14/7/2020 SIS 2.

Fundamentals of HVOF Spray for Reconditioning Components {0599, 0679,

2020/04/13
1000, 7000} (SEBF9236)

SMCS - 0599,0679,1000,7000 i08097857

Caterpillar Products
All

Introduction
Revision Summary of Changes in SEBF9236
15 Added Serial Number prefixes for New Product Introduction (NPI).
Revised media and titles in Table 2.
14 Added 16 serial number prefixes.
Updated part numbers in "Infrared Thermometer" Section.
Removed statement on using WOKA 3103 as buildup layer, and updated
13
table Updated Table 2.
Corrected WOKA 7103 finish thickness specification in first paragraph
12
under Powder Recommendations.
11 Updated Table 2 and added a qualifying statement on clean dry air.

Table 1

© 2020 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only.
Unauthorized use of this document or the proprietary processes therein without
permission may be violation of intellectual property law.

Information contained in this document is considered Caterpillar: Confidential

Yellow.

The purpose of this Guideline is to provide information on the basic process

fundamentals of High Velocity Oxygen Fuel (HVOF) Spray for reconditioning
components. Successful utilization of the HVOF spray process depends on incorporating
other support types of equipment. All processing, equipment, and installation
requirements must be understood for performance and safety reasons. Included in this
document is information, including cost, on the required tools and equipment necessary
to perform the described process.

For technical questions when using this document, work with your Dealer Technical
Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit

a form for feedback in the Service Information System (SIS Web) interface.

Utilize the Dealer Solution Network (DSN) for urgent issues or questions concerning
additional repair options or modifications to reuse and salvage techniques and/or
methods.

The manual either provides or references all the necessary information to achieve an
understanding of the HVOF spray process.

HVOF Spray Procedure Documents

Media
Publication Type and Title
Number
Reuse and Salvage Guidelines, "Reuse and Salvage of Front Suspension
REHS2099 Cylinder Housing Assembly, Head, and Rod for Certain Off-Highway
Trucks (OHT)".
Reuse and Salvage Guidelines, "Thermal Spray Procedures for D3B -
SEBF2175
D6H TTT Pivot Shaft".
Reuse and Salvage Guidelines, "Inspection and Salvage of Rear Wheel
SEBF8083
Spindles for All Off-Highway Trucks".
Reuse and Salvage Guidelines, "Yoke Bearing Journals on Bulldozer Lift
SEBF8127
Cylinders for Track-Type Tractors and Wheel Dozers".
Reuse and Salvage Guidelines, "HVOF Identification and Polishing
SEBF9233
(Superfinishing)".



https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControlN… 1/49

14/7/2020 SIS 2.0

Reuse and Salvage Guidelines, "Thermal Spray Procedures for D3 - D5G

SEBF9273
TTT Track Adjuster Yoke Shaft".
Reuse and Salvage Guidelines, "Thermal Spray Procedures for D7-D11
SEBF9274
TTT Pivot Shafts".
Reuse and Salvage Guidelines, "Thermal Spray Procedures for Hydraulic
SEBF9276
Cylinder Rods".
Reuse and Salvage Guidelines, "Thermal Spray Procedures for Square
SEBF9277
(Top Hat) Housing or Left/Right Housing".
Reuse and Salvage Guidelines, "Thermal Spray Procedures for Linkage
SEBF9284
Pins".
Reuse and Salvage Guidelines, "Thermal Spray Procedures for Motor
SEBF9287
Grader Blade Lift Yokes".
Reuse and Salvage Guidelines, "Thermal Spray Procedures for OHT
SEBF9295
Rear Struts".
Reuse and Salvage Guidelines, "Thermal Spray Procedures for TTT
SEBF9297
Bearing Sleeves".
Reuse and Salvage Guidelines, "Thermal Spray Procedures for TTT
SEBF9298
Dozer and Ripper Pins".
Reuse and Salvage Guidelines, "Thermal Spray Procedures for WTS Pan
SEBF9304
Lift Yokes".
Reuse and Salvage Guidelines, "Inspection and Salvage of Front Wheel
SEBF9309
Spindles for Certain Off-Highway Trucks".
Reuse and Salvage Guidelines, "Thermal Spray Procedures for MT
SEBF9340
Series OHT Front Spindle".

Table 2

For further information and background on the HVOF spray process or HVOF-related
preparation and finishing processes, refer to the following publications or articles:

HVOF Reference Publications

Reference Title Publisher
American Welding
"Thermal Spray Manual"
Society
American Welding
"Thermal Spraying: Practices, Theory, and Application"
Society
"The Science and Engineering of Thermal Spray Coatings, John Wiley & Sons,
Second Edition" Ltd.
"Oerlikon Technical Review Magazine" Oerlikon Metco

Table 3

Canceled Part Numbers and Replaced Part

Numbers
This document may include canceled part numbers and replaced part numbers. Use the
Numerical Part Record (NPR) on the Service Information System website (SIS web) for
information about canceled part numbers and replaced part numbers. NPR will provide
the current part numbers for replaced parts.

Safety

Illustration 1 g02139237



https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControlN… 2/49

14/7/2020 SIS 2.0

This bulletin is a reference to information provided in equipment operation manuals. Cat

dealers are requested to read the safety sections of operation manuals cited in this
bulletin.

Note: Refer to operation manuals for Oerlikon Metco equipment as the primary source of
operating and safety information. Other references for operating and safety information
are the following:

Safety References
Publication Title Publisher
"Flame Spray Handbook Vol. II - Powder Process" Oerlikon Metco
American Welding Society
"Welding Handbook, 8th ed., vol. 3"
(AWS)
"Thermal Spraying: Practices, Theory, Applications, and American Welding Society
Safety." (AWS)

Table 4

Like any process that generates dust and fumes, the HVOF spray process involves a
potential hazard to personnel. All personnel involved in this process must understand and
become familiar with operating practices and regulations [Occupational Safety and Health
Administration (OSHA) standards (US) or equivalent] for compliance.

Information in this bulletin is derived from the sources mentioned, but not all the safety
points are covered here.

Environmental Health & Safety Advisory

High Velocity Oxygen Fuel (HVOF) Thermal Spray is a process that is an alternative to
hard chrome electroplating on parts used in Caterpillar Products. Chrome electroplating
uses the hexavalent form of Chromium, which is recognized by the international Agency
for Research on Cancer (IARC) as a human carcinogen. Many countries have
Occupational Exposure Limits (OEL'S) for Hexavalent Chromium, which ranges from
0.005 mg/m3 (3.12x 10-10 lb/ft3) to 0.05 mg/m3 (3.12x 10-9 lb/ft3) for an 8-hour Time
Weighted Average (TWA) exposure. The electroplating process requires extensive EHS
controls because of the hazards posed to employees and the environment by corrosive
acid solutions of Hexavalent Chromium. The HVOF process is a dry process that
eliminates the need for employee handling of corrosive chromic acid solutions. The
HVOF process can be operated manually or robotically in a controlled booth
environment. Although the HVOF process can facilitate compliance with OEL'S and
comprehensive standards like the OSHA Hexavalent Chromium Standard, the HVOF
process has inherent safety and health hazards, which must be addressed. The metal
powders used for chrome coating can contain Chromium and other nickel. To protect
employees and comply with OEL'S for Hexavalent Chromium and other materials,
implementing the following actions is required:

Fire Prevention and Protection

Precautions for HVOF spray are essentially the same as for welding and cutting. Airborne
metal dust, or finely divided solids, should be treated as a possible explosive and a
breathing hazard. Adequate ventilation must be provided to minimize the danger of dust.
Metal Powders used to deposit Chromium can also contain Nickel. The HVOF process
will create dust particles, which can contain Nickel and some Hexavalent Chromium.
Measure employee exposure time to document employee exposure to Hexavalent
Chromium and Nickel.

U.S. Federal EPA emission standards require that exhaust systems for the HVOF spray
industry have an efficiency of 99.99%. Federal, state, and local exhaust emission
requirements in North America have become more demanding.

In the flame spray industry, the Dry Cartridge Dust Collection System is the most effective
method for cleaning exhaust gasses.

Enclosed operations would also need local exhaust ventilation systems equipped with
dust collectors. Employees performing dust collection system maintenance need to use
respiratory protection, disposable coveralls, and protective gloves to minimize inhalation



https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControlN… 3/49

14/7/2020 SIS 2.0

and skin exposure to Hexavalent Chromium and Nickel.

Good housekeeping must be practiced to avoid the accumulation of metal dust. Paper,
wood, oily rags, and flammable solvents must be removed from the spraying area.

Safety Material
Compliance with OSHA Hazard Communication Standard requires current Material
Safety Data Sheet (MSDS) and employee training.

Operating Considerations
HVOF differs from welding and cutting processes in sound generation. The high exhaust
gas velocity generates noise levels of over 110 dB. Chronic exposure will likely result in
hearing loss. A combination of booth sound insulation and personal protective equipment
(earplugs and earmuffs) should be used, to reduce this noise to a safe working level.

Like welding, the HVOF process involves gas cylinders or bulk gas containers. Improper
storage, handling, and/or use of gas cylinders can create serious safety hazards. For
example, if a valve is broken off a full gas container during a fall, the container will
become a missile. If an oil-contaminated regulator or gauge is installed in an oxygen
system, the assembly will explode.

For further detail on these operating hazards, refer to the following:

Operating Considerations References

Publication Title Publisher
"Safety in Welding, Cutting, and Allied American National Standards Institute and
Processes" ANSI/ASC Code Z49 American Welding Society

Table 5

HVOF Spray Equipment

Maintain and operate HVOF spray equipment exclusively to standards set by the
equipment manufacturer. All operators must be instructed to become familiar with the
operation of the spray equipment. If an HVOF spray gun malfunctions or backfires, the
cause of the trouble must be investigated.

When HVOF spraying is completed, the system must be properly "shutdown" as follows:

1. Close all gas cylinder valves.

2. Open the gun valves to release hose gases, with room ventilation on.

3. Back out all regulator screws until free.

4. Close the gun valve.

5. Check all first stage regulators to ensure that no pressure buildup is taking place.
Pressure buildup would indicate that a bottle valve has not been tightly closed.

Never use an open flame to light the thermal spray gun. Serious
burns or other personal injury could result. Equip the gun with
an electric ignition system or use a spark lighter.

