SX-1000 Intelligent Arc Spraying Equipment

The imported arc spray gun boasts the following distinct advantages: * Compared to conventional domestically produced spray guns, the imported gun features significantly higher spraying efficiency, greater deposition rate, denser and finer coatings, lower porosity, and more stable performance throughout the spraying process. * It is equipped with a switchable current power supply, making operation simpler and preventing excessive current flow. Under harsh spraying conditions, its specially designed sealed circuit ensures excellent reliability. The system’s design meets customers’ specific requirements and includes wire-feed drive and straightening mechanisms. * When paired with the new SX-1000 spraying power supply, this gun operates with a “synchronous transmission” system. This system features a single-sealed motor and a flexible drive mechanism, enhancing motor reliability and allowing the wire feed distance to be extended up to 20 meters, thereby ensuring smooth and fine coating application. * The spray gun offers a longer working distance from the coated workpiece, a lighter and more flexible gun body, and provides operators with a comfortable working environment, greatly improving work efficiency.

Newly upgraded intelligent arc spraying system

Arc Spraying Machine, Sanxin SX-1000 High-Power Arc Equipment with Imported Spray Gun

HVOF Supersonic Flame Process: In supersonic flame spraying, oxygen and aviation kerosene are mixed in a premixing system and then burned in a high-pressure combustion chamber. The resulting flame jet, combined with high-pressure air passing through a Laval nozzle, generates a high-temperature, high-velocity flame stream that heats metal-ceramic powders to a semi-molten state.

Tungsten carbide wear-repair machining for impeller blade coating

Description: Our company provides repair services for worn areas on fan impellers in cement plants, power plants, and other facilities, as well as surface reinforcement coatings for new impellers. These services can extend the service life of impellers by several times. We employ a supersonic thermal spraying tungsten carbide repair solution, which produces a dense coating with high hardness and excellent wear resistance, thereby significantly prolonging the service life of the components. Carbon

Spray-on repair for worn areas of fan impeller blades

Our company provides repair services for worn areas on fan impellers in cement plants, power plants, and other facilities, as well as surface enhancement coatings for new impellers, which can extend the service life of impellers by several times. We employ a supersonic thermal spraying technique using tungsten carbide coatings, resulting in dense coatings with high hardness and excellent wear resistance, thereby significantly prolonging the service life of components. Tungsten carbide powder coatings—Tungsten carbide (WC) is the primary raw material used in the production of cemented carbides and boasts exceptionally high microhardness. Commonly used WC-based powder coatings include WC 8% Co, WC 12% Co, and WC 17% Co. The addition of cobalt in varying proportions to WC primarily serves as a binder, enhancing the toughness of the coating while preventing excessive carbon burn-off during the spraying process. Chromium carbide (Cr2C3) features high hardness and exhibits excellent resistance to high-temperature oxidation and wear, with a maximum operating temperature of up to 800°C. Typically, Cr2C3 is mixed with Ni-Cr alloys and is mainly applied to high-temperature wear-prone areas. Mechanical component wear-repair coating process using tungsten carbide—tungsten carbide wear-resistant coating parameters: Processing steps: → Sandblasting → Preheating → Primer application → Tungsten carbide spraying (thickness: 0.04–1.0 mm) → Grinding; Processing methods: Plasma or supersonic flame spraying. Tungsten carbide coating performance indicators: Hardness: Up to HRC 70–80; Bonding strength: ≥90 MPa; High-temperature resistance: Above 1200°C; Coating thickness: 0.04 mm–1.0 mm; Service life: 3–6 times longer than that achieved by conventional methods. Processing range: Diameter—from tens of millimeters to hundreds of millimeters; Length—from several millimeters to several meters.

