The Plasmatron Advantage
Plasmatron’s robust infrastructure enables it to cater to a wide variety of jobs ranging from large parts to smaller parts in larger volumes. We can do so with flexibility and while adhering to customer deadlines and quality requirements. With the complete spectrum of Thermal Spray coatings processes and a variety of pre & post coating machining setup under one roof, Plasmatron has established itself as a one-stop-shop for its esteemed clients. We have total working area of 35,000 sq. ft. and material handling capacity of 20 tons.
Coating
- Atmospheric Plasma Spray
- HP HVOF - Liquid Fuel
- Detonation Spray
- Wire Arc Spray
- Powder / Wire Flame Spray
- Spray & Fuse
Machining
Plasmatron houses a wide range of machinery to carry out complete manufacturing of parts including pre-coating and post-coating machining operations. Our CNC VTL can handle cylindrical parts up to 2000mm diameter. Our other CNC Turning centers can handle diameters up to 900mm x Length 3000mm. Our grinding division has the capability of handling parts from diameter 10mm to 800mm. Our longest grinding setup can accommodate parts up to 6000mm length. We have a material handling capacity of upto 20 tons.
Cladding
We offer a wide range of Nickel, Cobalt and Ferrous based overlay solutions for critical parts used in Oil & Gas, Steel, Power Generation and High Pressure Compressor applications. We have all the necessary welding qualifications for these parts which is certified by an internationally recognized third party accreditation body and approved by our Clients. These weld surfaces exhibit excellent wear, abrasion and impact resistance with enhanced mechanical properties. Our welding station consist of Semi-Auto TIG, Semi-Auto PTA and Spray and Fuse process which can accommodate parts with a maximum weight of up to 5 tons, Diameter 1000mm and Length 3000mm.
Heat Treatment
We manufacture parts such as Piston rods, Shafts, Spindles, Diffusers, Rolls etc. in a wide variety of exotic materials for the Compressor, Pump, Steel and Power Generation sector. While the long length shafts and rods need to be soaked in a vertical furnace post machining, the weld overlayed valve parts need to be stress relieved to improve the welding quality. Few indigenous thermal spray coated parts are soaked after application of proprietary sealants to enhance coating integrity and efficacy. Plasmatron houses one of the very few electric vertical furnaces integrated with PID controllers and paperless recorder, which can accommodate parts up to 7000mm in length and diameter of up to 1000mm with a maximum part weight of around 5 tons.
Super-finishing and Lapping
Critical parts like Shafts, Piston rods, Mandrels, Sleeves, Rings etc. which are ground to close tolerance can be further processed to improve its surface finish and dimensional control. We have in-house automated super-finishing and lapping facility to achieve a surface finish of 0.01 Ra-micron and Flatness of less than 5 microns. It not only improves the aesthetics and accuracy of the part but also enhances the durability of coatings in extreme operating conditions.
Coating R & D and Test Lab
Our extensive testing setup is an integral part of our quality system which enables us to monitor and improve our coating quality. We also have simulation test rigs to check the tribological behaviour of coatings like erosion, abrasion, fatigue and corrosion. We spray test coupons with every batch of the components to ensure consistent coating quality and instil customer confidence. Few of the tests that we conduct are:
- Micro-structure and Micro-hardness Evaluation (Thickness, Particle distribution etc.)
- Porosity Levels
- Coating Interface Bonding validation
Inspection Facility
We are equipped with the best in class measuring and monitoring instruments comprising of micrometers, verniers, gauges, surface tester etc. for inspection of challenging critical to quality parameters. Our auto-notified Calibration Control System ensures all MME’s (Measuring and Monitoring Equipment) are calibrated before due course. The MME’s are stored in a secure and well ventilated room and all designated staff is trained to handle these instruments to ensure measurement repeatability and reproducibility. Our in-house Cordimesur CMM with a CNC probe and measurement range of 1000mm X 2000mm X 800mm can inspect critical part profiles with an accuracy of 2 microns.
