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Thermal Spray Application Industries and Components
Release time:
2020-08-30 17:06
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Thermal Spray Application Industries and Components
Aviation field
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 spray coatings 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 blade 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 causing relative motion between components can lead to impacts between 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 employed under varying operating conditions. Textile industry
In the textile industry, numerous components are used to connect various fibers such as polyester, polypropylene, nylon, polyethylene, glass fiber, and carbon fiber. These components experience varying degrees of wear and tear. The operational performance of today’s textile industry largely depends on the ability of these critical components to resist fiber abrasion. Thermal spray coatings made from ceramics and tungsten carbide can enhance the durability of these key components, improve production efficiency, and reduce wear.
Steel
The extreme working conditions in the steel industry often lead to various types of wear on different components. Over the past decade, we have conducted extensive research aimed at improving the productivity of steel manufacturing processes. In recent times, thermal spray coatings have proven to be an effective solution, and today we are exploring even broader application areas within this industry.
The extreme working conditions in the steel industry often lead to various types of wear on different components. Over the past decade, we have conducted extensive research aimed at improving the productivity of steel manufacturing processes. In recent times, thermal spray coatings have proven to be an effective solution, and today we are exploring even broader application areas within this industry.
Boiler tube
High-temperature wear and corrosion of boiler tubes are one of the primary causes of plant shutdowns for maintenance and repairs, and also represent a fundamental engineering challenge for these devices. The combustion process generates oxide particles that have melting points higher than the operating temperature of the boiler. These particles enter the exhaust port intact, leading to continuous impacts on the boiler tubes.
We often hear about corrosion issues related to boiler tubes, such as overheating of boiler tubes. In particular, as modern chemical plants increasingly demand that boiler tubes operate efficiently at high temperatures, the rate of wear on these tubes will accelerate. As operating temperatures rise, both corrosion and overheating problems in boilers become significantly more pronounced. Moreover, even online cleaning methods—widely used to address boiler tube overheating—can lead to severe corrosion issues. Given these challenging working conditions—overheating, erosion, and corrosion—it is extremely difficult to select the right thermal spray coating. If the coating or thermal spray process is chosen carelessly, it could ultimately result in complete failure.
Turbine
A steam turbine is a machine in which solid surfaces interact mechanically with one another. These interactions can lead to various forms of wear, including abrasion, high-temperature corrosion, erosion, microvibration-induced wear, and scratching. By employing high-performance materials and thermal spraying techniques, these mechanical wear phenomena can be effectively addressed, significantly enhancing both the service life and operational efficiency of the turbine. One popular thermal spraying technique currently in use is thermal barrier coating, which is commonly applied in high-temperature environments to enhance thermal performance and reduce heat loss.
Oil and natural gas
For many industries, petroleum is indispensable, and it also plays a crucial role in the sustained development of industrial civilization. Improving productivity and reducing failures in the petroleum and petrochemical industries have always been our goals. Thermal spraying technology offers an excellent solution for extending the service life of components. These components can operate under the most extreme conditions, thereby enhancing overall industrial efficiency.
The thermal spraying application for oil and gas has been introduced many years ago and has become a reliable solution for addressing wear problems. Tungsten carbide is a coating material frequently used on the shafts of ball valves and drilling equipment. This coating boasts high hardness and excellent wear resistance, while also exhibiting outstanding corrosion resistance. Tungsten carbide particles are embedded in a chromium matrix, creating a unique combination of material properties.
Turbine
Turbines are classified into three types: Pelton turbines, axial-flow turbines, and mixed-flow turbines. Typically, these turbines suffer from wear, corrosion, and cavitation. Hard particles gradually erode the turbine blades, ultimately leading to a decline in turbine efficiency. Welding repairs are extremely costly and can negatively impact the flow dynamics. Changzhou Shenli Thermal Spraying Technology Co., Ltd. has developed the HYDROCOAT series—a coating solution that ensures superior performance of turbine components.
