Application of Thermal Spraying Technology

1. Applications of Arc-Sprayed Metal Coatings: Various containers and storage tanks made of ordinary A3 steel can have their surfaces coated with stainless steel materials such as 1Cr18Ni9Ti, 0Cr, or 00Cr, followed by pore-sealing treatment. This approach has been widely adopted as an alternative to manufacturing these components entirely from stainless steel. Specific applications include spraying aluminum, tin, zinc, lead, and stainless steel coatings on the inner surfaces of carbonization towers in fertilizer plants, gas holders, wine storage tanks, beer fermentation tanks, distillation columns, and various chemical processing vessels. Additionally, this method is used for repairing large gate valves and butterfly valves. 2. Applications of Plasma-Sprayed Ceramic Coatings: Food and chemical industry enterprises use A3 steel reactors that are newly manufactured or refurbished by spraying ceramic coatings—such as alumina, titanium dioxide, and chromium oxide—on their inner surfaces, replacing traditional enamel coatings or localized enamel repairs. When enamel reactors or agitator blades, impellers, and other components suffer local damage and become unusable, they can be repaired by using the ZK1532 metal-ceramic powder high-velocity flame spray gun to apply a ceramic coating, followed by pore-sealing treatment to restore them to like-new condition. 3. Applications of Flame-Sprayed Plastic Coatings: Flame-spraying plastic coatings, also known as flame-plastic spraying, are primarily used for powder coating aimed at corrosion resistance. This technique features relatively thick coatings, simple application procedures, lightweight and portable equipment that can be easily transported to construction sites. It enables direct on-site spraying of various acid-, alkali-, and salt-resistant plastic coatings without the need for heating or curing equipment, making it especially suitable for large-scale flame-plastic spraying operations at construction sites. These three thermal spraying technologies have now been extensively applied in sealing solutions within the food industry. Although the above introduction provides only a brief overview of the applications of thermal spraying technology in the food industry, we hope it has been helpful. If you would like to learn more, please feel free to contact us—we look forward to your call! Sanxin Thermal Spraying specializes in the manufacture of various thermal spraying equipment, including plasma spraying systems, supersonic spraying equipment, arc-spraying equipment, zinc-spraying machines, flame powder spraying equipment, flame wire spraying equipment, aluminum-spraying machines, sandblasting machines, and a wide range of thermal spraying services, ceramic coating services, and tungsten carbide coating services.

