for repairing and preventing erosion/corrosion damage caused by fluid flow and entrained solids, impingement and bimetallic act on. Specially formulated to resist abrasive erosion, it is virtually non-machinable even with carbide tipped tools.

APPLICATION: CERAMETAL-2 is ideal for repair and preventing erosion/corrosion damage without heat to pumps, impellers, heat exchangers, valves, struts/rudders, tube sheets, water boxes, tanks, diffusers, piping.

PROCEDURE: Excessive dirt, rust scale, grease and oil should be first removed by abrasive blasting using either an angular metallic or nonmetallic abrasive. One section of repairs which are not required to bond to CERAMETAL-2 should be treated with Diffusion Masking Agenl/Masking Tape.

APPLYING: The mixed material should be applied using a clean brush to the prepared area, application should be carried out as soon as possible after surface preparation is complete and certainly on the same day. Where necessary, Reinforcement Tape should be stippled into the mixed product and further material applied over the tape. Should a second layer of CERAMETAL-2 be required, this application must be carried out within the initial set time for the first layer.

SWEAT ON PASTE

SOP composed of ultra-hard chromium boride crystals (second only to diamond on the hardness scale) is the most abrasion-resistant material available for antiwear use. Due to its high hardness alloy chemistry and needle-like structure, thin overlays of SOP provide outstanding resistance to severe abrasion and particle impact erosion.

APPLICATION: SOP has wide applications in mineral based industries, thermal power stations, cement plants, steel plants, sugar factories and agricultural industry where severe abrasion and erosion are to be contained. Exhauster fans, ID fans, conveyor screws, coal chutes, coal cutter, bits, ducts and 90° bends, disc harrows, plowshares, scraper blades, air separator guide vanes etc. are coated with SOP for exceptionally long service life.

PROCEDURE:
Acetylene Torch Application - SOP is brushed on the surface, which must be free of all dust, grease and scale to a thickness of not more than O.5mm. This must be allowed to dry. A generous, carburizing flame is applied to the surface at one point until the crystals cease to glow and are seen to bond with the base metal. As this bonding proceeds, the flame should be moved along at a rate sufficient to keep the surface sweating ahead of the flame. The width of the path travelled will be governed by surface area and parent metal thickness. On sections 6mm and heavier the carbon arc method is recommended.

Carbon Arc Application - Apply SOP not more than 1.50mm thick, with a spatula to a slightly warmed surface, free of grease, dirt and rust. The warm surface facilitates the drying of the paste faster. After drying this coating is fused to the surface, using a pointed 6mm/8mm carbon electrode negative polarity, with amperage governed by the thickness of base metal and paste. Beads of uniform width are produced with a crescent shaped weave, advancing at a rate to allow inclusions to float and leave a smooth surface. Succeeding beads should overlap 6mm to ensure uniform penetration.