Welding and Overlays
Automated P.T.A. overlays
Our system is currently set up to overlay external components of almost any size and shape, or internal bores down to as small as 3 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.
Traditional GTAW, GMAW and SMAW 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.
Many common alloys can be applied such as 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 accuracy and quality are not as critical to the finished product, Or on parts not economical to set up with automation ( small / Odd shaped ), Or it can also be used in conjunction with PTA to get full coverage on parts or in areas hard to reach by the automated PTA process.