Applications of Plasma Spraying Equipment in the Aerospace Field

As aircraft engines evolve toward higher performance, longer overhaul intervals, greater reliability, lower fuel consumption, and reduced costs, thermal spray technology has also undergone rapid development. A new-generation engine requires thermal spray coatings on more than 3,000 surfaces across over a thousand components. Thus, thermal spray technology has become an integral part of the aerospace industry. Among these applications, plasma spraying—owing to its numerous advantages such as low cost, high efficiency, simple operation, excellent coating quality, and suitability for large-scale, mass production—now accounts for over 80% of all sprayed parts in aircraft engines. The thermal spray coatings used in aircraft engines primarily include wear-resistant coatings, thermal barrier coatings, sealing coatings, and high-temperature protective coatings.

In the aviation industry, engines pose significant potential wear-and-tear challenges. With numerous moving parts that either come into contact with each other or involve fixed components that suddenly undergo changes, engines are highly sophisticated and intricate mechanical assemblies. For this reason, the aviation industry has become one of the first sectors to fully adopt thermal spraying—applying thermal spraying techniques to aircraft engines in order to optimize their operational performance, safety, and reliability.
Most engine systems consist of a fan, a compressor, a combustion chamber, high-pressure and low-pressure turbines, and an exhaust nozzle. The engine design includes a stationary (stator) system and two coaxial rotating systems. The stationary (stator) system comprises a structural frame and an outer casing. The low-pressure rotating system consists of a bladed disk, blades, a low-pressure turbine disk, turbine blades, and a connecting shaft. The high-pressure rotating system comprises a high-pressure turbine disk/bucket, compressor blades, turbine blades, and a connecting shaft. The operating environments of the engine’s various components differ significantly, primarily depending on the specific tasks the engine is designed to perform. Temperatures range from below zero degrees Celsius to 1095°C (2000°F), with rotational speeds reaching up to 15,000 revolutions per minute. The load-bearing capacity of rolling bearings varies from several megapascals to over 1720 MPa. Since the rotor rotates relative to the stator with sliding motion, the amount of sliding can range from a few thousandths of an inch to several hundredths of an inch; moreover, vibrations that cause relative motion between components can lead to impacts among mechanical parts. Different components are also affected by the coating materials used. To meet the engine’s design requirements, different coating materials and coating processes are selected for various operating environments.

Guangzhou Sanxin Thermal Spraying specializes in the manufacture of various thermal spraying equipment, including plasma spraying equipment, supersonic spraying equipment, arc spraying equipment, zinc-spraying machines, aluminum-spraying machines; flame powder spraying equipment, flame wire spraying equipment, flame plastic-coating equipment, as well as a wide range of thermal spraying coating services, ceramic coating services, and tungsten carbide coating services.

Application of Thermal Spraying Technology in the Chemical and Petroleum Industries

Application of Thermal Spray Technology in Aero-Engines

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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%.

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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.

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Applications of Plasma Spraying Equipment in the Aerospace Field