Wear-resistant coating for turbine flow passages

Why is it necessary to spray wear-resistant materials onto the flow passages of hydro turbines? The issues of sand erosion and cavitation in hydro turbines have long threatened the normal operation of hydroelectric generating units. The High-Velocity Oxygen-Fuel (HVOF) thermal spraying process has been proven by both domestic and international industries to be a reliable and advanced surface protection method. Hangzhou Liantuo Power Technology Development Co., Ltd., after introducing foreign technology and integrating its own years of practical experience, has developed an advanced repair and anti-erosion technology based on hard-facing welding and thermal spraying. The corresponding process codes are USO26116 and USO26102. This technology fully utilizes imported HVOF spraying equipment and materials, specifically designed to address sand erosion and wear on the flow passages of hydro turbines, providing your generating units with the most reliable anti-erosion protection. Since 1983, the application of wear-resistant coatings on hydro turbine flow passages has been widely promoted and applied domestically. Over 100 hydropower stations across China have used this technology to coat more than 200 units—including Francis turbine runners, turbine guide vanes, and sealing pads—with coatings that exhibit cavitation resistance more than 10 times superior to that of 1Cr18Ni9Ti stainless steel and at least 20 times better than that of ZG30 cast iron. Among the hydro turbine flow passage components, the runner and movable guide vanes suffer the most severe fluid erosion and cavitation damage, especially in hydroelectric units operating under high-sand-content conditions. To ensure the safe operation of hydro turbine generating units, research into surface protection technologies for runners and movable guide vanes is of great importance. Thermal spraying technology provides an effective means of protecting hydro turbine flow passages. A major issue facing hydropower stations is the cavitation damage and sand erosion of turbine flow passage components. Due to differences in water quality, the rate and extent of damage vary significantly. Some hydropower stations must shut down and replace parts after just one water supply season, which not only affects the safe and stable operation of the turbines and increases maintenance costs but also severely impacts power supply. Therefore, extending the service life of hydro turbines and ensuring the safe and economical operation of hydropower stations have been key research topics in China’s hydropower development for many years. Over the years, Chinese scientists and power station workers have jointly conducted extensive research to solve this problem. They have adopted thermal spraying technology to pre-protect relevant turbine components, achieving successful construction practices with remarkable results. This technology was officially approved through on-site technical appraisal in 1985, organized by the Gansu Provincial Science and Technology Commission and the Gansu Provincial Water Resources Department. Specific examples of its effectiveness include: The Xiehu Xia Hydropower Station in Ningxia, located downstream of the Daxia River—a tributary of the Yellow River—suffered severe wear on the turbine bottom ring, top cover, guide vanes, and main shaft due to high sand content in the water, affecting unit operation and power generation. After thermal spraying repair, the worn area on the journal of the No. 1 unit’s main shaft (2.5 mm thick, 310 mm in diameter, weighing about 2 tons) measured 540 mm in length. After repair, the coating remained intact and undamaged even after 25,900 hours of operation. In the Hongya and Hejiabao power stations in the Tianshui region, the high sand content in the water caused severe equipment damage. One new runner had to be scrapped after only 10,000 hours of operation, and all other flow passage components required frequent repairs, driving up maintenance costs to as much as one-quarter of the station’s total revenue. In 1984, five 1,000-kW units nearing scrapping were repaired by thermal spraying of their runners, guide vanes, and front and rear end covers, achieving highly satisfactory results. After the repairs, the Hongya power station operated for over a year with the coating remaining intact, the unit running smoothly and stably, and efficiency improving significantly. Under the same head and flow conditions, power output increased by 85% compared to 1984, and individual unit capacity rose from 700 kW before repair to 860 kW, representing a 22.8% increase. Moreover, the service life of the units was extended by 3 to 5 times, and maintenance costs were reduced by 13,000 yuan. China’s small hydropower stations are scattered throughout the country, and the experience gained in manufacturing equipment and constructing power stations has attracted international attention and received high praise. We believe that thermal spraying technology will play an important role in the development of hydropower stations in China. The working principle of supersonic flame spraying involves mixing and burning oxygen with a combustible gas or kerosene. The resulting flame jet is pressurized and passed through a Laval nozzle, forming a supersonic flame jet. Tungsten carbide-based hard alloy powder is injected into this supersonic flame jet and sprayed onto the surface of hydro turbine components, creating a hard, wear-resistant protective layer. The following diagram illustrates the principle of supersonic flame spraying: As a high-energy spraying method, HVOF spraying produces coatings that are dense and have strong bonding strength. It has been successfully applied to enhance the wear resistance of hydro turbines and has become a widely adopted sand-erosion-resistant process both domestically and internationally. In some power plants, it has achieved excellent results in actual operations, demonstrating high potential for wider adoption. Guangzhou Sanxin Metal Technology Co., Ltd. is one of the earliest companies in China to provide repair services for hydro turbine and pump station components. The company masters several key technologies and employs numerous well-known domestic experts and experienced technical personnel. Fully utilizing advanced machining equipment and quality management methods, the company is committed to delivering first-class quality and providing premium services to its customers. Repair services for hydro turbine components such as upper and lower wear plates, runners, runner chambers, guide vanes, and blades; thermal spraying services for pump-side plates, impellers, and other components; and refurbishment of old pump impellers.

Application of Zinc and Aluminum Spraying for Corrosion Protection of Metal Structures such as Hydroelectric Power Station Gate Valves

For metal structures such as sluice gates in hydropower stations, including steel gates, trash racks, and embedded components of gate slots, which are exposed for long periods to alternating dry and wet conditions, submersion underwater, and continuous scouring by flowing water, these structures are subject to erosion from atmospheric factors, sunlight, temperature fluctuations, aquatic organisms, as well as impacts and abrasion caused by sediment and other floating debris. As a result, the steel surfaces are highly susceptible to corrosion. Once corrosion sets in, the load-bearing capacity of the steel structure gradually declines, seriously compromising the safe operation of the project. To effectively control steel corrosion and extend the service life of sluice gates, it is essential to adopt effective anti-corrosion measures. In hydropower station projects, all metal structures (except for the back sides of hoisting mechanisms and embedded components) shall be protected with hot-sprayed zinc coatings that offer long-term corrosion resistance. The process involves applying zinc spray followed by sealing with coatings and subsequent topcoating. For the back sides of gate slot embedded components, after sandblasting to remove rust, a cement-sand mortar containing a caustic soda solution shall be applied. To facilitate quality control during construction and ensure the effectiveness of the anti-corrosion treatment, the key technical requirements for hot-spraying zinc coatings in hydropower station projects have been formulated, drawing upon current national standards and relevant guidelines such as the "Code for Corrosion Protection of Metal Structures in Hydraulic Structures."

Wear- and corrosion-resistant products and technologies for equipment in power plants, chemical plants, steel mills, and cement plants.

Wear-resistant and corrosion-resistant ceramic tiles are made by high-pressure molding and high-temperature sintering of various hard materials. They exhibit excellent resistance to acid and alkali corrosion and possess exceptionally high hardness.

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