Introduction to Plasma Spraying Technology: The SX-80 Plasma Spraying Equipment Plasma spraying is a thermal spraying process that uses a plasma arc as its heat source and relies primarily on sprayed powder materials. ① Steps of Plasma Spraying During plasma spraying, a DC arc is generated between the cathode and the anode (nozzle). This arc heats and ionizes the working gas introduced into the system, turning it into a high-temperature plasma that is ejected from the nozzle, forming a plasma flame. Powder particles are fed into the flame by a carrier gas, where they melt, accelerate, and are sprayed onto the substrate material, forming a coating. The working gas can be argon, nitrogen, or a mixture of these gases with hydrogen added; alternatively, a mixed gas of argon and helium can also be used. ② Characteristics of Plasma Spraying (1) It can spray a wide variety of coating materials, especially refractory materials with high melting points, such as refractory metals, ceramics, metal-ceramics, and other special functional materials. (2) Inert gases can be selected as the working medium, reducing oxidation reactions of the sprayed particles during flight. (3) The coating exhibits high bonding strength and low porosity; fine coatings can be produced by precisely controlling process parameters. ③ The main components of plasma spraying equipment include the spray gun, powder feeding mechanism, rectifier power supply, gas supply system, water cooling system, and control system. General Layout of Plasma Spraying Equipment 2. Configuration of the SX-80 Plasma Spraying Equipment The SX-80 plasma spraying equipment was developed based on the introduction and absorption of PT-A3000 and METCO-9M plasma spraying equipment. Its overall performance level is comparable to that of the METCO-9M. The equipment includes: ① Main Power Supply ② Control Cabinet ③ Transfer Box ④ Powder Feeder ⑤ Spray Gun ⑥ Heat Exchanger and Piping Connections (I) SX-80 Main Power Supply The main power supply is a thyristor-controlled rectifier with a maximum input power of 85 kW and a duty cycle of 100%. The maximum output power is 80 kW, and it can operate normally under grid voltage fluctuations of ±15%. Current fluctuation range: ±1% to ±2%. Dimensions: 770 mm (length) × 670 mm (width) × 1430 mm (height); Weight: approximately 1000 kg. The SX-80 plasma main power supply provides DC power to the spray gun, featuring intelligent module control, modular rectification, soft arc starting, and capable of continuous 24-hour operation without failure. It is currently the most advanced plasma power supply in China. SX-80 Plasma Spraying System Main Power Supply Parameter Table No. | Item | Basic Parameters --- | --- | --- 1 | Input Power | 3P AC 380V, 50Hz/60Hz 2 | Rated Output Power | 80 kW 3 | No-load Maximum Voltage | DC 125V 4 | Working Current | 10–1000 A 5 | Working Voltage | 30–100 V 6 | Power Supply Characteristic | Constant Current Source 7 | Current Accuracy | <1% 8 | Load Rate | 90% 9 | Power Supply External Dimensions | 770×670×1430 mm 10 | Weight | 1000 kg (II) SX-80 Transfer Box The transfer box serves as the central connection point for the entire spraying system, linking the power supply, control cabinet, heat exchanger, and spray gun. It is equipped with high-frequency ignition, water circuit, and gas circuit alarm devices. The box is movable, and the water cable length is 5 m (standard type). Dimensions: 615 mm (length) × 470 mm (width) × 300 mm (height); Weight: approximately 125 kg. The transfer box delivers the combined water and electricity from the plasma equipment to the spray gun, while also providing the high-frequency pulse voltage required for gun ignition and detecting the return water temperature and cooling water pressure. It is lightweight, flexible, and easy to move. It offers excellent arc-starting performance and reduces the instantaneous current surge when the nozzle starts the arc. SX-80 Plasma Spraying System Transfer Box Parameter Table No. | Item | Basic Parameters --- | --- | --- 1 | Input Voltage | AC 220V, 50Hz/80Hz 2 | Rated Power | 250 W 3 | Control Mode | External Control 4 | Output High-Frequency Voltage | AC 2500–3000 5 | External Dimensions | 615×470×300 mm 6 | Weight | 125 kg (III) SX-80 Control Cabinet The control cabinet is the central control unit for the entire equipment. It operates on single-phase 220V, 1 kW, and is equipped with a float flow meter, digital displays for current and voltage, and offers manual, automatic, and economical operating modes. It features alarm and fault display functions. Common alarm conditions include: - When the main or auxiliary gas pressure is below 0.3 MPa or the main gas flow rate is below 30 L/min; - When the water temperature exceeds 50°C or the water flow rate is below 8 L/min. Dimensions: 725 mm (length) × 620 mm (width) × 1750 mm (height); Weight: approximately 265 kg. The control cabinet is used for regulating and controlling water, electricity, gas, and powder. It monitors the entire system, allowing users to directly view system parameters such as voltage and