Abrasive Blasting Equipment

Maintain blasting equipment according to the manufacturer specifications. Replace worn
parts for efficient operation. Replace deteriorated hoses and nozzles.




https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControlN… 4/49

14/7/2020 SIS 2.0

Grit blasting produces airborne particulates that can act as

respiratory irritants. If inhaled, these particulates can cause
serious injury or death. Additionally, the grit from this process
can be abrasive to the skin and eyes of the operator and can
cause serious injury. If grit blasting is performed manually or
outside of a grit blast cabinet, operators must be provided with
respiratory protection, face shields, and helmets. Information on
face shields and helmets can be found in ANSI/ISEA Z87.1
(American National Standard for Occupational and Educational
Eye and Face Protection Devices) and ANSI/ISEA Z89.1
(American National Standard for Industrial Head Protection).
Information on the selection, operation, and maintenance of a
respiratory device can be found in ANSI/AIHA Z88.2 (Practices
for Respiratory Protection) or other local approval authority
documentation.

Mechanical Stripping and Finishing Equipment

Maintain lathes, grinding, and finishing equipment according to the manufacturer
specifications. Replace worn parts for efficient operation. All operators must be instructed
to become familiar with the lathe and grinding equipment operations.

Serious injury or death can result from contact with rotating

parts or pinch points. To avoid injury, rotating parts, such as
grinders, superfinishers, and lathes, should only be operated if
all guards and protective devices are properly installed and in
good working order. All equipment should be operated
according to the manufacturer instructions.

Other Safety Hazards

Other safety hazards include compressed gases, thermal burns, high voltage, and
mechanical pinch points from robots and turntables, which are potential ergonomic
hazards involved with handling parts. The American Society of Metals Thermal Spray
Society (TSS) has made two Safety Guidelines available to help provide control of the
process: "SG001-02 Safety Guidelines for the Handling and Use of Gases in Thermal
Spraying", and, "SG003-03 Thermal Spray Booth Design Guidelines". The guidelines are
available free from TSS web site or Corporate EHS.

Process Fundamentals
High Velocity Oxygen-Fuel (HVOF) spraying is a process where fine metallic materials
are deposited onto a prepared surface. HVOF is considered a "warm" part salvaging
method when compared to flame spray "cold" or welding and brazing (both "hot"
processes). HVOF is considered a warm process because the surface temperature of the
part is kept below 205° C (400° F) when a coating is applied. Therefore, the part
experiences no metallurgical or physical changes.

The Caterpillar HVOF spray salvage process uses an oxygen-fuel mixture. The Diamond
Jet Hybrid Spray System by Oerlikon Metco utilizes either propylene, propane or natural
gas as a fuel. The fuel gases are mixed in a nozzle system in the front portion of the
spray gun. The mixed gases are ejected from the nozzle of the gun and ignited externally.
The ignited gases form a circular flame, which surrounds the powdered spray material as
the material flows through the gun.

The circular flame shapes the powder stream to provide uniform heating and acceleration
of the spray material. Combustion temperatures approach 2760° C (5000° F)

Pre-selected oxygen, fuel, and airflow values optimize the dwell time of the spray material
in the flame.

Caterpillar salvage applications and process orientation in this guide assume the use of a
Diamond Jet Hybrid Spray System by Oerlikon Metco.



https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControlN… 5/49

14/7/2020 SIS 2.0

The gas exhaust velocities of the Diamond Jet Hybrid Spray System approach 2134 m/s
(7000 ft/s) [3 to 4 times the speed of sound]. Elevated particle velocities, optimized
powder feed rates, and internal central powder injection impart both thermal and kinetic
energy to the powder particles. The high velocity particles flatten when impacting on the
substrate to form dense tightly bonded coatings.

Nitrogen is used as a carrier gas for feeding the spray materials through the system. The
Diamond Jet Hybrid Spray System uses 9.5 L/min (2.5 US gal/min) of water to cool the
nozzle of the gun.

Powder Feed
All Diamond Jet Hybrid Spray Systems are fed by a pressurized feeding system. The
powder is transported and delivered to the gun by an inert gas (pre-purified Nitrogen) at a
constant rate, independent of the spray gun orientation or movement. The feed unit
provides a real-time powder feed rate, to help with coating process control.

Illustration 2 g06387461
Typical example of a cross sectional view of the Hybrid Nozzle Diamond Jet Spray System Gun.
(A) Powder
(B) Oxygen
(C) Fuel
(D) Air
(E) Water In
(F) Water Out
(G) Distribution Plug
(H) Nozzle
(J) Nozzle Nut
(K) Air Cap Body
(L) Water Adaptor
(M) Baffle
(N) Nut
(O) Air Cap

Coating Fundamentals
Through the High Velocity Oxygen Fuel (HVOF) spray process, a fine metallic uniformly
heated material is deposited onto a prepared surface. When the particles strike a surface,
the particles flatten (elongate), rapidly cool and quench to form micro-thin platelets. The
platelets conform to the surface of the substrate and to each other. The bond between
the base material and the HVOF coating is mechanical.

As the sprayed particles continue to impinge onto the surface, a layer or lamella structure
is formed. The lamella structure of HVOF coatings is dense and uniform. HVOF coatings
have the following characteristics:

High density

High bond strength [more than 83 MPa (12,000 psi)]

Essentially stress free

Low porosity (less than 3%)




https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControlN… 6/49

14/7/2020 SIS 2.0

Fine as-sprayed finishes

Greater hardness (DPH300 1000-3000)

Metal working capabilities

Excellent wear and corrosion resistance

Greater thickness

Since multiple particles are needed to create a coating, several transverse passes of the
gun are required to produce the desired coating thickness. These multiple passes should
be performed at a constant rate by mechanical manipulation. The actual thickness of a
coating depends on the run out of the component being salvaged plus an allowance for
finishing. The finishing allowance is generally 0.05 - 0.08 mm (0.002 - 0.003 inch) on a
side.

The formed coating is used for "surface" type applications. The coating will not provide
any strength to a part. The coatings only function is to add some desirable characteristic
to the surface that is lacking in the work piece part. Desirable HVOF spray characteristics
include:

Corrosion protection

Better wear characteristics

Dimension restoration

Electrically conductive or resistive

Because of the nature and structure of HVOF spray coatings, HVOF should not be used
when the coatings will be subjected to line or point-to-point contact and severe, sharp,
and repeated type of impact.

Chrome Stripping Mechanically

The chrome on a component being salvaged can be removed mechanically or
chemically. All plating shops that rechrome components remove existing coatings
chemically.

A solution containing chrome as a liquid is considered a hazardous waste, which makes

disposal expensive. Plating companies are prepared to handle these dangerous
chemicals, and are familiar with waste disposal methods and costs.

Note: A plating shop can be held financially responsible for problems caused by the
company who handles the waste disposal.

To avoid these hazardous chemicals, the hazardous waste, and waste removal costs, the
Caterpillar HVOF spray salvage program requires chrome to be removed mechanically.
Mechanical chrome removal methods are:

Conventional (wheel) Grinding

Belt Grinding

Turning

Grit Blasting

The most economical method to remove chrome mechanically is belt grinding. Belt
grinding removes chrome twice as fast as wheel grinding, and requires a much lower
capital investment than conventional grinding.




https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControlN… 7/49

14/7/2020 SIS 2.0

Illustration 3 g06389431
Chrome stripping

Belt grinding can be accomplished on most good quality lathes, by simply attaching a belt
grinding machine to the cross slide. The in-feed adjustment will control the amount of
load on the component and grinding belt. The cross slide feed will control the feed rate of
the belt grinder along the component. One can convert some wheel grinders to belt
grinders, by substituting a contact wheel for the stone wheel and installing a belt idler
assembly.

Chrome removal can be performed at a rate of 0.025-0.038 mm (0.0010-0.0015 in) per

pass at a traverse rate of 6 mm (0.25 inch) per revolution with the proper set-up and
tooling. A pass is defined as the belt grinder making a trip in one direction the length of
the component. 3M 966F belts should be used for chrome stripping.

If necessary to remove an HVOF coating from a piece, use a 3M Trizactgrit 70 micron

diamond belt, but only until breakthrough of the steel substrate. Test and development of
belts for chrome stripping continues, as does evaluation of different stripping methods.

A copper-sulfate/water solution can be prepared and atomized onto the dried surface of
the component after stripping passes, to determine the extent of chrome removal. This
procedure is not always necessary, because on most components a color change can be
noticed when the base material is exposed. Rewash to remove the solution prior to grit
blasting.

Coolant is necessary for chrome stripping and should be flooded into the contact area
between the belt and component. As contact pressures increase, the pressure of the
coolant must be adequate to assure that the belt and component are being cooled
properly. An additive must be mixed with coolant water to prevent rust, and counteract
bacteria growth. Treatment of hard make up water may be necessary, since the minerals
can inhibit additive performance.

Examples of additives are listed in "Surface Texture".

Coolant filtering is necessary to remove grinding "mud" if the machine is also used to
finish HVOF sprayed components. Small abrasive particles in the coolant can cause
problems with surface texture. A filter fixture/pump setup that uses a paper roll element
has several advantages, including significant capacity, automatic advancement of the
filter roll, and the ability to handle several machines simultaneously. The filter element
should be at least 50% efficient for 10-micron particles.

Check with your local environmental authorities on the handling of waste coolant and
filter elements containing chrome particles. Once the water evaporates, the chrome may
be sold as a waste metal, similar to the blow-by HVOF powder.

Surface Texture
HVOF coatings can be finished by the following mechanical methods:

Conventional (wheel) Grinding

Belt Grinding



https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControlN… 8/49

14/7/2020 SIS 2.0

The most economical method to finish an HVOF coating is belt grinding. Belt grinding is
sometimes referred to as belt sanding with a diamond belt or other aggressive abrasive
material. Belt grinding will finish HVOF coated components twice as fast as wheel
grinding.

Belt finishing of most components will require a two-step process. The first step will be to
grind the HVOF coating with a 3M Trizact M70 diamond belt to remove most excess
material and any taper from the component. The second step is to use the super finisher
to grind the component to the proper size and surface texture.

Although possible to finish components to the specified size and surface texture using
only a grinder, a super finisher has three important purposes. This procedure will remove
any blemishes or "striping" (barber poling) the belt grinder leaves on the component,
thereby eliminating variations in texture due to lathe conditions and operator experience.
Second, this procedure creates a slight crosshatch in the coating similar to the fine
cracks which occur in plated surfaces. This texture is desirable to help lubricate seals and
enhance seal life. The third purpose is to achieve a more polished surface appearance,
which is similar to what is produced by plating. A 20 micron film should be used for
superfinishing.

