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The U.S. Air Force is evaluating two cold spray processes.
Release time:
2019-12-12 16:48
Source:
The U.S. Air Force Research Laboratory recently conducted an evaluation that validated two cold-spray deposition technologies, making it possible to apply tungsten carbide–cobalt (WC-Co) coatings to high-strength steel components in aircraft. If subsequent tests are successful, these technologies could serve as an alternative to electroplated hard chrome (EHC).
The U.S. Air Force’s Aircrew Center extensively uses the EHC electroplating process when repairing and refurbishing damaged aircraft landing gear components, hydraulic cylinder actuators, propeller hub assemblies, and gas turbines. Chromium plating provides excellent metallic properties, such as hardness, wear resistance, corrosion resistance, and smoothness. However, the hexavalent chromium used in EHC electroplating is a well-known carcinogen; therefore, federal regulatory agencies impose strict controls on its use and handling. Compliance with these regulations has led to increased processing costs and also heightened the U.S. Air Force’s liabilities and risks.
The U.S. Air Force and other departments within the Department of Defense are currently exploring the use of WC-Co high-velocity flame thermal spraying as a replacement for EHC electroplating. Laboratory engineers have initiated several projects to validate and confirm the performance and limitations of the HVOF thermal spraying process. They have found that when a high-strength steel substrate is subjected to pressures exceeding 190 ksi, WC-Co coatings applied via HVOF thermal spraying will develop cracks, delaminate, and fracture. During HVOF application, the high temperatures experienced by the coating material cause the WC to undergo a brittle phase transformation and also subject the coating to significant internal stress. In contrast, cold spray deposition, which is carried out at low temperatures, can produce ductile coatings with properties similar to those achieved through EHC electroplating.
Due to the promising results of this initial assessment, the laboratory will implement a more comprehensive validation and verification plan to determine the mechanical properties of the coatings achieved through the optimized process. Cold spray technology will help reduce environmental dependence, the emission of hazardous waste, and the workplace safety challenges that the United States continues to face when maintaining its use of EHC plating.
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The complete set of plasma-sprayed equipment has been shipped to the customer’s site in Thailand.
Core spraying equipment: SX-80 plasma spray main unit, with a 15,000℃ flame suitable for multiple materials including zirconia and silicon carbide; powder feeding accuracy of ±1%, and coating thickness tolerance ≤ ±5 μm. Environmental protection support system: Customized soundproof booth + pulse dust collector—effectively addressing spray noise pollution while achieving highly efficient dust recovery, compliant with Thai environmental standards. Automated equipment: 6-axis industrial robot + intelligent spray cart, enabling precise spraying of complex workpieces and automated loading/unloading, boosting production efficiency by 40%.
On-site engineers provide hands-on training, focusing on the core operations of plasma spraying equipment such as the SX-80. Sanxin has customized a complete solution for its customers, including an automated spraying robotic arm, a soundproof booth, and a dust removal system—ensuring both high spraying efficiency and compliance with environmental standards.
Guangzhou Sanxin Thermal Spraying Turntable Shipment
Guangzhou Sanxin Company manufactures single-station and multi-station thermal spray turntables, which can be paired with plasma equipment, supersonic equipment, and arc equipment. We offer rapid, customized production tailored to customer requirements and product dimensions. A thermal spray turntable is a high-precision rotary worktable specifically designed for thermal spraying processes—including flame spraying, plasma spraying, and arc spraying. By providing controllable rotational speed and exceptional stability, it ensures uniform coating thickness on the workpiece surface, thereby enhancing spraying efficiency and quality.
SX-80 plasma equipment is being used at a customer site in Russia.
SX-80 plasma equipment is being used at a customer site in Russia.
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