Maintain fan efficiency for longer periods.

Reduce energy and maintenance costs.

Smooth surface for maximum wear resistance.

Extremely wear-resistant coating available on high strength steels.

Specifi c solutions developed for OEMs.

Protective coatings for industrial fans

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Industrial fansLarge fans are commonly used to provide significant quantities of air needed for opera-ting industrial processes. Coal and lignite fired power plants, cement, metal or woodchip manufacturing are just a few examples of industries that require homogeneous and reliable airflows. When particles are present in the air stream, they relentlessly wear-out the fan surfaces. This wear is present both when they are very fine, for example when conveying fumes, as well as when large particulate matter such as wood chips are transported. Impeller blades are the worst attacked components and, once they are worn-out, the resulting geometrical alteration can lead to dramatic drops in efficiency.Furthermore, balancing problems may appear which will affect ancillary equipment service life. As a result, operational conditions are changed; energy and maintenance costs increase and unplanned plant downtimes may be needed.

Protective coatings for industrial fans

Wear experienceAfter more than 20 years of experience gained in repairing and replacing fan parts, we have built a thorough knowledge of erosive wear phenomena that occur rapidly on rotating ma-chines. This know-how allowed us to develop dedicated solu-tions for fans such as our Xuper- Wave welding pattern.

Castolin solutionsFor improving equipment service life and, consequently, allowing a more regular process with lower energy consumption, a full range of solutions are available:

Pre-fabricated bi-metallic plates are made by depositing a highly wear-resistant alloy on top of a standard construction steel plate using either welding or powder fusing technologies. They are utilized as liners or, when mechanical stress is low, even as structural parts. They are regularly used for manufacturing large centrifugal fans and also casings.

Coating rich of erosion-resistant carbides

Airfoil blades made with powder bi-metallic plates

Blades and impeller protection made with welded bi-metallic plates

Complete casing made with welded bi-metallic plates

Worn-out bladeWorn-out impeller XuperWave pattern and wear trai-ning for Castolin engineers

Worn-out blades leading to efficiency decrease and higher operation costs

- Extreme erosion resistance We provide nickel-based coatings with up to 60% of tungsten carbides as well as Na-noAlloy® iron-based coatings.

- High strength steel substrates Difficult to weld steels such as 1.8928 (S690QL) an 1.8988 (S690QL1) can be protected without dramatic drop of mechanical properties.

- Good flatness and smooth coating surfaceParticular attention is given during the coating process to limit deformation and keep the overlay surface smooth which eventually leads to an easier part assembly and limits wear rate. Manufacturing parameters are also opti-mized for having a good interface between coating and the steel substrate (low dilution).

Stronger, with Castolin Eutectic 3

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Stronger, with Castolin Eutectic

www.castolin.com www.eutectic.com

- Optimization of surface wear-resistanceIn order to optimize the overall fan wear resistance, various alloys can be applied in different zones. Thus, the most cri-tical positions will have extremely resistant coatings, while the less exposed to wear will be coated with an alloy that of-fers a sufficient resistance. As a result, the wear-resistance is optimized while the cost is kept to the minimum.

- Precise partsDue to the high content of carbides in our VentiTec coa-tings, cutting and forming parts require experience and correct machines. Consequently, we provide to our custo-mers ready-to-assemble parts.

- EngineeringSince our VentiTec customers have very specific requests such as, for instance, the part geometry tolerances or mantaining the steel strength properties after coating, we manage this range with engineer driven projects. Our engineering department provides assistance to our custo-mers for developing the optimum cost-effective solutions.

Rich tungsten carbides coating

Smooth surface of nickel-based coating with high content of tungsten carbides. Controlled interface between coating and substrate.

Blade bent at the correct radius

Blade coated with highly resistant Nano-Alloy® and chromium carbide alloy.

Blade coated with two highly resistant powder alloys rich of tungsten carbides.

Airfoil leading edge protection ready to be installed

Engineering department

VentiTec coatings have been specifically developed for extremely demanding cases. They are typically used by Original Equipment Manufacturers (OEMs), that need:

Stronger, with Castolin Eutectic

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CastoLab® ServicesDepending on customer needs, tests are regularly done to develop the optimum solution in CastoLab® Services workshops. Ready to be used parts are produced, cut and formed in our facilities while arc-spray coatings can either be made in our spraying booths or directly at your site.

With our international presence, we are always close our customers for helping them to improve their equipment service life and to reduce their costs. Do not hesitate to contact your sales representative to get more information about our fan protective solutions.

Axial fan manually protected in our workshop

Manual finishing Axial fan leaving CastoLab® Axial fans protected at customer sitePart production site

Axial blade protected with robot in our workshop

Airfoil blades protected on-siteWear resistant coating made with arc-spray

CastoLab Services® worldwide presence

Arc-spray wear-resistant coatings are applied on thin parts or lightweight fans that are working in a airflow which is not too heavily charged with particles, but still require a cost-efficient protective layer. Erosion and corrosion solutions are available for complex geometries such as airfoil blades that can easily be coated in our workshops as well as directly on-site when equipment needs to be repaired.