Belt grinding can be accomplished on most good quality lathes, by mounting a belt
grinding machine to the cross slide. The in-feed adjustment will control the amount of
load on the component and grinding belt. The cross slide feed will control the feed rate of
the belt grinder along the component. It is possible to purchase wheel grinders converted
to belt grinders.

Illustration 4 g06389441
Abbott CNC Roll Grinder with Belt Grinding Attachment

The super finisher should be mounted to the cross slide of a lathe. To save floor space
and reduce capital investment, the super finisher can be combined up with a rear-mount
belt grinder in a set on one lathe. This arrangement up will allow both operations to be
performed on the same machine, avoiding excess material handling.

With the proper set-up and tooling, HVOF coatings can be ground at a rate of
0.038-0.051 mm (0.0015-0.0020 inch) per pass at a traverse rate of 5.0 mm (0.1875 inch)
per revolution. A pass is defined as the belt grinder making a trip one direction the length
of the component. HVOF coatings can be super finished at a rate of 0.013-0.038 mm
(.0005-.0015") per pass at a traverse rate of 0.64 m/min (25 in/min)

Coolant with a rust and bacteria inhibitor is required for the HVOF grinding and super
finishing operations. Hard water may require treatment, since minerals can interfere with
rust inhibitors and other coolant additives. The coolant should be flooded into the contact
area between the abrasive and the component. As contact pressures increase, the
pressure of the coolant should be enough to assure that the abrasive and components
are being cooled properly. To improve diamond belt life, a coolant formulated for
machining high Nickel content materials should be used. The following coolants meet this
requirement:

Castrol WE3-046A



https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControlN… 9/49

14/7/2020 SIS 2.0

Castrol Syntello 9954

CimPerial 1070 from Cincinnati Milacron

Bosse Grind, Rust Bar 750 (Star Metal Fluids)

Milacron 46C

Since lathe coolant systems are only designed to let coarse chips collect in the sump, the
system must be modified to provide adequate filtration. The lathe pump should pipe the
coolant to an auxiliary filtering system which is at least 50% efficient for 10 micron
particles. This is necessary to remove abrasive "mud" which can damage rod texture and
also the lathe. The modification should also include coolant plumbing to wash abrasive
material from the machine ways, to prevent premature wear. A filter tank/pump setup
using an automatically advancing paper roll element has several advantages. These
systems have far more capacity than canister filters, and can be sized to handle several
machines simultaneously. Filter fixture suppliers include:

Oberlin Filter Company

Hydromation Division, Filtra Systems

J.R. Schneider Co., Inc.

Hoffman Air and Filtration Systems

Illustration 5 g06387613
Filter paper suppliers include:

Lydall Manning

National Filter Media Corp.

Industrial Filter Fabrics

The products and manufacturers listed here are not intended as the only acceptable
choices. For information on these or other suppliers, questions, or to address an urgent
issue, use the following resources to communicate your request to Caterpillar Repair
Process Engineering: Cat dealer Technical Communicator, Dealer Solution Network
(DSN), Caterpillar Technical Representative, or Knowledge Network.

Check with your local environmental authorities on the handling of waste coolant and
filter material.

Once the water has been removed by evaporation, the waste material may be sold as a
waste metal similar to the blow-by HVOF powder.

If necessary to remove all HVOF coating from a piece, the diamond belt should only be
used until first breakthrough of the steel substrate.

Support Equipment and Operations




https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 10/49

14/7/2020 SIS 2.0

Straightening
A component with more than 0.076 mm (0.0015 inch) runout will have to be straightened
before the HVOF salvage process.

The component should be loaded into a straightening press with adequate gauging to
straighten the component to less than 0.038 mm (0.0015 inch) runout per every 914 mm
(36 inch).

Straightening is crucial to conserving spray materials, and in minimizing both thermal

spray and machining cycle times.

Reducing overall component runout, decreases the volume of spray material that must be
deposited onto the component to compensate for the out-of-round condition.
Components requiring higher volumes of material will increase the thermal spray cycle
time. Component machining times will also increase, because of the need to remove the
excess spray material.

Degreasing
All components should be degreased before the grit blast operation. Degreasing helps
prevent contamination of the grit, and assures there is no oil or grease on the surface of
the component to be coated. Oil and/or grease on the surface of the component will
increase the probability of finishing problems and coating defects.

Grit Blasting
Grit blasting before the thermal spray process is considered surface texturing. This
operation provides a slightly rough surface texture that the HVOF metal particles will
interlock with. Clean, dry compressed air, and sharp, coarse blasting abrasive that is free
from contaminants must be used to avoid finishing problems.

Two types of grit blasting systems are found in most shops: pressure and suction. For
surface preparation of a coating, the pressure type system is preferred because:

1. Pressure blast systems can handle both aluminum oxide and steel angular grits.

2. A pressure blast system is more efficient and, therefore, more economical.

3. Pressure blast provides the best surface texture and depth using either aluminum
oxide or angular steel grit.

4. A suction head can be mounted next to the pressure blast nozzle, to quickly and
efficiently remove blast media as the surface texturing is being completed.

Aluminum oxide 20 mesh is the recommended grit blast media to prepare surfaces for
HVOF.

Aluminum oxide is a hard and brittle abrasive, used primarily on heat-treated steel
substrates. It is not used for preparing aluminum or cast type substrates because the fine
dust generated during the blasting operation tends to embed into the surface of the
component. Because this type of grit is light in weight, it can be used at low pressures.
The use of lower operating pressures allows the use of aluminum oxide grit on hard and
soft components. The recommended blast air pressure is 413 kPa (60 psi). Heat-treated
rods should be rotated at 61 SMPM (200 SFPM). Non-heat treated rods should be
rotated at 122 SMPM (400 SFPM), with the blast nozzle traversing across the piece at a
rate of 5.0 mm (0.1969 inch) per revolution. Blast nozzle to work piece distance should
be maintained at a 101 mm to 127 mm (4 inch to 5 inch) range to obtain a minimum
surface profile of 6.0 µm (250 µinch).

Using higher than recommended pressures results in rapid breakdown of grit, and more
grit usage.

It may be necessary to grit blast chrome from long, small diameter parts due to bending
problems when grinding. This method shall be used when necessary, since the chrome
particles will mix with the grit. Chrome or other grit contaminants can be embedded in the
surface of the component during blasting.



https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 11/49

14/7/2020 SIS 2.0

Note: Visually inspect used grit to ensure sharpness. If dull or contaminated grit is found,
replace the grit before poor surface preparation results.

Masking Aids
Masking is required to protect critical surfaces and holes from the effects of the grit
blasting and thermal spraying. Any type of material that can withstand the effects of either
operation is considered a suitable masking material.

The mask can be permanent sheet metal or a temporary material. Temporary-type

masking materials are:

Hard Rubber

High temperature silicon rubber

high temperature fiber type materials

Several layers of duct or masking tape

Cloths

Liquids

Spray Booths and Rooms

Any flame spraying process generates dust and fumes. The HVOF process also
generates an extreme amount of noise, due to gas exhaust velocities of 7000 ft/sec
(2134 m/sec). The noise will be in the 135 dB to 140 dB range.

For environmental control and personnel safety, an enclosed soundproof area is

appropriate. Dealer Support or a local supplier can recommend various dry cartridge
exhaust and soundproof rooms, to meet your local safety standards and regulations.

Rotational/Traverse Equipment
Rotating the cylindrical components should be accomplished in a lathe or other dedicated
rotational device. The standard lathe or dedicated rotational device should provide
variable rotational settings to relatively high RPM capability. Specially designed rotating
systems manufactured by Oerlikon Metco and other companies can withstand the dusty
spray environment, yet provide the part rotational requirements.

Rotational requirements for parts are provided in the Applications section. The following
formulas can be used to calculate either RPM (revolutions per minute) or SFPM (surface
feet per minute) for a part.

(3.82 x SFPM)/ rod diameter in inches = RPM

0.262 x RPM x rod diameter in inches = SFPM

For traverse motion of the HVOF spray gun, the following guidelines should be used to
apply an even coating deposit:

Flat work (non-rotating): Traverse at a rate of 15-30 cm (0.5-1.0 inch) per second,
making 6.3 mm (0.25 inch) gun increments per pass.

Round/Rotating Work: Traverse the gun at a 5.0 mm (0.1875 inch) per revolution.

Painting
After a hydraulic cylinder rod has been repaired, the eye, yoke, or other method of
attachment should be repainted to prevent exposure of unprotected surfaces.

During testing, the highest level of corrosion occurred on the blend radius shown in
illustration 6. A recommended practice to help avoid corrosion in this area is to paint the
area when the repair has been completed.

Note: Protect the pin bore, pin bore face, and all threaded holes during the painting
process.



https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 12/49

14/7/2020 SIS 2.0

Illustration 6 g06389461

Improving Efficiencies
Improving the efficiency of any HVOF salvage operation is an on-going continuous task.
The following ideas are recommendations from Dealer Support, other Cat dealers,
suppliers, and Caterpillar Technical Center.

These ideas or examples should be used as starting points to generate good efficiency
improvements at your facility.

The following topics will be discussed:

Color Coding

Batch Processing

Equipment Usage

Blast Cabinets

Coating Repairs

Color Coding
Color coding of components as they are initially inspected is a good way to initially
separate in-process inventory. A spot of paint on the chrome area of a rod can identify a
rod for eye repair, straightening, HVOF repair or rerodding.

Color coding is also a quick way to determine the amount of in process inventory in the
Hydraulic Repair Area.

Batch Processing
Rods of similar diameter or length can be processed together to minimize machine set-up
times.

Wheeled "A" frame carts can be used to move batch parts quickly from one operation to
the next.

A few HVOF coated rods of high volume can be kept on hand to improve turn around
time. A large inventory of HVOF coated rods is not recommended, unless warranted by
sales volumes.

Equipment Usage
Initially four lathes, four headstock/ tailstock configurations, or a combination of the two
should be purchased to perform the HVOF process. These pieces of equipment should
have similar capacities, so that the same size component can be processed in each area.
Itis recommended to use the equipment as rotational devices for the following operations:

Chrome Stripping

Surface Preparation (grit blast)




https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 13/49

14/7/2020 SIS 2.0

HVOF process

Coating Finishing

The volume of components that must be processed to justify the capitol expenditure of
this magnitude requires the sufficient volume. Performing a market study will determine
volume of Caterpillar and non-Cat opportunity.

A fifth smaller lathe or headstock/ tailstock configuration can be used for stripping chrome
and coating finishing of small diameter components.