Hydraulic cylinder
Hydraulic cylinders are used in a wide variety of industrial applications, and they must maintain excellent performance even under the harshest conditions. Whether it's sand particles, high-temperature gases, freshwater, or saltwater, all these substances can damage the cylinder’s surface, ultimately leading to failure of the piston rod. Changzhou Shenli Thermal Spraying Technology Co., Ltd. has pioneered the HYDROX series, which guarantees the superior performance of hydraulic cylinders.
A hydraulic cylinder generates power through fluid pressure—typically, hydraulic oil serves as the working fluid. A hydraulic cylinder consists of a cylinder barrel, along with a piston and a piston rod that reciprocate inside it. The cylinder head and cylinder bottom of the barrel are both sealed. When the piston rod extends, it is exposed to various operating environments, such as freshwater or saltwater, extreme high temperatures, sand or slurry, rocks, or other objects—all of which can exert significant influences on the rod. To protect the surface of the piston rod, the industry has long relied on hard-chrome plating. Although this method is reasonably priced, it imposes very strict limitations on coating thickness and dimensions. In recent years, due to increased regulatory oversight by environmental agencies regarding production processes and industrial wastewater treatment, the cost of hard-chrome plating has continued to rise. Therefore, it has become critically important to find a coating or process technology that can either replace hard-chrome plating—or offer even better performance—without any adverse environmental impacts.
Casting and forging equipment operates in environments characterized by dust and corrosiveness, leading to significant wear and corrosion of mechanical components. My company We can repair and refurbish various hydraulic system components of casting machines, such as hydraulic plungers, as well as mating surfaces for different parts, including bearing seats and sealing areas. 。 Since chemical and pesticide machinery often operate in highly acidic and corrosive environments, when repairing such machinery, corrosion prevention must be taken into account. Xinyi Pesticide plant hydraulic plunger Cold spraying On-site repair services: Repair of pumps, plungers, valve cores, and other components in hydraulic and pressure systems. My company Repair of hard defects such as grooves on hydraulic cylinders—for example, various bearing supports in flour mills, motor rotors, and dough-pressing rollers; as well as repair of mating surfaces on components of imported sugar-making equipment.
Lifespan extension and enhanced repair of inner walls of steaming pots, drying cylinders, and ovens; surface strengthening and repair of various types of rollers; repair of components such as centrifugal pumps, axial-flow pumps, steam boilers, valves, and shaft seals for mixers; surface strengthening of corrugating rolls. All utilize our company’s cold-spray coating reinforcement technology. 。
Lola, wire guide hook, rapier loom weft selector Wear-resistant coating ; press rollers of the cotton loosening machine, small pressure rollers, tin-plate rollers, cast-iron outer discs, roller surfaces, feed roller shafts, upper cutting blade drive shafts, doffer shafts; steam valves of the sizing machine, planar joints at the edges of the drying chamber shafts, immersion basket shafts, sizing roller shaft heads, main shaft journals, yarn-guiding rollers, sizing rollers, moisture-recovery and humidity-measuring rollers, warp shaft journals, weaving machine shaft journals; additional-grade and breakage-detection rollers, large rollers (black rollers), finishing machine rollers, guide-driver rollers, heated rollers and fiber-dividing rollers, fabric-guiding rollers, printing roller surfaces and journals, thread spools, friction discs (plates), and more. All are manufactured by our company. Wear-resistant coating Technology 。
Printing impression rollers; ceramic anilox rollers; coating rollers, ink rollers, printing rollers, and water rollers; dental pads; dental trays, etc. All use our company’s cold spray coating technology. 。
Our company can prepare. Heat- and corrosion-resistant coatings for blast furnace tuyeres and slag outlets; crystallizers, guide rolls, and conveyor rolls in continuous slab casting lines; various process rolls used in the processing of ferrous and non-ferrous metals; and various types of rolls used in steel surface treatment production lines (such as rolls for continuous annealing furnaces). Galvanized Coatings with wear resistance, corrosion resistance, and anti-scaling properties for submerged rolls as well as various guide rolls, tension rolls, and the like.
