SURFACE
TREATMENT

SURFACE
TREATMENT

THERMAL SPRAY COATING

Comprehensive Processes & Materials Applied via Robotics and Automation Aided Coating Systems.

  • Surface rebuilding
  • Protection against mechanical wear/tear
  • Corrosion prevention
  • Thermal/Electrical resistance

Thermal Spray Coating is the R&D focus and key technology of Frontken's Surface Metamorphosis Technology philosophy.

We are the market leader in provision of Thermal Spray Coatings services in the South-East-Asia region, offering the most comprehensive range of coating processes and capabilities customizable for your applications.

Frontken's coating services allow maximum cost-effectiveness, improving the value and in-service performance of your components and equipment through upgrading and life extension capabilities.

We can provide technical consultation for recommendation of material + process combinations, allowing deposition of virtually any type of materials such as Metals, Alloys, Ceramics, Cermets, Polymers, Composites or graded materials for your repair, maintenance & upgrade requirements.

Functions & Benefits
Thermal Spray Coatings can be applied for the most common function of worn surface reclamation, wear resistance or corrosion prevention. It can also reduce frictional energy losses, act as a diffusion barrier, thermal insulation and electrical insulation among countless other purposes.
General TSC Coating Materials
Thermal spray coatings have been and are used in a very broad range of applications. The main advantage being that thermal spray coating can provide the surface properties for specific requirements.
General TSC Coating Materials
  • Pure Metals: Al, Zinc, Mo, Ti . .
  • Carbides: WC/Co & Cr3C2-NiCr
  • Ceramic: Al2O3, ZrO2, Cr2O3, TiO2, YSZ
  • Alloys: MCrAlY, NiAl, NiCr, Stellite . .
  • Fused self fluxing alloys (NiCrSiB)
  • Application customized composites and more
Process Capabilities:
  • Plasma
  • HVOF
  • Electric Twin Arc
  • Flame Wire
  • Flame Rod (Ceramic)
  • Flame Powder
  • Self-Flux Alloy (Fusion)
Application Examples:
Piston Rods, Pipe Spools, Valves, Pulleys & Guides, Rolls, Rotor Shafts, Pump Casings, Crankshaft Journals, Plunger, Screw Shaft, Pressure Vessel, Turbine Casing, Flame Tubes, Transition Piece and many more.
Why Frontken for your TSC applications?
  • We operate the largest and most comprehensive TSC facilities in the region
  • Supported by in-house Research & Development specialists and facilities
  • Multiple-axes robotic arms and automation systems
  • Atmosphere-controlled process chambers
  • In-house post-TSC processes such as welding, machining, fabrication heat treatment and others.
  • On-Site Anti-Corrosion TSC Capabilities

COLD BUILD UP COATING

Spray & brush applied composite paints (Metal / Ceramic / Epoxy), Xylan, Molykote and Slurry.

Frontken Composite Coating

Frontken's ceramic composite coating offers wear & corrosion protection in seawater, freshwater or chemical environment for your pumps, machines & industrial structures & plants. Key benefits of application to pumps are improved efficiency, lesser downtimes and reduced maintenance over the long run. In addition to offering cost-saving life extensions, Frontken composite coating also complements our core technology via application as finishing layer on HVOF Coatings for long term protection.

Dry Film Lubricants Coating
Mokykote & Xylan Coating.
Slurry Coating Functions:
Protection against corrosion, Anti-folding
Coating System:
  • Metallic blast coat
  • Organic Sealer
  • Organic (PTFE) Top Coat
Main Application:
  • Stationary & rotating turbo compressor parts
  • Compressors vanes & Blades
  • Diaphragms
  • Guide vanes
  • Rotors
  • Impellers
  • Shrouds

PLATING & CONVERSION COATING

Provides intermediate or long term protection to shield your components from external harsh elements, allow lubricity to enable maximum potential of your production, enhance grip on surfaces & more.

  • Selective Brush Plating
  • Silver Plating
  • Electroless Nickel Plating
  • Zinc & Manganese Phosphating

SPECIALIZED WELDING / PLASMA TRANSFERRED

In addition to Plasma Transferred Arc Welding, and complementing our comprehensive range of surface engineering capabilities, Frontken is also equipped with other conventional processes such as TIG, MIG, Electric Arc, Micro-resistance and Powder Welding.

Plasma Transferred Arc hardfacing is a high energy, inert gas welding process that produces very high quality and precise alloy coatings. The deposit microstructures are made up of dense metallurgical bond between the substrate and deposit, an overlay that offers optimal protection with minimal dilution (3-10%) or deformation to mechanical parts that are subject to intense wear, significantly extending their service life.

A wide range of overlay alloys are available for surface rebuilding of worn out components such as pumps volute, ball valves and mechanical rotors while materials with superior hardness and resistance properties can be employed to protect localized surfaces that are subjected to harsh operating conditions.

Welding capabilities are critical for surface rebuilding, recovery & repair works. In addition to Plasma Transferred Arc Welding, and complementing our comprehensive range of surface engineering capabilities, Frontken is also equipped with other conventional processes such as TIG, MIG, Electric Arc, Micro-resistance and Powder Welding.