The following stripping and finishing equipment configurations are recommended:

Four-Lathe Shop

Chrome Stripping Kelsey Super G-4 Belt Grinding Machine

Coating Finishing Kelsey Super G-4 Belt Grinding Machine Kelsey SF-4 Super
Finishing Machine

Five-Lathe Shop

Chrome Stripping Kelsey Super G-4 Belt Grinding Machine

Coating Finishing Kelsey Super G-4 Belt Grinding Machine Kelsey SF-8 Super
Finishing Machine

Small Lathe Kelsey Super G-1 Belt Finishing Machine Kelsey SF-4 Super
Finishing Machine

The grinder on the Coating Finishing machine should be used for one or two passes to
rough finish the HVOF coating. The Super Finisher will then be used to polish the
component into the proper tolerances (dimensionally and surface texture) in one to two
passes.

Blast Cabinets
Grit blasting and HVOF coating on the same piece of equipment is not recommended.

The throughput time of the HVOF salvage operation will be drastically reduced by
performing these two operations on the same piece of equipment.

A combination cabinet will become contaminated with the blasting media. Contamination
will reduce the cleanliness level of the components being coated, thus reducing the bond
strength of the HVOF coating.

Coating Repairs
The following guidelines should be used when repairing a blemish on an HVOF coated
component:

1. If the coating thickness is less than 0.51 mm (0.020 inch), the coating should be
removed completely and returned to the surface texturing operation.

2. If the coating thickness is over 0.51 mm (0.020 inch), then the following steps
should be followed:

a. Remove 0.13 mm (0.005 inch) of coating thickness.

b. Heat the component to 177° C (350° F) for 3 hours to remove all oils from the
surface of the coating.

c. Apply a degreasing agent to the surface of the coating and dry with clean
shop air.

d. Apply the HVOF Coating.

Surface texture Inspection




https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 14/49

14/7/2020 SIS 2.0

When an HVOF coated component has not failed at time of disassembly, the surface
roughness of the component must be measured. If the surface texture does not meet the
specification, the component should be repolished and checked again. After repolishing,
the following inspection procedure should be conducted:

Place component on rollers, in a lathe, or hang vertically.

Clean the inspection area with isopropyl alcohol and a lint free cloth.

Holding an LED pen light less than 1 ft from the surface and at an approximately 30
degree angle, look for any shiny sparkles. If any are seen, circle the area with a
permanent marker or paint pen.

Hold a ball point pen at approximately a 45° angle and lightly drag the tip across the
marked areas. Reject the part if a pit is felt when moving the pen across the
surface.

Illustration 7 g06038724
Holding the LED pen light less than 1 ft from the surface and at an approximately 30° angle.

Illustration 8 g06038694
Holding the ball point pen at approximately a 45° angle.

HVOF Spray Equipment




https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 15/49

14/7/2020 SIS 2.0

Illustration 9 g06389462

Illustration 10 g06389769
The Caterpillar HVOF spray salvage program will use the Diamond Jet Hybrid Spray
System byOerlikon Metco. The Diamond Jet Hybrid Spray System consists of the
following basic components:

Hybrid Diamond Jet Gun (DJ-A Automatic)

DJC Diamond Jet Control Unit

9MPDJ or DJP Powder Feed Unit

2DJR Diamond Jet Gas Regulators and Manifolds

4AC Air Cleaner

7GNR Nitrogen Regulator

DJC 2600 Water Sensing Interface Box 



https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 16/49

14/7/2020 SIS 2.0

DJ 2700 Hybrid Air Cap Assembly (designed for propylene, propane, or natural gas
as a fuel)

Note: Hydrogen assist is required when using propane, propylene, and natural gas.

Note: The TAFA JP5000 is an option for the Diamond Jet Hybrid Spray System.

Illustration 11 g06389879
9MP-DJ Powder Feed Unit on right DJC Diamond Jet Control Unit on left

Illustration 12 g06389890
Vertical Spray Cabinet

Illustration 13 g06389915
DJ2700 Hybrid Gun Arrangement

Sound Suppression Equipment

The acoustical spray room should meet the following minimum parameters:

Walls and roof shall have a minimum Sound Transmission Class (STC) rating of 40
as tested in accordance with ASTM E90-75 and noise Reduction Coefficient (NRC) 


https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 17/49

14/7/2020 SIS 2.0

of 0.95 tested in accordance with ASTM C423-77. See table below.

Windows should be provided with a number six filter to prevent glare when viewing
the thermal spray process in operation. Windows should also be thermopane
glazed and supplied with a desiccant material between the panes to prevent
fogging.

Acoustic Performance
Sound Transmission Loss dB E-90-75
Octave Band Center
63 125 250 500 1k 2k 4k 8k STC
Frequency (Hz)
Noise Shield Regulate 20 21 27 38 48 52 56 — 40
Noise Lock Door — 26 42 43 47 61 61 67 47
Noise Lock Windows 27 28 31 47 55 61 61 67 47
Sound Absorption Coefficients(1)
Noise Shield Regulator — 0.89 1.20 1.16 1.09 1.01 1.03 0.93 0.95
Noise Reduction — 15 19 24 34 41 46 45 50

Table 6
(1)
ASTM C423-81A Standard test method for sound absorption and absorption coefficient via
reverberation method, mounting method A, formally mounting number four.

Consult your local environmental laws for exact sound regulations.

Illustration 14 g06389970
Blast Cabinet (right) and HVOF Cabinet (left).

System Recommendations
Powder Delivery
Different powder feeder hoses are available from Oerlikon Metco that have varying
internal diameters. The different sizes are coded by color, as shown in the table below.
Cat dealers generally use the blue powder feed hose, however, the appropriate choice of
hose depends the length of the hose. Each operation should consult with an Oerlikon
Metco representative to determine the appropriate internal diameter for the powder feed
hose.

Oerlikon Metco's
Standard Powder Feed Hose Sizes

Hose Type Insides Diameter

Blue Ø 2.29 mm (0.090 inch)
Orange Ø 3.18 mm (0.125 inch)
Black Ø 4.76 mm (0.188 inch)

Table 7

Fuel Delivery



https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 18/49

14/7/2020 SIS 2.0

Bulk fuel storage tanks must be heated to prevent fuel gases from liquefying. Also, an
important procedure is to have gas lines from the bulk storage tanks to the Oerlikon
Metco equipment heated to prevent gas condensation.

Spray booths or shop areas that are not climate controlled should heat the fuel gas lines
from the Oerlikon Metco controller to the HVOF gun to prevent condensation.

Illustration 15 g06389978
Bulk Oxygen Tank

Illustration 16 g06389982
Natural Gas Arrangement

Illustration 17 g06385002
HVOF Shop Air Schematic
(1) Upstream Filter
(2) Air Dryer
(3) Downstream Filter
(4) Downstream Filter

Dry, clean shop air is critical to the quality of a thermally sprayed coating. Separate air
filters and an air dryer should be used prior to the shop air entering the HVOF system.



https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 19/49

14/7/2020 SIS 2.0

NOTICE
Clean dry air is defined as ISO 8573 - Class 3 air or better.

The preferred system configuration is shown in the HVOF Shop Air Schematic. refer to
Illustration 17. The air dryer [2] should have a filter [1] placed up stream and two filters [3,
4] down stream. Refer to Illustration 17.

1. Particulate Filter (5 micron) - Wilkerson: FC35-OC-F00 or equivalent

2. Air Dryer - Pneumatech AD-1500, AD-1700 or equivalent (based on air

consumption and the ambient climate in the shop)

3. Coalescing Filter (0.5 micron) - Wilkerson: M35-OC-FS0 or equivalent

4. Coalescing Filter (0.01 micron) - Wilkerson: M35-OC-F00 or equivalent

Water Chiller
A water chiller for the 2700 Hybrid water-cooled nozzle by Oerlikon Metco must meet the
following parameters:

Water Chiller Parameters

Water Parameter
Flow 7.6 L/min (2.0 US gal/min)
Temperature (Inlet to Gun) Below 26.6° C (80° F)
Pressure 275.6 kPa (40 psi)
Cooling 30,000 BTU/hour (31,650 kJ/hour)
Cleanliness Tap water

Table 8

Tap water can be used to cool the nozzle in most locations and then diverted to drain. If
water recycling is required, the following chiller or equivalent is recommended:

5MK Heat Exchanger by Oerlikon Metco

Exhaust/Ventilation
For environmental control and personnel safety, a proper dust and fume exhaust system
is required. EPA (U.S.) rules dictate exhaust systems be 99.9% efficient. Both Torit and
Oerlikon Metco can supply the required equipment.

Illustration 18 g06389991
Exhaust System for grit blast and HVOF.




https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 20/49

14/7/2020 SIS 2.0

Illustration 19 g06389993
CNC Panel to control grit blast and HVOF

Manipulators/CNC
The HVOF/Grit Blast cells are computer controlled to provide high-quality coatings via a
controlled process. Vertical or horizontal booths can be used to blast and spray the
cylinder rods.

Illustration 20 g06387621
HVOF Coating being applied to a hoist cylinder

Illustration 21 g06389994
HVOF Spraying Operation

Design/Support
Cat dealer Support and Research can provide the necessary information for planning an
installation. Working with suppliers, a turnkey package can be created to fit the
requirements of the dealer.

