Pumps & Valve Industry

Reciprocating Plunger


Problem :

Plungers use a mechanism (typically rotational) to create a reciprocating motion along an axis, which then builds pressure in a cylinder or working barrel to force gas or fluid through the pump. These plungers come in contact with corrosive gases and abrasive contaminants present in the fluid during operation. As a result during the reciprocating action the plunger surface tends to wear out at the mating section thereby damaging the seal and causing the operation to cease. In certain applications the plungers are also subjected to fatigue load and impact due to which the plunger and its mating part gets severely damaged.

Solution :
Wear and Corrosion Resistant Coatings

We provide highly wear resistant nickel and carbide based coatings which are impermeable and chemically resistant to corrosive gases. Our range of coatings can be applied with HP-HVOF process that produces a dense and homogeneous coating and used in wear and corrosion resistant applications. Plungers are spray and fused with nickel based self-fluxing alloys for applications with high impact and fatigue load. The coatings are ground and super-finished, further enhancing the sliding properties and reducing wear of mating seal parts. Our range of coating solutions proves to be the best replacement for hard chrome plated and nitrided plungers and improves the operational life by 5 - 8x. Our coated plungers have been operating successfully over the years for applications in coal gasification, slurry pumping, hydrogen gas environment and high pressure water pipeline services.

We have in-house capabilities for refurbishment of worn out plungers and complete manufacturing of new plungers as per customer requirement. We have multiple CNC and grinding machines to cater to huge production volumes of various sizes.

Industry PIC C832 PIC C832 PIC DC09
Process Spray and Fuse HVOF HVOF
Bonding Metallurgical Mechanical Mechanical
Micro Hardness (HRc) 58 - 64 58 - 64 72 - 74
Coating Application Impact Resistance Abrasion Resistance Abrasion and Corrosion Resistance
Finish Coating Thickness Up to 1mm 450 to 500 µm 180 to 200 µm
Surface Finish < 0.4 Ra µm


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