High Velocity Thermal Spray

WSI’s High Velocity Thermal Spray System combines advanced field technology, skilled craft application, and comprehensive support services

The World Leader in Pressure Equipment Life Extension – WSI has added High Velocity Twin-Wire Arc Spray to our extensive line of corrosion/erosion mitigation services. WSI’s High Velocity Thermal Spray Solution offers our client partners a high-density metal coating designed to freeze the existing surface condition of critical assets suffering from corrosion, erosion, abrasion, impact and wear damage. Through superior permeability and uniformity, this custom life extension application withstands aggressive processes, high temperature, and high-pressure environments while eliminating the potential for Heat Affected Zones (HAZ) and no requirement for Post-Weld Heat Treatment (PWHT).

WSI’s Team of Experienced Professionals is dedicated to protecting and improving the critical components of your operations.

Innovative coating technology for superior erosion/corrosion protection

Market pressures have evolved, and WSI is a diverse partner that continues to evolve in kind. WSI offers engineered solutions that provide the best possible outcome for critical assets within Refineries, Nuclear, Waste-to-Energy, Fossil Fuel Power Plants, Pulp & Paper, Metals & Mineral Processing, and Petrochemical facilities.

Key Benefits of WSI High Velocity Thermal Spray:

WSI High Velocity Thermal Spray is a rapidly applied, low-cost intermediate repair solution that keeps more types of assets online while minimizing downtime.

• Versatile Single-Source Contractor Solution: WSI provides a combination of corrosion/erosion mitigation services to extend the life of critical assets in energy facilities. These include Weld Metal Buildup (WMBU) with like material, Corrosion Resistance Overlay (CRO), Structural Weld Overlay (SWOL), and High Velocity Twin-Wire Arc Spray.
• Material Analysis & Recommendation: WSI offers proprietary and commercially available corrosion-resistant alloys (CRAs), each with unique benefits. Our modified Fe-based, Ni-based, and Co-based alloys deliver unmatched defense in severely erosive, abrasive, and corrosive environments. WSI’s Materials Science Department will partner with clients’ facilities to select the correct alloy composition for each unique situation and process.
• Custom Field-Ready Systems: WSI leverages our extensive machine-welding history to develop rugged brown-field-ready equipment suited for confined space conditions.
• Schedule Optimization: WSI mechanically bonded metal coatings are applied efficiently to a wide range of substrate materials, incorporating high velocity and density, reducing the spraying time with outstanding quality.
• Prioritizing Safety & Environment: WSI’s industry-approved modular Ventilation Systems are explicitly designed to eliminate Hexavalent Chromium (Cr(VI)) exposure (less than 1 μg/m³) to personnel and the surrounding environment. WSI’s commitment to health and safety ensures production schedules are maintained without concerns of a work stoppage due to safety and environmental interference.

Applications of High Velocity Thermal Spray Coatings:

WSI’s High Velocity Thermal Spray Coating system, with its proprietary protective surface enhancers and specialty alloy materials, is a versatile solution for diverse industrial applications. It offers improved protection against corrosion, oxidation, wear, and dimensional repair and restoration. This adaptability ensures the longevity of critical equipment, providing a high return on investment.

• Corrosion & Oxidation: Corrosion and oxidation-resistant coatings are most beneficial for surfaces exposed to extreme high-temperature and high-pressure conditions, such as boilers, superheaters, heat exchangers, digesters, amine units, gas purification units (H2S/CO2), and other process equipment.
• Wear: Wear-resistant coatings are applied to industrial process environments where components lose material due to erosion, abrasion, and impact. Some typical applications are CFB boilers, fan blades, coal chutes, mining conveyors, drill bits, pipes, pumps and valves, and turbine components.
• Repair & Restoration: WSI’s High Velocity Thermal Spray coating system allows for the restoration of worn or damaged components to their original specifications, extending their operational life and significantly reducing replacement costs.
• Performance Enhancement: WSI High Velocity Thermal Spray coatings are designed to meet specific operational demands and significantly improve the performance of essential components. Functioning as a thermal barrier, while increasing surface hardness, and protecting against degradation, WSI ensures client’s critical assets run at peak performance and operational efficiency.

Trust WSI to provide the most appropriate solution for your unique problem.