Progressive Surface Design




https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 21/49

14/7/2020 SIS 2.0

Illustration 22 g06386528
HVOF Facility (1:60 Scale)
(D) Dust Collector and Blower (To be Located Outside)
(E) Heat Exchanger (Optional)
(F) Powder Feeder (Optional)
(G) JP-800 Controller (Optional)
(H) Electrical Enclosure
(J) Booth Walls Are Shown Transparent
HVOF Facility Dimensions
Location Minimum Maximum
A 5968.2 (234.97) 5974.8 mm (235.23 inch)
B 14141 (556.74) 14148 (557)
C 5485.6 mm (215.97 inch) 5492.2 mm (216.23 inch)

Table 9




https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 22/49

14/7/2020 SIS 2.0

Illustration 23 g06386694
Grit Blast Facility (1:60 Scale)
(N) Electrical Enclosure
(P) Dust Collector and Blower (To be located outside)
(R) Sweco
(S) Pressure Pot System
(T) Booth Walls Are Shown Transparent

Grit Blast Facility Dimensions

Location Minimum Maximum
K 4095.8 mm (161.25 inch) 4102.4 mm (161.51 inch)
L 12552.2 mm (494.18 inch) 12558.8 inch (494.44 mm)
M 5502.4 mm (216.63 inch) 5509 mm (216.89 inch)

Table 10

Ring Power System




https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 23/49

14/7/2020 SIS 2.0

Illustration 24 g02759121
Fintech Grit Blaster

Illustration 25 g06389052
Fintech Grinder

Illustration 26 g06390187
Zoom of Fintech Grinder

Illustration 27 g06390207



https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 24/49

14/7/2020 SIS 2.0

HVOF Machine

Illustration 28 g06390220
HVOF Spray Nozzle

Illustration 29 g06390236
Stainless Steel Cover




https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 25/49

14/7/2020 SIS 2.0

Illustration 30 g06390245
Infrared Heat Sensor

Illustration 31 g06390250
Zoom of HVOF Control Panel




https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 26/49

14/7/2020 SIS 2.0

Illustration 32 g06390254
HVOF Coated Cylinder and Equipment

HVOF Machining Equipment

Illustration 33 g06390262
Belt Grinding Machine
Cat dealer HVOF salvage program applications will use a mechanical method to strip
existing chrome or HVOF coating from salvageable hydraulic cylinder rods and OHT
struts. A mechanical method will also be used to finish all components after the HVOF
operation. The choices of grinding/finishing equipment are:

Abbott CNC Cylindrical Grinder

Finishers Tech Super G-6 Belt Grinding Machine or equivalent

Supfina 210, IMPCO, GEM, or equivalent




https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 27/49

14/7/2020 SIS 2.0

Illustration 34 g06390318

Equipment Specifications
Chrome Stripping and HVOF Grinding:

Finishers Tech Super G-6 Belt Grinding Machine ( 51 mm (2 inch) wide contact
wheel) or equivalent [Two required, one for chrome stripping and one for HVOF
finishing]

Variable Speed Controller

14.9 kW (20 hp) motor

Digital Amp load readout

Capable of 3048 surface meters per minute (10,000 SFPM) belt speed

50 mm (2 inch) diameter air cylinder for belt tension

90 Durometer Shore A, Plain face contact wheel (finishing)

90 Durometer Shore A, Scoop (or J-72) wheel (stripping)

The contact wheel diameter depends on the lathe the machine is mounted on. A large
wheel will provide more clearance between the grinder and tailstock. Most installations
use a 406 mm (16 inch) diameter wheel.

Scoop wheels, which have slanted slots cut into the wheel face, are used for stripping
because they exert more unit pressure on the cylinder rod or strut. An alternate to the
Scoop wheel is the J-72. This is similar in appearance to the Scoop wheel, except the
slots are flat-bottomed and do not break out the sides of the face.

The inside diameter of some as-delivered contact wheels has been found to be rough
and/or not concentric with the tire. It is recommended that you use a drawing from Dealer
Support to produce hubs for Ø 406.4 mm (16.00 inch) diameter wheels, and bore the
wheels to fit the hub. The wheels and hubs should be balanced individually at speeds up
to 1,500 RPM, for interchangeability. Whenever switching to a different wheel on a hub,
the replacement wheel should be dressed for concentricity before a belt is installed. Use
the following procedure:

1. The grinder should be mounted on the machine with the wheel shaft centerline as
parallel as possible to the machine centers.

2. Use chalk, or preferably a white paint stick, to place marks the full circumference of
the contact wheel.

3. Place a straight rod between machine centers, and use solvent to clean a section of
the rod.

4. Cut a rectangular section of adhesive backed abrasive that is wider than the contact
wheel, and apply the abrasive section lengthwise on the clean surface.

5. Rotate the rod and position the contact wheel so the wheel is about 6.35 mm
(0.250 inch) from the abrasive surface.



https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 28/49

14/7/2020 SIS 2.0

6. Start the grinder and set the speed to 304.8 surface meter per minute
(1,000 SFPM) or less (240 RPM with a Ø 406.4 mm (16.00 inch) diameter wheel).

7. Infeed slowly until the wheel contacts the abrasive, then traverse the wheel across
the abrasive.

8. Infeed an extra 12.70 µm (500 µinch) and repeat the traverse, until the entire face
of the contact wheel has been dressed.

Illustration 35 g06389081
Finishing a rod with a diamond belt

Illustration 36 g06390364
SG-6 control panel




https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 29/49

14/7/2020 SIS 2.0

Illustration 37 g02778421
Hub, with wheel clamp ring loose

Illustration 38 g06390505
Scoop wheel - Ø 406.4 mm (16.00 inch) diameter, 51 mm (2 inch) wide.

HVOF Texture
Supfina 210, IMPCO, GEM, or equivalent




https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 30/49

14/7/2020 SIS 2.0

Illustration 39 g06391028
Supfina 210 Super Finisher

Illustration 40 g06391042
Finisher's Tech SF- 4 Super Finisher

HVOF Machining Abrasives

Cat dealer HVOF spray salvage program applications will use the following abrasives to
strip existing chrome plating, or HVOF coating, from salvageable hydraulic cylinder rods
and OHT struts, and to finish all components following the HVOF operation.

Chrome Stripping
3M Cubitron 966F 24 grit

51 mm x 3353 mm (2 inch x 132 inch) belts will be required for the Finishers Tech Super
G-6 Belt Grinding Machine. If necessary, 51 mm x 1524 mm (2 inch x 60 inch) belts for
the optional grinding equipment (Finishers Tech Super G-1 Finishing Machine).

NOTICE
This operation should always be performed wet.

The product is designed for wet grinding where high, sustained stock removal is required.
The belt will perform well in moderate pressure grinding on various materials including
steel, stainless steel, and exotic alloys. The recommended belt speed is 6000-7000 RPM.

When using the 967F Multicut belt to remove chrome, a high amp load (that is, 10 amps
or greater above the idle amp load) should be used to break down the special ceramic
aluminum oxide mineral. By continuously breaking down the mineral on the belt, new
cutting edges are exposed.

HVOF Stripping
3M Trizact Diamond Cloth belts 663FC (70 micron) 


https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 31/49

14/7/2020 SIS 2.0

51 mm x 3353 mm (2 inch x 132 inch) belts will be required for the Finishers Tech Super
G-6 Belt Grinding Machine.

HVOF Texture (Grinding)

3MTrizact Diamond Cloth belts 663FC (70 Micron)

51 mm x 3353 mm (2 inch x 132 inch) belts will be required for the Finishers Tech Super
G-6 Belt Grinding Machine. 51 mm x 1524 mm (2 inch x 60 inch) belts for the optional
grinding equipment (Finishers Tech Super G-1 Finishing Machine).

Super Finishing
3M Diamond Microfinishing film 675L (20 micron)

Illustration 41 g06391050
Finishing with diamond belt

Illustration 42 g06389076

102 mm (4 inch) wide 3M diamond strips will be required for the Finishers Tech SF-4
Super Finishing Machine. 203 mm (8 inch) wide 3M diamond strips will be required for
the optional equipment (Finishers Tech SF-8 Super Finisher Machine). The 3M strips can
be ordered in various lengths. 1219 mm (48 inch) of cutting surface with a 610 mm
(24 inch) leader and 610 mm (24 inch) tail is a standard length. The leader and tail
portion is required to feed the strips through the super finisher.

A good practice is to keep a few of the plastic spools the 3M strips are shipped on, to
reduce the machine setup time when switching 3M strip grades.

Belt Storage
When belts are not in use, they should be hung around an object at least the same
diameter as the idler wheel on the grinder. Two or four inch long, half-sections of metal
duct pipe can be fastened to a board or steel plate. The board or plate can be mounted
on a wall next to the grinding equipment. This provides easy belt identification, and
proper storage. 


https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 32/49

14/7/2020 SIS 2.0

Belt Life
The rotation of diamond belts should be alternated when being used. Using a permanent
marker, mark the inside new belts with several large arrows indicating the original
direction of rotation, prior to initial use. When reinstalling the belt, switch to the opposite
rotation direction. It is a good idea to mark the grit and the date of first use, for easy belt
identification.

During grinding, the diamond belts will load up with small particles of binder and the
ground material, taking on a black color. This "mud" should be removed periodically by
steam cleaning the belt.

As it is used, a 966F belt will stop removing chrome efficiently. The grinder current draw
will be high, with little chrome removal. These belts will also become capped, and can be
dressed in the same method as the diamond belts. If performance is not improved, the
belt should be turned around so it rotates in the opposite direction. Rotating the belt
allows use of the other leading edge of the belt when traversing the rod, thereby
providing more service.

HVOF Prep Equipment

Illustration 43 g06391088
"Stroke Control" Manual Straightening Press

Illustration 44 g06391102
Semi-Automatic Straightening Press



https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 33/49

14/7/2020 SIS 2.0

Material preparation (prep) for the HVOF spray salvage process is an important operation
regarding the overall coating quality and life.

There are three separate steps for component preparation:

1. Straightening

2. Degreasing

3. Surface Texturing (grit blast)

Straightening
Straightening of all hydraulic cylinder rods and OHT struts Caterpillar currently markets
(as of February 1997) would require a 160 Ton press.

The cost of a new 160 Ton press is approximately $100,000 US. The capital cost of
straightening presses declines for presses under 100 Tons. Reducing the tonnage of a
press will limit the diameter of a component to be straightened.

The current price and availability of new and used presses should be discussed with a
press manufacturer or used equipment dealer. The size of a press purchased will be a
capital cost versus size limitations trade-off.

The straightening press purchased should be capable of straightening 75% to 90% of the
work to be salvaged with the HVOF process. Components that cannot be straightened on
the press will have to be straightened by other conventional means.

Eitel presses, located in Orwigsburg, PA is a well-known company in the straightening

press business. Eitel presses can be called directly at (717) 366-0585. Their manual
stroke-controlled straightening presses will fulfill all the requirements of the Caterpillar
HVOF spray salvage program.

Degreasing
A surface that is free from oils and greases is critical to the bonding strength of the spray
coating. The following items are chemicals recommended to degrease components prior
to grit blasting:

1. Metco Cleaning Solvent

2. Zep Cleaner: ID Red

3. ICI General Chemicals: Triklone LE

4. LPS: ZeroTri

5. LPS: NoFlash

6. Sherwin: Dubl-Chek

7. An Equivalent Degreaser

The main requirement of a degreasing agent will be evaporation from the surface of the
component and not leaving behind an oily film.

To test your degreaser, pour a small amount of liquid into a clear glass bowl and let it
evaporate. Once evaporated, examine the bowl for any films or residues left behind. If
there is a film or residue in the bowl, investigate using a different degreaser.

Degreasing agents should be applied prior to HVOF coating and allowed to evaporate if
contamination is a concern.