PRECISION CLEANING

Precision Cleaning means cleaning to very exacting standards, with very low tolerance for left-over microscopic (<0.3 microns) particles or other contaminants. Components requiring the most stringent cleanliness standards are processed in heavily regulated air conditions that are similiar to those our clients operate their machines in.

In many high-tech precision industries such as semiconductor, digital display & storage media; Precision Cleaning is a prerequisite for newly manufactured parts prior to assembly, and a routine service and maintenance activity for delicate process equipment.

Dedicated Team
A dedicated division of qualified engineers and specialists are organized to respond quickly to the wafer fabrication plants' changing needs and can turnaround critical process kits at a short notice for our clients.
Confidentiality and Security
Safeguarding of our customer's confidential and proprietary information is our foremost priority. Corporate non-disclosure agreement is commonly practiced with our customers and our engineers/specialists may be required to enter confidentiality agreement before commencement of a project. We also have in place a strong data security system with controlled access that are monitored and controlled around the clock.
Customer Benefits
  • Assured service quality & response time
  • Increased equipment availability
  • Decreased wafer contamination & production cost
  • Surface profiling for contaminant adhesion
  • World class process kits recyling facility
Frontken Offers the following range of Precision Cleaning Processes

a) Spray Cleaning

Spray cleaning involves delivery of a liquid cleaning agent to the surface through the use of a pump and nozzle. This same pump and nozzle arrangement delivers mechanical energy to the cleaning site as the stream of spray impinges on the surface. In general, spray cleaning is highly effective on any surface that can be “seen” directly by the spray. Different effects can be achieved by changing the pressure of the spray, the spray pattern and the volume of cleaner sprayed to provide more or less impingement on the part.

b) Immersion Cleaning

Immersion cleaning involves immersing the part directly in a liquid cleaning agent. Immersion alone does not inherently supply any mechanical energy. Mechanical energy is supplied by a number of auxiliary means that may be used alone or in combination.

c) Ultrasonic Cavitation and Implosion

Ultrasonic agitation uses high frequency sound waves create small cavities (bubbles) in the cleaning liquid that collapse (implode), releasing considerable energy. Due to the nature of the phenomenon, this action is mostly concentrated at the interface between the cleaning solution and the contaminant being removed. Ultrasonic waves can penetrate thin layers of metal and propagate around corners to clean work pieces inside and out. Frontken cleans new and used components and assemblies, such as shields, platens, stainless liners, shutters, process chamber doors, transfer plates, rotating drums, process chambers, box coaters, CVD and PVD parts, load lock chambers, shielding, valves, ion sources, diffusion pumps, ion pumps, wave guides, etc., for the semiconductor, disk drive, medical, vacuum and related industries.

ABRASIVE BLASTING

Roughness control and surface preparation via surface texturing.

Abrasive blasting is a process where selected grades of abrasive particles are pneumatically accelerated and directed against components to achieve desired surface finish.

We carry out surface roughening as a pre-coating preparation process for contamination removal (rust, paint and depositions) and surface texturing to produce matt finishing according to customers’ special process specifications and requirements:

  • Surface preparation (roughening) for subsequent coating processes
  • Removal of rust, scale, sand, paint or burrs
  • Provides a matte surface finish for special processes

Frontken plant facilities are well equipped to cope with large or small surface texturing activities and know-how to achieve the most suitable surface finish for optimum performance or coatings bond.

MACHINING & GRINDING

High Precision Lathes and Fully Equipped Facilities Ideal for Servicing of Cylindrical Rotors, Crankshafts, Rolls and More. Our comprehensive range of mechanical equipment and facilities allow us to undertake machining operations of regular and large sizes.

  • Small/Large Capacity Cylindrical
  • Components & Crankshaft Grinding
  • CNC & Conventional Turning
  • Milling & Others.
  • Precision Turning (up to Ø2m x L10m x <10μm)
  • Cylindrical & Crankshaft Grinding (up to Ø 1.4m x L 6.5m)
  • Horizontal Boring (up to Ø 1.5m x L 1.6m)
  • Vertical Boring (up to Ø 5m x H 2.8m)

Small/Large Capacity Cylindrical, Components & Crankshaft Grinding, CNC & Conventional Turning, Milling & Others.

PRECISION MANUFACTURING

Precision Component Manufacturing via Multi-axis CNC Machining, Conventional Machining and Flow-Forming.

Frontken has contract manufacturing capabilities for components and assemblies of highest precision standards. We are also capable of 3D reverse engineering and prototyping via CMM, CAD/CAM & multi-axes CNC manufacturing technologies, offering our customers complete manufacturing solutions from design engineering and consultation to finished products.

MECHANICAL FITTING & ASSEMBLY

Expert handling, assessment, fitting & assembly works on wide-range of industrial equipments.

Complementing our core technology in Surface Metamorphosis Technology, we offer supporting activities such as machining, mechanical overhaul services and many others, this allows most intermediate processes to be carried out without unnecessary delays & in the shortest time, making our engineering plants the One-Stop Service Center for your equipments & components.