current levels. If the electrical or gas parameters fail to meet requirements, the system automatically alarms to prompt the user to make adjustments. By adjusting the current and voltage on the control panel, the temperature of the plasma arc can be regulated. Users can also adjust the main and secondary gas flows and their ratios via the control panel to change the length of the plasma arc and the velocity of the flame, thereby influencing the speed of the powder particles. SX-80 Plasma Spraying System Control Cabinet Parameter Table No. | Item | Basic Parameters --- | --- | --- 1 | Input Power | AC 220V, 50Hz/80Hz 2 | Input Power | 300 W 3 | Control Type | PLC Control + Relay 4 | Main Gas Type and Pressure | Argon, Nitrogen 0.6–0.8 MPa 5 | Maximum Main Gas Consumption | 2 m³/h 6 | Secondary Gas Type and Pressure | Hydrogen, Helium 0.25–0.4 MPa 7 | Air and Pressure | Dry 0.5 MPa 8 | Gas Usage | Argon, Argon+Hydrogen, Nitrogen, Nitrogen+Hydrogen 9 | Control Cabinet External Dimensions | 725×620×1750 mm 10 | Total Weight of Control Cabinet | 265 kg (IV) SX-80 Powder Feeder One single-cylinder powder feeder is provided. The particle size range for powder delivery is 5–200 μm, and the repeatability error is less than ±1%. Two cylinders can deliver powder simultaneously, with a feeding rate ranging from 8 to 250 g/min. Dimensions: 560 mm (length) × 530 mm (width) × 1130 mm (height); Weight: approximately 138 kg. The SX-80 plasma powder feeder is a device used to store spraying powder and deliver it to the spray gun according to process requirements. It uses the main gas from the spray gun as the carrier gas. The powder is transported through the rotation of the powder feeding scraper to the outlet of the feeder, and then exits the feeder along with the gas pressure into the spray gun. The potentiometer on the control cabinet panel can adjust the speed of powder delivery. SX-80 Plasma Spraying System Powder Feeder Parameter Table No. | Item | Basic Parameters --- | --- | --- 1 | Powder Delivery Method | Scraper Air Pressure Type 2 | Single-Cylinder (Dual-Cylinder) Capacity | 3.0 (6.0) L 3 | Powder Carrier Gas | Argon or Nitrogen 4 | Powder Carrier Gas Pressure | 0.45–0.6 MPa 5 | Powder Delivery Speed | 8–250 g/min 6 | Powder Delivery Accuracy | ±1% 7 | Powder Carrier Gas Flow Rate | 300–700 L/h 8 | Powder Feeder External Dimensions | 560×530×1130 mm 9 | Powder Feeder Weight | 138 kg (V) SX-80 Spray Gun An imitation of the METCO9MB spray gun is available. The main working gas is argon or nitrogen, and the auxiliary gas is hydrogen. The working current ranges from 100 to 800 A, and the working voltage is 50–75 V for Ar+H2 and 50–80 V for N2+H2. The spray gun is shown in the figure below, and comes with the following accessories: nozzle, powder and cooling air jet holder, water cable, electrode tip, insulator, sealing ring, and specialized tools. The SX-80 plasma machine is equipped with an SX-80 spray gun, which is designed for industrial thermal spraying operations. Its maximum output power reaches 80 kW. Due to its high rated power, this gun can handle high powder feed rates in production environments, shortening spraying time and reducing processing costs. Its standard structure allows for quick hardware replacement. Various nozzles, electrodes, and powder ports are available to accommodate different material requirements. SX-80 Plasma Spraying System Spray Gun Parameter Table No. | Item | Basic Parameters --- | --- | --- 1 | Rated Output Power | 80 kW 2 | Rated Current | 10–1000 A 3 | Working Voltage | 30–100 V 4 | External Dimensions | 80×75×190 mm 5 | Weight | 3.5 kg (VI) SX-80 Heat Exchanger (Refrigerator) The SX-80 heat exchanger, also known as a refrigerator or chiller, is primarily used to cool distilled water passing through the spray gun. After being cooled by the refrigeration principle, the water is circulated back into the spray gun at a lower temperature, effectively cooling the gun and maintaining its optimal working temperature, thus extending the nozzle’s lifespan. The dual-compressor drive reduces the overall machine volume and increases your workspace. SX-80 Plasma Heat Exchanger Parameter Table No. | Item | Basic Parameters --- | --- | --- 1 | Unit External Dimensions | 2000×780×1910 (mm) 2 | Circulating Water Tank Capacity | 250 kg 3 | Cooling Capacity | 35 kW 4 | Outlet Water Temperature Fluctuation | 5℃ 5 | Power Supply | 3P AC 380 50HZ/80HZ 6 | Compressor | Dual compressor, made in Japan Daikin (joint venture) 7 | Outlet Water Pressure | 4–8 kg adjustable 8 | Outlet Water Flow Rate | 6 m³/h 9 | External Circulation Pump | Rated Power 1.1 kW, Rated Current 1.5 A 10 | Refrigerant Charge | 11 kg, refrigerant F22 11 | Fan Power | 85W×2 12 | Total Input Power | 13.5 kW 13 | Weight | 450 kg Features and Functions: - Temperature measurement and control range: -4.9℃—94.9℃; - Display resolution up to 0.1℃; - Control sensitivity: 0.1℃; - Offset range: -0.5℃—10℃; - Uses AC 220V power supply; - Instrument operating environment: relative humidity ≤90% RH, temperature 0–45℃, non-corrosive and waterproof.