Grit Blasting
Surface texturing is also critical to the bond strength of the spray coating to the
component. A 6.3 µm to 7.5 µm (250 µinch to 300 mµinch)Ra surface texture is desired
prior to spraying. A random pattern is preferred over a circumferential pattern. The
random pattern will increase bond strength and reduce the possibility of crack
propagation through the coating by following the substrate and coating boundary. 


https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 34/49

14/7/2020 SIS 2.0

The grit blast system must be dedicated to the metal spray parts preparation and must
not be used for any other shop operation.

The same grit blast system may be used for all thermal spray salvage applications.
However, to avoid grit contamination, the system should not be used by any other shop
area.

Blast Equipment Options Include:

Clemco blast room with recycling equipment

Empire Blast Cabinet Model 4848PRC-6

PBV-05U-30L-CP Portable Vacuum Recovery

Pressure Blaster

Finishers Tech automated blast system

Progressive Industries automated blast system

Recommended blasting media:

20 mesh Aluminum Oxide or equivalent

Using a long nozzle on the blasting equipment can increase the blasting efficiency of the
blasting media by maximizing the particle velocity.

Blasting System Improvements:

A slurry pipe can be used on grit recovery systems to increase the life of the pipe
connecting the grit recovery hopper to the pressurized chamber.

A Schmidt Thompson valve can be added to most grit blast systems. Schmidt
Thompson mixing valves have a rugged design that will outlast most OEM mixing
valves.

Ventilation
For environmental control and personal safety, proper dust and fume exhaust system are
required. EPA (U.S.) rules dictate exhaust system be 99.99% efficient. The
recommended system supplier is Torit Downflo Dust Collectors. These systems can be
purchased separately or through Oerlikon Metco.

Oerlikon Metco recommends 76 m/min to 91 m/min (250 ft/min to 300 ft/min) air flow
across a part being sprayed. A booth with a 1.12 m2 (12.00 ft2) opening would require
102 m3/min (3,600 ft3/min).

NOTICE
Consult your local environmental laws for exact
exhaust regulations.

For proper equipment to meet HVOF spray requirements, contact Caterpillar Repair
Process Engineering via the following: Cat dealer Technical Communicator, Dealer
Solution Network (DSN), Caterpillar Technical Representative, or Knowledge Network .

Refer to Progressive Surface design layouts located under the Tools and Equipment tab

Materials
Every commercially available powder has different coating characteristics of:

Shrink

Wearability

Corrosion Resistance



https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 35/49

14/7/2020 SIS 2.0

Particle Size Distribution

Composition

Chemistry

Flow

Therefore, consider the following criteria when selecting a coating material:

Engineering material composition, base metal, temperature and environmental

factors, and piece part geometry.

User reliability, performance requirements, versatility, reproducibility, finishing

requirements, equipment limitations, and economics.

Historical application similarities and past application success.

Powder Recommendations
WOKA 7103 powder is the recommended material for chrome replacement. WOKA 7103
has a thickness limitation of 0.51 mm (0.020 inch) per side. The coating shall be
deposited in layers of 0.0127 mm (0.0005 inch) per pass.

WOKA 3103 has a thickness limitation of 0.76 mm (0.030 inch) and shall be applied in
layers of 0.0127 mm (0.0005 inch) per pass.

Based on desirable powder criteria and application development, the WOKA 7103
(Chrome carbide/nickel chromium), WOKA 3103 (Tungsten carbide), and Metco 1008
powders are recommended. These materials offer the following benefits when the HVOF
material is applied:

Allow self-bonding to any clean substrate

Exhibit a low coefficient of thermal expansion so that thick coatings can be applied

Offer high internal integrity

Can be used efficiently and economically

The recommended HVOF spray material for each specific component and application is
listed in the component spray procedure document. Table11 provides a list of all HVOF
component spray procedure documents.

Powder Parameters
WOKA 7103
WOKA 7103 with Propane Gas
Spray Material WOKA 7103
Spray equipment type DJ 2700
Auxiliary cooling YES
Nozzle assembly DJ7-9
Distribution plug DJ2-9
Powder injector tube DJ8-9
Air cap 2701
Pickup Shaft "B" pickup shaft
Powder Feed Hose Blue powder feed hose
Air pressure 689 kPa (100 psi)
Air capacity (Flow meter setting) 375 SLPM (857 SCFH) [48]
Oxygen pressure 1034 kPa (150 psi)
Oxygen flow (Flow meter setting) 240 SLPM (549 SCFH) [38]
Fuel gas pressure 620 kPa (90 psi)
Fuel gas flow 68 SLPM (156 SCFH) [38]
Carrier gas pressure 1035 kPa (150 psi)



https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 36/49

14/7/2020 SIS 2.0

Carrier gas flow 13 SLPM (30 SCFH) [55]

Spray rate/build up 75.4 gm/min (10 lb/hr)
Gun to work piece distance 229 mm (9.0 inch)
Rotation speed of part 46-122 SMPM (150-400 SFPM)
Rotation speed of part (RPM) RPM varies depending on diameter
Traverse rate of gun 5 mm (0.1875 inch) per revolution
Gun fixturing method Hard mount to traverse apparatus
Thickness limitation 0.51 mm (0.020 inch)
Laydown rate 0.0127 mm (0.0005 inch) per pass

Table 11

WOKA 7103 with Propylene Gas

Spray Material WOKA 7103
Spray equipment type DJ 2700
Auxiliary cooling YES
Nozzle assembly DJ7-9
Distribution plug DJ2-9
Powder injector tube DJ8-9
Air cap 2701
Pickup Shaft "B" pickup shaft
Powder Feed Hose Blue powder feed hose
Air pressure 689 kPa (100 psi)
Air capacity (Flow meter setting) 375 SLPM (857 SCFH) [46]
Oxygen pressure 1034 kPa (150 psi)
Oxygen flow (Flow meter setting) 253 SLPM (578 SCFH) [40]
Fuel gas pressure 689 kPa (100 psi)
Fuel gas flow 70 SLPM (176 SCFH) [40]
Carrier gas pressure 1035 kPa (150 psi)
Carrier gas flow 13 SLPM (30 SCFH) [55]
Spray rate/build up 75.4 gm/min (10 lb/hr)
Gun to work piece distance 229 mm (9.0 inch)
Rotation speed of part 46-122 SMPM (150-400 SFPM)
Rotation speed of part (RPM) RPM varies depending on diameter
Traverse rate of gun 5 mm (0.1875 inch) per revolution
Gun fixturing method Hard mount to traverse apparatus
Thickness limitation 0.51 mm (0.020 inch)
Laydown rate 0.0127 mm (0.0005 inch) per pass

Table 12

WOKA 7103 with Natural Gas

Spray Material WOKA 7103
Spray equipment type DJ 2700
Auxiliary cooling YES
Nozzle assembly DJ7-9
Distribution plug DJ2-9
Powder injector tube DJ8-9
Air cap 2701
Pickup Shaft "B" pickup shaft
Powder Feed Hose Blue powder feed hose
Air pressure 689 kPa (100 psi)
Air capacity (Flow meter setting) 360 SLPM (822 SCFH) [46]
Oxygen pressure 1034 kPa (150 psi)



https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 37/49

14/7/2020 SIS 2.0

Oxygen flow (Flow meter setting) 278 SLPM (635 SCFH) [44]
Fuel gas pressure 758kPa (110 psi)
Fuel gas flow 189 SLPM (432 SCFH) [58]
Carrier gas pressure 1035 kPa (150 psi)
Carrier gas flow 13 SLPM (30 SCFH) [55]
Spray rate/build up 75.4 gm/min (10 lb/hr)
Gun to work piece distance 229 mm (9.0 inch)
Rotation speed of part 46-122 SMPM (150-400 SFPM)
Rotation speed of part (RPM) RPM varies depending on diameter
Traverse rate of gun 5 mm (0.1875 inch) per revolution
Gun fixturing method Hard mount to traverse apparatus
Thickness limitation 0.51 mm (0.020 inch)
Laydown rate 0.0127 mm (0.0005 inch) per pass

Table 13

WOKA 7103 Increase Deposition

WOKA 7103 with Propane Gas
Spray Material WOKA 7103
Spray equipment type DJ 2700
Auxiliary cooling YES
Nozzle assembly DJ7-9
Distribution plug DJ2-9
Powder injector tube DJ8-9
Air cap 2701
Pickup Shaft "B" pickup shaft
Powder Feed Hose Orange powder feed hose
Air pressure 689 kPa (100 psi)
Air capacity (Flow meter setting) 375 SLPM (857 SCFH) [48]
Oxygen pressure 1034 kPa (150 psi)
Oxygen flow (Flow meter setting) 240 SLPM (549 SCFH) [38]
Fuel gas pressure 620 kPa (90 psi)
Fuel gas flow 68 SLPM (156 SCFH) [38]
Carrier gas pressure 1035 kPa (150 psi)
Carrier gas flow 13 SLPM (30 SCFH) [55]
Spray rate/build up 75.4 gm/min (10 lb/hr)
Gun to work piece distance 229 mm (9.0 inch)
Rotation speed of part 46-122 SMPM (150-400 SFPM)
Rotation speed of part (RPM) RPM varies depending on diameter
Traverse rate of gun 5 mm (0.1875 inch) per revolution
Gun fixturing method Hard mount to traverse apparatus
Thickness limitation 0.38 mm (0.015 inch) per side
Laydown rate 0.025 mm (0.001 inch) per pass

Table 14

WOKA 7103 with Propylene Gas

Spray Material WOKA 7103
Spray equipment type DJ 2700
Auxiliary cooling YES
Nozzle assembly DJ7-9
Distribution plug DJ2-9
Powder injector tube DJ8-9 


https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 38/49

14/7/2020 SIS 2.0

Air cap 2701

Pickup Shaft "B" pickup shaft
Powder Feed Hose Orange powder feed hose
Air pressure 689 kPa (100 psi)
Air capacity (Flow meter setting) 375 SLPM (857 SCFH) [46]
Oxygen pressure 1034 kPa (150 psi)
Oxygen flow (Flow meter setting) 253 SLPM (578 SCFH) [40]
Fuel gas pressure 689 kPa (100 psi)
Fuel gas flow 70 SLPM (176 SCFH) [40]
Carrier gas pressure 1035 kPa (150 psi)
Carrier gas flow 13 SLPM (30 SCFH) [55]
Spray rate/build up 75.4 gm/min (10 lb/hr)
Gun to work piece distance 229 mm (9.0 inch)
Rotation speed of part 46-122 SMPM (150-400 SFPM)
Rotation speed of part (RPM) RPM varies depending on diameter
Traverse rate of gun 5 mm (0.1875 inch) per revolution
Gun fixturing method Hard mount to traverse apparatus
Thickness limitation 0.38 mm (0.015 inch) per side
Laydown rate 0.025 mm (0.001 inch) per pass