The Plasmatron Advantage
Plasmatron’s robust infrastructure enables it to cater to a wide variety of jobs ranging from large parts to smaller parts in larger volumes. We can do so with flexibility and while adhering to customer deadlines and quality requirements. With the complete spectrum of Thermal Spray coatings processes and a variety of pre & post coating machining setup under one roof, Plasmatron has established itself as a one-stop-shop for its esteemed clients. We have total working area of 35,000 sq. ft. and material handling capacity of 20 tons.
Coating
- Atmospheric Plasma Spray
- HP HVOF - Liquid Fuel
- Detonation Spray
- Wire Arc Spray
- Powder / Wire Flame Spray
- Spray & Fuse
Machining
Plasmatron houses a wide range of machinery to carry out complete manufacturing of parts including pre-coating and post-coating machining operations. Our CNC VTL can handle cylindrical parts up to 2000mm diameter. Our other CNC Turning centers can handle diameters up to 900mm x Length 3000mm. Our grinding division has the capability of handling parts from diameter 10mm to 800mm. Our longest grinding setup can accommodate parts up to 6000mm length. We have a material handling capacity of upto 20 tons.
Cladding
We offer a wide range of Nickel, Cobalt and Ferrous based overlay solutions for critical parts used in Oil & Gas, Steel, Power Generation and High Pressure Compressor applications. We have all the necessary welding qualifications for these parts which is certified by an internationally recognized third party accreditation body and approved by our Clients. These weld surfaces exhibit excellent wear, abrasion and impact resistance with enhanced mechanical properties. Our welding station consist of Semi-Auto TIG, Semi-Auto PTA and Spray and Fuse process which can accommodate parts with a maximum weight of up to 5 tons, Diameter 1000mm and Length 3000mm.
Heat Treatment
We manufacture parts such as Piston rods, Shafts, Spindles, Diffusers, Rolls etc. in a wide variety of exotic materials for the Compressor, Pump, Steel and Power Generation sector. While the long length shafts and rods need to be soaked in a vertical furnace post machining, the weld overlayed valve parts need to be stress relieved to improve the welding quality. Few indigenous thermal spray coated parts are soaked after application of proprietary sealants to enhance coating integrity and efficacy. Plasmatron houses one of the very few electric vertical furnaces integrated with PID controllers and paperless recorder, which can accommodate parts up to 7000mm in length and diameter of up to 1000mm with a maximum part weight of around 5 tons.
Super-finishing and Lapping
Critical parts like Shafts, Piston rods, Mandrels, Sleeves, Rings etc. which are ground to close tolerance can be further processed to improve its surface finish and dimensional control. We have in-house automated super-finishing and lapping facility to achieve a surface finish of 0.01 Ra-micron and Flatness of less than 5 microns. It not only improves the aesthetics and accuracy of the part but also enhances the durability of coatings in extreme operating conditions.
Coating R & D and Test Lab
Our extensive testing setup is an integral part of our quality system which enables us to monitor and improve our coating quality. We also have simulation test rigs to check the tribological behaviour of coatings like erosion, abrasion, fatigue and corrosion. We spray test coupons with every batch of the components to ensure consistent coating quality and instil customer confidence. Few of the tests that we conduct are:
- Micro-structure and Micro-hardness Evaluation (Thickness, Particle distribution etc.)
- Porosity Levels
- Coating Interface Bonding validation
Inspection Facility
We are equipped with the best in class measuring and monitoring instruments comprising of micrometers, verniers, gauges, surface tester etc. for inspection of challenging critical to quality parameters. Our auto-notified Calibration Control System ensures all MME’s (Measuring and Monitoring Equipment) are calibrated before due course. The MME’s are stored in a secure and well ventilated room and all designated staff is trained to handle these instruments to ensure measurement repeatability and reproducibility. Our in-house Cordimesur CMM with a CNC probe and measurement range of 1000mm X 2000mm X 800mm can inspect critical part profiles with an accuracy of 2 microns.