Welding and Overlays

Automated P.T.A. overlays

Our Plasma transferred Arc Welding capabilities are the overlay of external components to almost any size and shape, or internal bores down to as small as 2.25 inches in diameter.

The Taskmaster Plasma Transferred Arc Welding System is a precise, high energy, inert gas welding process. It produces a very high quality deposit offering optimal performance with minimal dilution or deformation of the base material. Unlike some thermal spray processes, which have a mechanical bond, PTA technology produces a metallurgical "welded" bond that is particularly effective in protection against corrosion, erosion, abrasion, and thermal shock.

A wide range of overlay alloys are available designed to suit practically any application. The system works with metal powders as overlay material, so almost any desired product can be applied. Examples are: chrome carbide, tungsten carbide, nickel or cobalt based powders, stainless steels, and future development of possible ceramic-based powders.

The accuracy in application and parameter control results in a dilution level of only 3 to 7%, compared to traditional welding processes which can dilute with the base metal by as much as 40%. The process results in a very narrow heat-affected zone, and with the low dilution rate, prevents undesired substrate changes that can enhance the alloy's performance in manufacturing components. The Taskmaster PTA welding system can deposit metal alloys at rates of up to 20 lb/h, and is fitted with automated manipulation to handle different parts, even those with complex shapes and narrow tolerances.

In a competition with laser surfacing, the PTA technology offers much higher productivity, with comparable quality of deposits, and significantly lower costs.

Typical application areas of the PTA technology are equipment for mining, crushing, rolling, road building and tunneling, extruding screws, valves and seats, power generation, cutting tools (milling cutters, broaches, knifes), Process equipment in ceramics and cement production, plastic molds, forging dies, pulp and paper industry equipment, and agricultural equipment.

 

 

 

 

 

 

 

 

 

 

 

32 foot long, Non-Magnetic Flex Collar. Hardbanding in tandem with two PTA"s. Application innovations that save you time.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Taskmaster PTA system set up on Internal application production

 

Traditional WELDED overlays

GTAW ( tig ), GMAW ( mig ), and SMAW ( stick ) weld overlay materials, although not as high in performance as that of PTA, have made many advancements in recent years, and due to lower equipment set up costs are still in wide spread use in industry.

We have integrated the mig welding process with our custom designed Automation equipment to ensure highest quality results with predictable repeatability.

Many common alloys can be applied such as Aluminum Bronze, Chrome Carbide, Tungsten Carbide Composites, Nickel or Cobalt base, and Low alloy Manganese products.

Taskmaster can provide these services as a cost effective alternative to PTA hard facing when the application if better suited or more efficient utilizing these traditional means. On parts not economical to set up with automation ( small / Odd shaped ), We have the expertise to apply these products manually, so we can get into the most unusual places with a desired coating. Another option we commonly offer, is to use traditional welded overlays in conjunction with PTA to get full coverage on parts or in areas hard to reach by the automated PTA process.

 

 

 

 

 

 

Welded Aluminum Bronze coating on alloy Steel Part, coating finished at 1/4 inch thick.

 

Tungsten Carbide Composite Overlay Selections

TM-100. Standard Plasma Transferred Arc Weld Overlay (PTA). These overlays can come tailored specifically for a variety of environments from impact resistant - soft matrix applications to ultra hard matrix - extreme wear duty. In addition a choice of several Carbide types are available such as Macro, Cast, Sintered, Spherical or a combination blend. TM-1000. PTA overlay with large particle infusion! With our proprietary overlay equipment, we are able to introduce solid tungsten carbide particles roughly 0.060" in size into our standard PTA overlays. This boost in overall carbide content as well as surface area exposure of larger carbide particles has shown marked improvements in direct wear resistance.	TM-100 Carbide Concentration by weight: up to 65%	TM-1000 Carbide Concentration by weight:  up to 80%	TM-TXP Carbide Concentration by weight:  up to 85%
TM-TXP. (Tile Xtreme Performance) Tungsten Carbide Tiles fused via PTA process! Similar in idea to the old way where tiles are fused by a "puddle torch method" only without the extreme heat input. Much higher quality and better wear resistance because the bonding agent is a true PTA weld overlay. The Ultimate in wear resistant solutions!
The Overlay selections TM-1000 and TM-XMP are proprietary developments of Taskmaster Technologies Inc. The exact Methods, Procedures, as well as Equipment design appliations are confidential in nature.

 

 Bearing application hardfaced with TM - 1000 enhanced PTA overlay