Table 15

WOKA 7103 with Natural Gas

Spray Material WOKA 7103
Spray equipment type DJ 2700
Auxiliary cooling YES
Nozzle assembly DJ7-9
Distribution plug DJ2-9
Powder injector tube DJ8-9
Air cap 2701
Pickup Shaft "B" pickup shaft
Powder Feed Hose Orange powder feed hose
Air pressure 689 kPa (100 psi)
Air capacity (Flow meter setting) 360 SLPM (822 SCFH) [46]
Oxygen pressure 1034 kPa (150 psi)
Oxygen flow (Flow meter setting) 278 SLPM (635 SCFH) [44]
Fuel gas pressure 758 kPa (110 psi)
Fuel gas flow 189 SLPM (432 SCFH) [58]
Carrier gas pressure 1035 kPa (150 psi)
Carrier gas flow 13 SLPM (30 SCFH) [55]
Spray rate/build up 75.4 gm/min (10 lb/hr)
Gun to work piece distance 229 mm (9.0 inch)
Rotation speed of part 46-122 SMPM (150-400 SFPM)
Rotation speed of part (RPM) RPM varies depending on diameter
Traverse rate of gun 5 mm (0.1875 inch) per revolution
Gun fixturing method Hard mount to traverse apparatus
Thickness limitation 0.38 mm (0.015 inch) per side
Laydown rate 0.025 mm (0.001 inch) per pass

Table 16

WOKA 3103
WOKA 3103 with Propane Gas 


https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 39/49

14/7/2020 SIS 2.0

Spray Material WOKA 3103

Spray equipment type DJ 2700
Auxiliary cooling YES
Nozzle assembly DJ7-9
Distribution plug DJ2-9
Powder injector tube DJ8-9
Air cap 2701
Pickup Shaft "B" pickup shaft
Powder Feed Hose Blue powder feed hose
Air pressure 689 kPa (100 psi)
Air capacity (Flow meter setting) 375 SLPM (857 SCFH) [48]
Oxygen pressure 1034 kPa (150 psi)
Oxygen flow (Flow meter setting) 240 SLPM (549 SCFH) [38]
Fuel gas pressure 620 kPa (90 psi)
Fuel gas flow 68 SLPM (156 SCFH) [38]
Carrier gas pressure 1035 kPa (150 psi)
Carrier gas flow 13 SLPM (30 SCFH) [55]
Spray rate/build up 75.4 gm/min (10 lb/hr)
Gun to work piece distance 229 mm (9.0 inch)
Rotation speed of part 46-122 SMPM (150-400 SFPM)
Rotation speed of part (RPM) RPM varies depending on diameter
Traverse rate of gun 5 mm (0.1875 inch) per revolution
Gun fixturing method Hard mount to traverse apparatus
Thickness limitation 0.51 mm (0.020 inch)
Laydown rate 0.0127 mm (0.0005 inch) per pass

Table 17

WOKA 3103 with Propylene Gas

Spray Material WOKA 3103
Spray equipment type DJ 2700
Auxiliary cooling YES
Nozzle assembly DJ7-9
Distribution plug DJ2-9
Powder injector tube DJ8-9
Air cap 2701
Pickup Shaft "B" pickup shaft
Powder Feed Hose Blue powder feed hose
Air pressure 689 kPa (100 psi)
Air capacity (Flow meter setting) 375 SLPM (857 SCFH) [46]
Oxygen pressure 1034 kPa (150 psi)
Oxygen flow (Flow meter setting) 253 SLPM (578 SCFH) [40]
Fuel gas pressure 689 kPa (100 psi)
Fuel gas flow 70 SLPM (176 SCFH) [40]
Carrier gas pressure 1035 kPa (150 psi)
Carrier gas flow 13 SLPM (30 SCFH) [55]
Spray rate/build up 75.4 gm/min (10 lb/hr)
Gun to work piece distance 229 mm (9.0 inch)
Rotation speed of part 46-122 SMPM (150-400 SFPM)
Rotation speed of part (RPM) RPM varies depending on diameter
Traverse rate of gun 5 mm (0.1875 inch) per revolution
Gun fixturing method Hard mount to traverse apparatus
Thickness limitation 0.51 mm (0.020 inch)



https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 40/49

14/7/2020 SIS 2.0

Laydown rate 0.0127 mm (0.0005 inch) per pass

Table 18

WOKA 3103 with Natural Gas

Spray Material WOKA 3103
Spray equipment type DJ 2700
Auxiliary cooling YES
Nozzle assembly DJ7-9
Distribution plug DJ2-9
Powder injector tube DJ8-9
Air cap 2701
Pickup Shaft "B" pickup shaft
Powder Feed Hose Blue powder feed hose
Air pressure 689 kPa (100 psi)
Air capacity (Flow meter setting) 360 SLPM (822 SCFH) [46]
Oxygen pressure 1034 kPa (150 psi)
Oxygen flow (Flow meter setting) 278 SLPM (635 SCFH) [44]
Fuel gas pressure 758 kPa (110 psi)
Fuel gas flow 189 SLPM (432 SCFH) [58]
Carrier gas pressure 1035 kPa (150 psi)
Carrier gas flow 13 SLPM (30 SCFH) [55]
Spray rate/build up 75.4 gm/min (10 lb/hr)
Gun to work piece distance 229 mm (9.0 inch)
Rotation speed of part 46-122 SMPM (150-400 SFPM)
Rotation speed of part (RPM) RPM varies depending on diameter
Traverse rate of gun 5 mm (0.1875 inch) per revolution
Gun fixturing method Hard mount to traverse apparatus
Thickness limitation 0.51 mm (0.020 inch)
Laydown rate 0.0127 mm (0.0005 inch) per pass

Table 19

Metco 1008
Metco 1008 with Propane Gas
Spray Material Metco 1008
Spray equipment type DJ 2700
Auxiliary cooling YES
Nozzle assembly DJ7-9
Distribution plug DJ2-9
Powder injector tube DJ8-9
Air cap 2702
Pickup Shaft "B" pickup shaft
Powder Feed Hose Blue powder feed hose
Air pressure 724 kPa (105 psi)
Air capacity (Flow meter setting) 399 SLPM (912 SCFH) [50]
Oxygen pressure 1034 kPa (150 psi)
Oxygen flow (Flow meter setting) 152 SLPM (347 SCFH) [24]
Fuel gas pressure 620 kPa (90 psi)
Fuel gas flow 72 SLPM (165 SCFH) [40]
Carrier gas pressure 1035 kPa (150 psi)
Carrier gas flow 13 SLPM (30 SCFH) [55]
Spray rate/build up 75.4 gm/min (10 lb/hr) 


https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 41/49

14/7/2020 SIS 2.0

Gun to work piece distance 229 mm (9.0 inch)

Rotation speed of part 46-122 SMPM (150-400 SFPM)
Rotation speed of part (RPM) RPM varies depending on diameter
Traverse rate of gun 5 mm (0.1875 inch) per revolution
Gun fixturing method Hard mount to traverse apparatus
Thickness limitation 0.51 mm (0.020 inch)
Laydown rate 0.0127 mm (0.0005 inch) per pass

Table 20

Metco 1008 with Propylene Gas

Spray Material Metco 1008
Spray equipment type DJ 2700
Auxiliary cooling YES
Nozzle assembly DJ7-9
Distribution plug DJ2-9
Powder injector tube DJ8-9
Air cap 2702
Pickup Shaft "B" pickup shaft
Powder Feed Hose Blue powder feed hose
Air pressure 724 kPa (105 psi)
Air capacity (Flow meter setting) 383 SLPM (876 SCFH) [48]
Oxygen pressure 1034 kPa (150 psi)
Oxygen flow (Flow meter setting) 164 SLPM (375 SCFH) [26]
Fuel gas pressure 689 kPa (100 psi)
Fuel gas flow 70 SLPM (176 SCFH) [40]
Carrier gas pressure 1035 kPa (150 psi)
Carrier gas flow 13 SLPM (30 SCFH) [55]
Spray rate/build up 75.4 gm/min (10 lb/hr)
Gun to work piece distance 229 mm (9.0 inch)
Rotation speed of part 46-122 SMPM (150-400 SFPM)
Rotation speed of part (RPM) RPM varies depending on diameter
Traverse rate of gun 5 mm (0.1875 inch) per revolution
Gun fixturing method Hard mount to traverse apparatus
Thickness limitation 0.51 mm (0.020 inch)
Laydown rate 0.0127 mm (0.0005 inch) per pass

Table 21

Metco 1008 with Natural Gas

Spray Material Metco 1008
Spray equipment type DJ 2700
Auxiliary cooling YES
Nozzle assembly DJ7-9
Distribution plug DJ2-9
Powder injector tube DJ8-9
Air cap 2702
Pickup Shaft "B" pickup shaft
Powder Feed Hose Blue powder feed hose
Air pressure 724 kPa (105 psi)
Air capacity (Flow meter setting) 319 SLPM (730 SCFH) [40]
Oxygen pressure 1034 kPa (150 psi)
Oxygen flow (Flow meter setting) 189 SLPM (433 SCFH) [30]
Fuel gas pressure 758 kPa (110 psi)



https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 42/49

14/7/2020 SIS 2.0

Fuel gas flow 202 SLPM (461 SCFH) [62]

Carrier gas pressure 1035 kPa (150 psi)
Carrier gas flow 13 SLPM (30 SCFH) [55]
Spray rate/build up 75.4 gm/min (10 lb/hr)
Gun to work piece distance 229 mm (9.0 inch)
Rotation speed of part 46-122 SMPM (150-400 SFPM)
Rotation speed of part (RPM) RPM varies depending on diameter
Traverse rate of gun 5 mm (0.1875 inch) per revolution
Gun fixturing method Hard mount to traverse apparatus
Thickness limitation 0.51 mm (0.020 inch)
Laydown rate 0.0127 mm (0.0005 inch) per pass

Table 22

Powder Storage
To prevent powder contamination with moisture, store the powder in a heated cabinet
when not in use. Powder contaminated with water will clog feed lines and reduce coating
quality.

Cabinet temperature should be kept between 45.0° C (113.00° F) and 65.0° C

(149.00° F). A welding rod oven or an old refrigerator modified with a heat lamp can be
used to store powders at lower cost than purchasing a heated storage cabinet.