Overhaul of Stationary & Rotating Equipment.

Frontken offers more than 10 years of experience in overhaul of stationary & rotating equipments. We provide maintenance, refurbishment, modifications or upgrading as part of our complete overhaul solution for pumps, compressors, Steam or Gas Turbines.

DYNAMIC BALANCING

Troubleshooting & correction of unbalanced rotating equipments of up to 22 tonnes

Excessive vibration indicates problems or deterioration in the equipment. If the underlying problems are not corrected, it can cause unacceptable levels of noise, premature bearings failure and damage to the equipment. Eventually reducing the performance efficiency.

Dynamic Balancing allows sets of bearing pedestals to be connected to sensors and the unbalance at the two planes can be independently identified, thus reducing vibrations to a level that will prolong the bearing life and will reduce noise levels.

In addition to our standard repair & overhaul procedure. Frontken offers up to 22 tonnes with 4 Ø Dynamic Balancing capability for troubleshooting & correction of unbalanced rotating equipment experiencing vibrations.

HEAT TREATMENT

On-Site Large Capacity Heat Treatment for stress relieving of welded component.

Frontken provides stress relieving for large welded components.

  • Large Capacity
  • Furnace heat monitoring and control
  • Regional Mobility

ON-SITE MACHINING

On-site in-line boring, facing, milling, drilling and more.

Frontken provides specialized on-site engineering services for the marine, offshore, oil & gas, power generation, pharmaceutical, dredging, construction, industrial plant, mining and water reclamation industries. We help customers to facilitate maintenance, repairs or modification operations on-site or in-house. Apart from providing quality work, we take utmost care in ensuring our jobs are done efficiently and on-time to comply with project/shut-down schedules, potentially saving your business enormous costs & maintenance hours while improving productivity.

With a multi-disciplined field team, we can carry out different services under a single contract. We are available and at your service around the clock and our on-site team can be dispatched to any locations around the world on short notice. Our response to your request is further enhanced by access to our permanently established facilities located throughout the region.

We provide on-site maching services such as In-line boring, facing, milling,drilling and more. Anything which cannot be machined in a workshop can be dealt with just as efficiently by having equipment and manpower brought on-site. With access to portable machines, we are continuously building up our range of specially designed equipment to carry out precision and heavy duty machining operations at any locations throughout the region.

METAL STITCHING

Cold-repair of cracked/fractured metal castings with on-site capability.

Frontken provides specialized on-site engineering services for the marine, offshore, oil & gas, power generation, pharmaceutical, dredging, construction, industrial plant, mining and water reclamation industries. We help customers to facilitate maintenance, repairs or modification operations on-site or in-house. Apart from providing quality work, we take utmost care in ensuring our jobs are done efficiently and on-time to comply with project/shut-down schedules, potentially saving your business enormous costs & maintenance hours while improving productivity.

With a multi-disciplined field team, we can carry out different services under a single contract. We are available and at your service around the clock and our on-site team can be dispatched to any locations around the world on short notice. Our response to your request is further enhanced by access to our permanently established facilities located throughout the region.

Specializing in cold repairing of cracks and fractured castings, we utilize state-of-the-art metal stitching system and products from Lock-N-Stitch to provide stronger and lasting metal stitching repairs. Proven by pressure & load tests, It is the 'cold' method of repairing cracks in cast metals without welding and is a valuable alternative to avoid difficulties encountered in welding. We do not lock metals together, we stitch them!

LASER ALIGNMENT

Inaccuracy detection, measurement and correction of flatness, straightness, bore-alignment and more.

Frontken provides specialized on-site engineering services for the marine, offshore, oil & gas, power generation, pharmaceutical, dredging, construction, industrial plant, mining and water reclamation industries. We help customers to facilitate maintenance, repairs or modification operations on-site or in-house.

Apart from providing quality work, we take utmost care in ensuring our jobs are done efficiently and on-time to comply with project/shut-down schedules, potentially saving your business enormous costs & maintenance hours while improving productivity. With a multi-disciplined field team, we can carry out different services under a single contract. We are available and at your service around the clock and our on-site team can be dispatched to any locations around the world on short notice. Our response to your request is further enhanced by access to our permanently established facilities located throughout the region.

Frontken is able to provide precise on-site alignment services, utilizing modern laser techniques to detect, measure & correct inaccuracy & mispositioning in your equipment.

Applications
  • Equipment Calibration
  • Vibration Reduction
  • Wear Prevention
  • Efficiency Improvement
  • Machining Bore Alignment
  • Shaft Alignment
  • Split / Horizontal Flatness Measurement
2-axes Alignment System
For straightness and flatness measurement or bore to bore alignment checks.
Multi-Plane Lasers
Generate up to 3-ultra flat planes and can be used on multiple axes to check alignment in most cases with one setup.

PLANT ENGINEERING & CONSTRUCTION

Structural, mechanical and piping, electrical, instrumentation & control, equipment maintenance and overhaul, testing and commissioning for process & chemical facilities.

For detailed information and enquiries:
www.frontkenprojects.com
sales@frontkenprojects.com