Repair of ball mill components, turbine rotor and generator rotor journal bearings, and cylinder mating surfaces; wear- and corrosion-resistant coatings for boiler four tubes; anti-cavitation and wear-resistant coatings for hydro-turbine blades; high-temperature protective coatings for gas turbine blades, flame tubes, and transition sections; wear-resistant coatings for fan impellers and other worn parts such as ball mills; wear- and corrosion-resistant coatings for door cores, door rods, valve cores, valve accessories, and valve seats, as well as reinforcement and repair of related boiler equipment components.
Wear-resistant coatings for various worn areas; repair and pre-strengthening of automobile engine blocks, synchronizer rings, and crankshaft journals; wear-resistant coatings for bearing housings in gearboxes, cylinder pistons, support shafts for front and rear axles, and pivot pins; wear-resistant coatings for dredger rake heads, wear-resistant rings, mud buckets, cutter blades, bucket teeth, mud pump impellers, ship propeller shafts, propeller shaft bronze bushings, eccentric bushings, gear transmission shafts, mud pump seal necks, mud gates, sliding plates, and scraper blades for sand-dredging machines, among others.
Repair of various containers, reactors, pipelines, pumps, valves, and sealing components; on-site repair of various enamel tanks and specialized containers; repair of components for boilers, air compressors, water pumps, and other equipment.
A ceramic coating is applied to the surfaces of the lifting rollers and conveying rollers using thermal spraying, enhancing their corrosion resistance to molten glass. This coating inhibits the adhesion of molten liquid phases to the roller surfaces, slows down the erosion of the roller surfaces by molten glass, and helps keep the roller surfaces smooth for a longer period. As a result, maintenance and repair of the lifting and conveying rollers are reduced, glass quality and product yield are improved, and production costs are lowered.
Electrician wire harness assembly
Adopt Thermal Spray Welding The process is applied to the surfaces of parts such as wire-drawing tower wheels, wire-drawing machines, wire-drawing wheels, spools, wire-drawing tanks, winding reels, and guide grooves. weld Carbide ceramic coatings can achieve surface hardness levels of... HRc75 exhibits significantly higher wear resistance than grinding wheel steels or chilled cast irons. Moreover, it allows these parts to be manufactured using conventional steel or cast iron as the base material, thereby reducing costs and extending service life.
Long-lasting thermal spray protective coatings for various types of steel structures—corrosion resistance and long-term anti-corrosion performance—with a single application offering a service life of up to: Over 30 years
Spray-on strengthening and repair for plastic molds; spray-on strengthening for extruder screws and rubber mixer rotors; spray-on repair and strengthening for various roller bearing journals.
Sanxin Company’s Coating Processing Equipment and Capabilities
1. Coating Processing Equipment: Equipped with U.S.-made More than ten units of Praxair supersonic spraying equipment, U.S.-made Miller plasma equipment, domestically produced supersonic spraying equipment, domestically produced plasma equipment, and arc spraying equipment.
II. The coating processing workshop is equipped with: Two enclosed spray-painting workrooms; one enclosed sandblasting workroom; capable of processing 100,000 coated products annually.
3. Coating Machining Equipment: We are equipped with more than ten types of machining equipment, including various lathes, high-precision grinding machines, and precision polishing equipment, as well as a complete set of advanced quality inspection equipment. , coating surface condition analysis instruments, etc.
Undertaking various thermal spray processing services.
Plasma spraying processing Apply high-performance ceramic coatings, with coating materials including aluminum oxide, chromium oxide, titanium oxide, and cemented carbides.
High-speed arc spraying processing Applies various functional coatings, including stainless steel, zinc, aluminum, copper-lead-molybdenum, and Babbitt alloy.
Supersonic Gas Thermal Spraying Process Spraying hard alloy and metal-ceramic coatings; coating materials include tungsten carbide, nickel-chromium chromium carbide, nickel-chromium alloy, and others.
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Relevant Information
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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