Miscellaneous Support Equipment

The following is a list of equipment that is required to salvage components following the
Caterpillar HVOF spray guidelines:

Surface Analyzer

Coating Thickness Gauge

Infrared Thermometer

Hardness Tester

Surface Analyzer
The following surface analyzers are available through the Caterpillar parts system:

448-3697 Indicator Profilometer (M300) and Drive Unit MarSurf RD 18

448-3698 Indicator Profilometer (PS10)

Illustration 45 g03507589
448-3697 Indicator Profilometer (M300) and Drive Unit MarSurf RD 18




https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 43/49

14/7/2020 SIS 2.0

Illustration 46 g03507627
448-3698 Indicator Profilometer (PS10)
The surface analyzer provides quick, accurate checks of the components being finished,
while still chucked or between centers. The analyzer can also provide a paper copy of the
final analysis to verify part quality. Use a 5 micron (200 µinch) diamond stylus for
measuring, and take multiple measurements at different locations on the rod.

It is important to clean the surface of the rod with 70% isopropyl alcohol before taking any
surface measurements, as contamination on the rod will skew the measurement. Also,
keep in mind that external vibrations can affect the results.

The OmniSurf software package is available for use with the Indicator Profilometer
(M300), and will provide the following features:

Processing of measured or created profiles

Graphical presentation of the processed profile in the working area

Graphical presentation of the loaded or recorded profile in the overview area

Roughness evaluation of the zoomed profile sections

Measurement/evaluation of interrupted profiles, excluding profile sections, for

example, bores

Presentation of the aligned profile and the waviness and roughness profiles in
separate areas

Presentation of the altered profile as a result profile

Storage of the processed profile, i.e. the result, in a file

The recommended Filter Cutoff Selection Options, as used in factory operations, for the
OmniSurf software are as follows:

Short (ls) = 8.0 µm (314.96 µin)

Roughness (lc) = 0.8000 mm (0.03150 in)

Bandwidth (lc:Ls) Ratio = 100:1

Type = Robust

Spine Tension = Form-Following

End Region Discard = 1 Cutoff

Coating Thickness Gauge




https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 44/49

14/7/2020 SIS 2.0

Illustration 47 g06393604
Elcometer 355 coating thickness gauge
Use of a coating thickness gauge is a quick method to check the thickness of an as
sprayed or finished machined coating. The gauge will work on combinations of coatings
and base materials where one is magnetic and the other is non-magnetic.

Elcometer makes two thickness gauge models. The 345 is a basic model that will also
perform some statistical analysis of the coating measurements. The 355 has a few extra
features.

These gauges will work on WOKA 7103 sprayed coatings and on other thermal spray
salvage processes.

Contact Elcometer Inc. directly for more information and price inquiries.

Infrared Thermometer

Illustration 48 g06393608
192-3755 Infrared Thermometer
A thermometer is necessary to check the temperature of components during the spray
process. The warning temperatures stated in the Salvage Applications should not be
ignored for fear of annealing the components being salvaged. Annealing of a component
will change the microstructure of the base material, which changes the strength and other
material characteristics.

An infrared thermometer will measure the temperature of the component being salvaged
without actually touching the surface of the component. IR thermometers measure the
temperature of a circular area, emanating in a cone shape from the thermometer tip at an
approximate 8:1 ratio. Thus, at a distance of 2.4 m (8.00 ft) from the thermometer, the
temperature of a 0.3 m (1.00 ft) diameter circle is indicated.

There are some thermometers that use a contact thermocouple to measure the
temperature of a component. The thermocouple can contaminate the surface of the
component, thereby reducing the strength and integrity of the thermal spray coating. In
addition, contact thermocouples cannot be used during spraying since the part is rotating.



https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 45/49

14/7/2020 SIS 2.0

Caterpillar distributes several infrared thermometers through the standard parts

distribution system, which are available under the following part numbers:

192-3750 Infrared Thermometer

192-3755 Infrared Thermometerwith Laser

349-4200 Infrared Thermometer Group

349-4201 Infrared Thermometer Group (110-Volt, AC Adapter)

Part numbers 192-3755 and 349-4201 have a laser targeting light to aim the thermometer
at the component. Both thermometers will provide the required information. However, the
349-4201 can be mounted to the same assembly as the HVOF gun and has the extra
features of temperature recording and an overtemp warning signal.

Surface Hardness

Illustration 49 g06393609
Krautkramer Branson MIC 10 Hardness Tester
The surface hardness of chrome to be stripped can easily be checked with a portable
hardness tester. The Krautkramer Branson MIC 10 is a unit for fast, accurate, hardness
measurements. The unit works by measuring the linear displacement of a pointed probe,
which is forced against the test piece.

Masking Aids
Masking aids are used to protect certain areas (threads, bolt holes, and so on) on the
substrate from the HVOF and/or surface preparation processes. The protected areas
usually require no salvaging or repair.

Masking aids can be divided into four categories:

Tapes

Masking compounds (putty)

Paint

Permanent masks

Note: At the end of this bulletin, several masking aid suppliers will be listed.

Tapes
Tapes can be used to protect the surface of components for both the HVOF and the
surface preparation processes. Masking tapes are a consumable to the salvage process,
because they can only be used one time.

Masking a surface for surface preparation with tape can be accomplished in the following
manner.

Apply several layers of duct tape or masking tape to the area that requires protection 

from the grit blasting operation.
https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 46/49
14/7/2020 SIS 2.0

Conventional tapes used as a masking aid for the surface preparation process, must be
removed prior to the HVOF operation due to their flammable nature.

Masking a surface from the HVOF process with tapes requires a special metal or
thermally resistant tape. These tapes are more expensive than conventional tapes, but
are easily used to protect areas that have an irregular contour or shape.

Masking Compounds
Masking compounds are a soft conformable putty-like material for masking holes,
grooves, key slots, or other unique characteristics. The material is easy to use.

The putty-like material is pressed onto the substrate by hand. After applying the material
to a surface for protection, the masking compound must be cured. The amount of heat
and required curing time varies depending on the material being used. Average curing
cycles are 25 minutes at 121° C (250° F).

Once the material has been cured, it becomes a strong abrasion resistant and thermally
resistant material. Following the HVOF process, the material can be cut and removed like
a silicone material.

Masking compounds are available in tapes, extruded profiles, and other pre-formed
shapes. However, these masking compounds can only be used once.

Paint
Masking paints are applied by brush to a surface for protection. The paint creates a
surface barrier that a thermal sprayed coating cannot bond to (similar to a surface that
has not been properly prepared). Following the coating operation, the thermal sprayed
material can be removed from the painted area.

For thermal spray processes (that is, flame spray and arc spray), paint is a viable
masking compound. Paints are not able to withstand the higher temperatures of the
HVOF process. As new paints are developed, this section will be updated.

Permanent Masks
Permanent masks are objects or materials that can be used multiple times. These items
can be any of the following or a combination of the following:

Shields placed between the gun and substrate

Sleeves or collars

Rubber stoppers (some stoppers will be considered consumables)

Thermal blanket/insulation materials

Cutouts (steel or rubber)

Suppliers
Tape

3M (contact local representative)

Furon

Tape Works

Greenbelt Industries

Masking Compounds

Oerlikon Metco

MachBloc (product of Tape Works)

Greenbelt Industries

Permanent Masks 


https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 47/49

14/7/2020 SIS 2.0

Acme Masking Company

Links to Equipment Information and

Suppliers
An HVOF Variable Cost Analysis Worksheet is available on the Repair Process
Engineering (RPE) website under the Metal Restoration link. The worksheet
automatically calculates variable costs based on information the dealer enters into the
program. It utilizes the following categories: Prep Costs (material preparation costs),
Spray Costs, and Machining Costs (includes both chrome stripping and HVOF finishing).

Reference: Caterpillar Repair Process Engineering (Metal Restoration)

https://dealer.cat.com/en/ps/service/rpe/c/metal-restoration.html

Reference: 3M

www.3m.com

Reference: Torit Products

P.O. Box 1299

1400 West 94th Street
Minneapolis, Minnesota 55440
1 (800) 365-1331
www2.donaldson.com/torit

Reference: Oerlikon Metco

www.oerlikon.com/metco

Reference: TAFA

www.praxair.com/thermalspray

Reference: Eitel Presses

www.eitelpresses.com

Reference: Progressive Surface

4695 Danvers Drive SE

Grand Rapids, Michigan 49512
1 (616) 285-8390
www.progressivesurface.com

Reference: Abbott Machine Co.

700 W. Broadway
Alton, IL 62002
1 (618) 465-1898
1 (800) 262-6478
www.abbottmachineco.com

Reference: Supfina

Schmelzergrun 7
77709 Wolfach, Germany
49 (7834) 866-0
www.supfina.com

Reference: IMPCO Machine Tools

3417 West St. Joseph Street

Lansing, Michigan 48917
1 (517) 484-9411
www.impco.com

Reference: Grinding Equipment & Machinery Company, LLC 



https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 48/49

14/7/2020 SIS 2.0

15 South Worthington Street

Youngstown, Ohio 44502
1 (330) 747-2313
www.gem-usa.com

Reference: Oberlin Filter Company

404 Pilot Ct.

Waukesah, WI 53188
1 (262) 547-4900
www.oberlinfilter.com

Reference: Schmidt Manufacturing Inc.

P.O. Box 37
Fresno, Texas 77545
1 (713) 431-0581
Fax: 1(713) 431-1717

Reference: Elcometer Inc.

1893 Rochester Industrial Drive

Rochester Hills, Michigan 48309
(810) 650-0500 or
1-800-521-0635
Fax: (810) 650-0501

Reference: Krautkramer Branson

600 N. Shepherd Drive, Suite 115

Houston, TX 77007
(713) 861-3270
Fax (713) 861-4784
http://www.stroudsystems.com

Reference: Furon

1 (508) 686-7301

Reference: Tape Works

2285 Avenue A
Bethlehem, Pennsylvania 18017
1 (800) 752-1125
1 (610) 264-5115
www.tape-works.com

Reference: Acme Masking Company

240 South Production Drive

Avon, Indiana 46123
1 (317) 272-6202

Reference: Greenbelt Industries

45 Comet Street
Buffalo, New York 14216
1 (800) 668-1114




https://sis2.cat.com/#/detail?keyword=software transmission engine&tab=3&mediaNumber=SEBP3022&componentId=&serialNumber=aty&infoType=43&serviceMediaNumber=SEBF9236&serviceIeSystemControl… 49/49