Frequently Asked Questions
Below you’ll find answers to some of the most frequently asked questions at Cold Cast. We are constantly adding most asked question to this page so if you have a question and don’t see your answer, don’t hesitate to email us at info@coldcast.pro
The general characteristics of the technological process include:
– material utilization efficiency of 20-30%,
– coating rate from 0.2 to 0.8 kg/hour,
– Thickness of coating – from 100 microns to 50 mm
– Substrate material for deposition – any metals and ceramics.
At present more than a dozen kinds of powder materials for aluminum, copper, zinc, nickel, tin, lead-based coatings have been developed. All these powders can be applied in different modes and with different nozzles. A great variety of coating properties can be obtained. Nevertheless, they are mainly characterized by the general properties listed above.
Please note that Cold Cast cannot apply hard coatings or abrasion resistant coatings. Heat-resistant coatings provide protection up to 1000-1100oC. Electrical conductivity is on average 80-90% of the electrical conductivity of the bulk material. Corrosion resistance depends on the characteristics of the aggressive environment.
Basic rules when working with Cold Cast equipment:
– 6 atm compressed air pressure,
– powder flow rate – start working with the minimum powder supply,
– temperature mode – the higher the temperature, the higher the powder deposition efficiency and the lower the coating quality, and vice versa – the lower the temperature, the lower the deposition efficiency, but the higher the quality.
Cold Cast technology provides a tight bond of high adhesion (30-100 MPa). Reliable electrogalvanic contact between coating and substrate is guaranteed. The coatings can be processed by all known machining methods.
When operating the Cold Cast, you need a compressor that supplies compressed air at a minimum pressure of 6 atm (0.6 MPa). It is also desirable to use an exhaust fan or filter, especially in closed rooms. The personnel must be skilled in working with power tools and compressed air. A brief practical training in the basic requirements is required to get started. The training can be carried out at our premises or via video link.
Broken parts and cracks in the alloy wheel must be repaired by TIG welding. Cold Cast equipment can quickly and easily repair deep scratches and potholes in the disc plane. Diamond tapping or hand sanding can be done at a later date.
The crack on the cast iron block must be fixed with a mill or drill 1,5 – 2 mm deep, so that the crack did not go further when heated. This is the most important thing to do.
Next, we treat the surface with Cold Cast equipment using abrasive powder Corundum, until a good roughness appears. This makes the cast iron look white. If you use an abrasive other than Corundum, make sure the machined surface is really rough. (Sand and some abrasives do not give a good roughness). Good roughness is the basis for a strong adhesion of the coating to the cast iron.
Now powder A-3 (aluminum zinc) fill the prepared place of the crack. This composition well closes gaps and holes. First build up the edges of the groove, then fill the entire plane with the upper bump.
While working, the part is slightly heated with hot air. The detail must cool down for 15 minutes. If the crack was not treated well, after 15 minutes there will be a crack in the coating. If a crack appears, the process must be repeated again.
Repairs take very little time and are very cost effective when repairing various shafts, including steering racks.