Properties and Application Ranges of Four Common Ceramic Spraying Materials

Characteristics and Application Ranges of Four Common Ceramic Coating Materials: 1. Alumina: This material is white in color and has a melting point of 2050℃. Due to its high hardness, it can be used as an abrasion-resistant coating for mechanical seals, plungers, shaft components, and other similar applications. It also exhibits excellent resistance to corrosion by acids, alkalis, and salts. 2. Aluminum-Titanium Composite Ceramic: As the TiO₂ content increases, the coating color shifts from light gray to bluish-black. Its melting point is approximately 1800℃, and the coating features low porosity with exceptional smoothness after polishing. Moreover, it does not generate static electricity during use. Consequently, aluminum-titanium ceramic coatings are widely employed in industries such as chemical fiber textiles, printing, and dyeing. 3. Chromium Oxide: This material is dark green in color. The coating is dense and achieves excellent smoothness after polishing. It boasts outstanding chemical stability and is insoluble in a variety of solvents, including acids, alkalis, and salts. As a result, this coating is extensively used in environments exposed to various corrosive media. Additionally, it possesses high hardness comparable to tungsten carbide-cobalt, making it suitable for wear-resistant applications. 4. Zirconia: This material is white in color and has a melting point of 2860℃. It is used for protecting high-temperature gas-erosion-resistant parts and for preparing thermal insulation coatings. We have accumulated extensive experience in material, equipment, process, and solution development for coating applications, and we are currently replicating these successful cases. We will guide you through the entire coating manufacturing transformation process, ensuring: rapid production start-up; a reliable supply solution covering materials, equipment, and processes comprehensively; coating trials conducted either on-site at your facility or at our technical center; and consistently high coating quality and efficiency. Start collaborating with us today and reap success tomorrow!

Tungsten carbide wear-resistant coating for textile and synthetic fiber machinery parts

Wear-resistant tungsten carbide coatings for textile and synthetic fiber machinery parts include: rollers, grooved cylinders, wire-guide hooks, oiling wheels, doubling spindle cups, silk-length measuring devices, and weft-selection fingers for rapier looms; large and small pressure rollers for carding machines, cylinder shafts, cast-iron outer discs, roll surfaces, cotton-feed roller shafts, drive shafts for upper cutting blades, and doffer shafts; air valves for sizing machines, planar joints at the edges of drying chambers, immersion flower-basket shafts, sizing roller heads, main shaft journals, yarn-guiding rollers, sizing rollers, moisture-content measurement rollers, warp-shaft journals, and weaving-machine shaft journals; wear-resistant coatings for rollers in twisting and breaking machines, large rollers, warping machine rollers, wire-guide machine rollers, heated rollers and thread-dividing rollers, fabric-guiding rollers, printing roller surfaces and journals, friction discs, and other components.

Wear-resistant coatings for rollers, wire-guiding hooks, and weft-selection fingers on textile machinery.

Wear-resistant coating application for mechanical parts in textile and synthetic fiber machinery: wear-resistant coatings for rollers, wire-guide hooks, and weft-selection fingers on shuttle looms; large and small pressure rollers, cylinder shafts, cast-iron outer discs, roll surfaces, cotton-feed roller shafts, upper cutter drive shafts, and doffer shafts on carding machines; air valves, planar joints at the edges of drying chambers, immersion flower-basket shafts, sizing roller heads, main spindle journals, yarn-guiding rollers, sizing rollers, moisture-recovery and humidity-measuring rollers, warp-shaft journals, and weaving-machine shaft journals; wear-resistant coatings for feed rollers and draw-in rollers, large rollers (black rollers), finishing machine rollers, take-up rollers, heated rollers and fan rollers, fabric-guiding rollers, printing roller surfaces and journals, friction discs (plates), and other components.

Automotive Industry – Spray Coating for Wear-Resistant Cylinder Linings in Engines

Automotive Industry—Advanced Surface Treatment Technologies for Engine Cylinder and Piston Ring Coatings: Spray-on Wear-Resistant Coatings to Reduce Friction Coefficients. These cutting-edge surface treatments create specialized wear-resistant coatings with exceptionally high adhesion strength and outstanding wear resistance, reducing the friction coefficient by 20–30% and significantly lowering fuel consumption. Materials—Equipment—Processes—Solutions: We have accumulated extensive experience in coating application and are now replicating these successful cases. We will guide you through the entire coating manufacturing transformation process, ensuring: rapid production start-up; a reliable supply solution covering materials, equipment, and processes all in one place; coating trials conducted either on-site at your facility or at our technology center; and consistently high coating quality and efficiency.