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Plasma Spraying Ceramic Coating Process
Release time:
2020-08-30 22:31
Source:
Plasma Spraying Ceramic Coating Process
Principle of plasma spraying:
A plasma flame jet is generated by a plasma torch (also known as a plasma arc generator). The tungsten electrode (cathode) and the nozzle (anode) of the torch are connected to the negative and positive terminals of the power supply, respectively (the workpiece remains electrically neutral). A high-frequency spark ignites an arc, causing the working gas supplied to the torch—typically Ar or N2—to become ionized into a plasma under the influence of the arc. Under the combined effects of mechanical compression, self-magnetic compression, and thermal compression, the arc is compressed, forming a non-transferred plasma arc. Powder feed streams deliver powder coating materials into the plasma arc, where they are rapidly heated to a molten or semi-molten state. These heated particles are then propelled at high velocity by the plasma flow and impact the pre-treated substrate surface, forming a strong and durable coating on the substrate. As a result, the coated surface of the part acquires various specialized physical and chemical properties, such as hardness, wear resistance, heat resistance, corrosion resistance, insulation, thermal insulation, and lubricity, thereby meeting the specific performance requirements of the part under different operating conditions.
Plasma spraying process:
Plasma spraying is a meticulous process, and numerous factors can significantly influence the quality of the coating during this procedure. The main steps are:
1. Select the plasma gas. From the perspective of gas availability and cost-effectiveness, N2 is a suitable choice. Not only is it inexpensive, but its ionized flame also has a relatively high heat output and conducts heat fairly quickly. However, for certain materials that are prone to nitriding reactions, N2 is not an appropriate choice; in such cases, a slightly more expensive gas—Ar—is used instead.
2. Arc power. During the process, the arc power requirement is also very strict—neither too high nor too low. If the arc power is too high, the arc temperature will rise and the gas will be ionized into a plasma, causing the plasma flame temperature to increase as well. This could potentially lead to changes in the properties of the coating. On the other hand, if the arc power is too low, the plasma temperature will drop too much, which can also alter the properties of the coating.
Materials - Equipment - Processes - Solutions
We have accumulated extensive experience in coating applications, and we are now replicating these successful case studies. We’ll guide you through the entire coating manufacturing transformation process, ensuring: rapid production start-up; a reliable supply solution that covers everything—from materials and equipment to processes; coating trials conducted either at your site or at our technology center; and consistently high coating quality and efficiency. Start collaborating with us today and reap success tomorrow!
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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