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To isolate metallic foreign objects, lithium battery material manufacturers apply protective coatings to components of production equipment that come into contact with the materials. The three key properties—wear resistance, high-temperature resistance, and non-metallic nature—make tungsten carbide spraying an ideal choice; consequently, most lithium battery material production processes incorporate extensive tungsten carbide spraying for protection.
Characteristics of Tungsten Carbide Thermal Spray Coatings: 1. The flame jet velocity is extremely high—typically 53 times the speed of sound. 2. The coating is highly dense with strong bonding strength; its porosity can be less than 1%, and the bonding strength can exceed 70 MPa. 3. The coating material exhibits low oxidation, minimal carbon loss, and high hardness.
A key feature of insulated bearings is the presence of an extremely thin (on the order of micrometers) coating on their surface, which provides electrical insulation and can withstand electrical arcing caused by voltages exceeding 500V. A thicker coating can even resist high-voltage discharges up to 1,000V, thereby effectively preventing defects such as arcing induced by induced currents on the spindle and bearing, which could lead to corrosion on the bearing surface, the formation of shrinkage cavities on metal surfaces, and the creation of grooves on the bearing’s rolling elements. Here, a special note: At high frequencies, the induced shaft current can become substantial. If insulated bearings are not used, the circulating currents that flow through the bearing can easily cause overheating or severe electrochemical corrosion, ultimately leading to bearing damage.
Introduction to Plasma Spraying Technology Plasma spraying is a thermal spraying method that uses a plasma arc as the heat source and relies primarily on spray powder materials. Steps of Plasma Spraying During plasma spraying, a direct-current arc is generated between the cathode and the anode (nozzle). This arc heats and ionizes the introduced working gas, transforming it into a high-temperature plasma that is ejected from the nozzle, forming a plasma flame. The powder material is fed into the flame by a carrier gas, where it is melted, accelerated, and sprayed onto the substrate material to form 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.
5. The plasma spheroidization powder-making equipment includes: a powder collection tank, an exhaust gas filter, a plasma power supply, a control cabinet, a powder feeder, a transfer box, and a chiller, with a power rating of 80 kilowatts. 6. The powder processed by the plasma arc has a throughput of 2.8 to 10 kg/hour, and the powder feeder can deliver particles in the size range of 5–200 μm.
The Sanxin SX-80 plasma spraying production line is being used for coating tungsten carbide components at a hard alloy enterprise in Jiangsu Province. Plasma spraying is a surface enhancement and modification technology that endows substrate surfaces with properties such as wear resistance, corrosion resistance, resistance to high-temperature oxidation, electrical insulation, thermal insulation, radiation shielding, reduced friction, and sealing. In plasma spraying, a plasma arc powered by direct current serves as the heat source, heating ceramic, alloy, metal, and other materials to a molten or semi-molten state. These materials are then sprayed onto the pre-treated workpiece surface at high velocity, forming a firmly bonded surface layer.
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