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Pratex
Advanced technology – Here and Now.
About the company
§  Pratex was created in 2007 as a natural successor to company
called «Amulet» which then specialized in manufacturing
Thermal sparay equipment such as Detonation spray systems.
The team that was working in Amulet, has experimented with
laser systems for number of years and eventually developed its
own laser engraver which put a start to a full line of production
of laser-engraved anilox rolls.
§  Full line of production has started operation in 2008 and since
Pratex grew to a company that is serving its products to clients
in CIS countries. Acquired 2 laser engravers with CO2 and YAG
lasers, has build its own full mechanical facility with lathes,
milling, grinding and polishing machines. Its capability allow to
produce rolls with ceramic coating and laser engraving in sizes
from 10cm and up to 3 meters in length.
Available technology: Detonation Spray
Detonation spraying — a type of thermal spray process, based on the principle of
"shooting" spray powder on the product with directed blasts of oxy-fuel mixture of
propane. Semi-molten particles hit the surface and solidify, forming a solid coating.
Our CNC controlled Detonation spray system Ceram-3000 (our own design and
development), has following features:
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Application of coatings with various properties (wear resistance / wear, friction /
anti-friction, resistant to heat, corrosion and aggressive media, etc.) for products of
different shapes;
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Restoration of worn parts to the products or coatings (e.g. - neck rolls, sleeves,
fingers, etc.);
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use for application of various materials: metals, alloys, oxides, corundum, carbides,
etc, to obtain coatings with desired properties;
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Spray fragile items, as this process has very little thermal affect on sprayed part;
Advantages:
Due to high energy of the “shot” and
correct choice of the sprayed materials,
obtained very high adhesion to the substrate
material (95-255МPa), high density(95-98%, practically of a sintered material) and
very low (0,5-1%) porosity of the coating.
Available Technology: Plasma Spray
Plasma spraying is known for more than half a century - in an electric arc between
the cathode and anode in the form of nozzle, a gas is feeding and forming a plasma
jet. In this jet the coated powder is fed, heated and emitted in a two-phase flow
from the nozzle and when it hits the surface it solidifies and forms a coating.
Our plasma spray system (Supplied by Praxair Plc) has following features:
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Application of coatings with different properties (wear resistance / wear, friction /
anti-friction, resistant to heat, corrosion and aggressive media, etc.) for products of
different shapes;
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Restoration of worn parts to the products or coatings (e.g. – roll necks, sleeves,
fingers, etc.);
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Use for coating range of materials: metals, alloys, oxides, corundum, carbides, etc,
to obtain coatings with desired properties;
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Coat parts made of many different materials, including not allowing the heat
treatment in a furnance;
Advantages:
This method allows to obtain
high density coatings with
required surface qualities;
high adhesion level (35-80MPa) with the surface,
density (90-95%) and low porosity of the coating (0,8-5%).
Available Тechnology: Laser Engraving
Pratex LLC uses two main laser technologies Nd:YAG and CO2.
Nd:YAG lasers are optically pumped used laser diodes and having air or fiber optics
delivery system. Wavelength of Nd:YAG laser is around 1064 nm. Our company has
both types of lasers, using fiber optics delivery system as a main one.
Carbon dioxide laser (CO2 laser) has a wavelength of around 9.4 and 10.6 micrometers.
Two types of different lasers allow to obtain the most optimal types of engraving, as
clients require engraving of different shape and sizes.
Our possibilities
§  Surface technology of protective coatings
§  3D-Laser
§  Water-Jet cutting with cut control
§  Material Processing facility:
o  3D-milling center
o  Diamond grinding and finishing
o  Spot welding
o  CNC Sheet bender
o  Lathe and grinding
o  Tube bender
o  Polyurethane casting
o  Surface finishing of stainless steel
Mechanical facility
Materials: metals (Steel, stainless steel, aluminum and alloys), ceramic (oxides,
carbides, etc.)
Lathe, miling, Circular grinding treatment
Dimensions (lathe):
L (length): 2800mm
D (diameter): 300mm
Positioning precision: 10 micrometers
Precision of treatment: 10 micrometers
Dimensions (grinding):
L (length): 2000mm
D (diameter): 250mm
Positioning precision: 1 micrometer
Grinding quality preliminary: Ra 0.8
Grinding quality finished: Ra 0.2
Diamond super finishing machine (Loeser, Germany)
Dimensions:
L (length): 2800mm
D (diameter): 300mm
This system allows to obtain surface finish of highest possible level (0,1 Ra), it can be
set up to polish either stainless steel surface or treat ceramic surface with diamond
tool.
3D-Laser MAZAK SpaceGear II
Materials treated:
Steel, stainless steel, aluminum and alloys.
Dimensions:
2D: 2000х1250mm;
3D: 300mm;
Dmax: 150mm;
Lmax: 2000mm (up to 6m max.);
Positioning: 1 micron;
Precision of treatment: 10 micron;
Cut quality: not less than 3.2;
Advantages:
- High precision and CNC processing allows to obtain result with ideal tolerances.
- After cutting, no more finishing jobs required, the part is ready to go to assembly
line. No extra leftovers as the system optimizes the cutting job.
Example: docking of two rectangular parts (on a "lock"); production patterns, etc.
Water Jet cutting Idroline 5-axis
Materials:
Metal, stone, glass, rubber, polymers, etc.
Dimensions:
2D: 4000х3700mm;
3D: 250mm;
Dmax: 150mm;
Precision of positioning: 10 micron;
Precision of treatment: 100 micron;
Precision of Cut: 10 micron;
Note: due to the presence of so-called "fifth axis" setting allows you to automatically
compensate for taper cutting, which is especially important with the thick / solid
billets.
Advantages:
- High speed cutting virtually any material, from plastic to the hardest. Including combinations;
- Ability to receive cuts of any shape - curved, angled, etc., with very high precision
cutting;- The possibility of cutting materials with a rough / difficult surfaces;- lack
of thermal, strain and shock to the work piece;
-  High repeatability, allowing us to obtain any number of identical products;
-  Highly environmental process - the lack of exhaust gases, dust, etc.
Other industries
Company serves with thermal spray coatings such
industries:
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Aerospace
Automotive
Mining
Energy
Chemical
Possibilities
Pratex LLC is an “owner” of the technology
It is possible to expand operations without substantial
investment into machinery, as technology is available to
duplicate.
-  Detonation spray: 100% own development
-  Plasma spray: Plasma system is acquired, but
positioning robot, gas treatment and installation is own
development.
-  Laser engraver, only the core laser is acquired, the
engraver and installation is of own design and
development.
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