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Cold spray equipment

The company specializes in the R&D and design of coating preparation equipment. Our coating preparation equipment features a high degree of automation and boasts stable, reliable performance! Vacuum cold spraying offers flexible operating procedures, is not restricted by the shape of the workpiece, and is easy to use.

Category:

Coating spray equipment

Key words:

冷喷涂设备、冷喷涂系统、冷喷涂加工

Request for quotation E-mail:CarrieFeng07@outlook.com

Product Description

SX-LP80 Cold spray system

Cold spraying (CS) is a novel thermal spray technology that, based on aerodynamic principles, uses high-temperature, high-pressure gas to carry powder particles axially into a Laval nozzle of the spray gun, generating a supersonic flow. After being accelerated to speeds ranging from 500 m/s to 1200 m/s within the spray gun, the powder particles impact the substrate in a fully solid state, undergoing plastic deformation and depositing onto the substrate surface to form a dense coating.

It is possible to prepare coatings with high thermal conductivity and high electrical conductivity; the coating has minimal thermal impact on the substrate; grain growth is extremely slow (potentially allowing the nanostructure to be preserved); the microstructure closely resembles that of forged materials (with higher hardness compared to conventional coatings); the phase composition and chemical constituents are stable; and the coating thickness can exceed 10 cm.

Principle of Cold Spray

Cold Spray ( CS) It is a new type of thermal spraying technology, from the 20th century. 80 In the mid-20th century, research on theoretical and applied mechanics conducted by the Soviet Union So Papyrin He and his team were the first to propose it. It is based on aerodynamic principles and uses high-pressure gas to carry powder particles from an axial inlet. Laval nozzle for spray gun ( Laval nozzle) The nozzle generates a supersonic airflow, and powder particles ( 1-50 micrometer ) Accelerated to by a high-speed airflow 500 m/s–1200 m/s Subsequently, upon impact with the substrate (such as metal, ceramic, or glass) in a fully solid state, it is deposited onto the substrate surface via plastic deformation. The surface forms a dense coating. The gas typically used is nitrogen, Helium Gas or a mixture of both.

Advantages of cold spraying

The most significant feature that distinguishes cold spraying from other spraying methods is that it does not melt the coating material; instead, it forms the coating through a purely physical process. Compared to arc spraying, plasma spraying, and HVOF spraying, cold-sprayed coatings exhibit virtually no oxides and are highly dense. The electrical conductivity of a cold-sprayed pure copper coating can reach 90% of that of cast bulk material, whereas the electrical conductivity of flame-sprayed and HVOF-sprayed coatings is less than 50% of that of the as-cast bulk material.

*High deposition efficiency (reaching over 95% for certain materials) and low oxide content;

*Coating is dense;

*Can be used to prepare coatings with high thermal conductivity and high electrical conductivity (thermal and electrical conductivities can reach over 90% of those of the corresponding bulk materials);

*Minimal thermal impact on the substrate;

*Grain growth is negligible (the nanoscale microstructure can be maintained);

*Close to the forged microstructure (higher hardness compared to conventional coatings); the spraying process does not cause changes in phase or chemical composition.

*Different nozzle shapes are available, and the cross-sectional area of the spray jet can range from 20 mm to 60 mm.

* Extremely short spray distance (can be less than 10mm);

*Coating thickness can reach over 10 cm;

* The powder is collectible and reusable (high powder utilization rate).

Applications of Cold Spray

Metal powders undergoing plastic deformation, as well as composite powders containing components of materials that undergo plastic deformation, are suitable for cold spraying. The range of metals that can be sprayed extends from low-melting-point zinc to high-melting-point titanium and zirconium. Like thermal spraying, cold spraying is carried out in a soundproof booth equipped with an air-suction and dust-collection system. Its noise level is significantly lower than that of HVOF spraying.

Composition of the Cold Spray System Components: main control cabinet, operation control display screen, main heater, spray gun and nozzle, powder feeder, gas piping circuit, and others.

Overall layout diagram of cold spraying

Schematic diagram of cold spray structure

Main Technical Parameters of Cold Spray Equipment

Available working gases: nitrogen, helium, or mixed gases.

Work pressure: 0-3.5Mpa

Operating temperature: 0–450℃

Gas flow: Nitrogen, Helium -3000L/min

Powder feed rate (copper powder): 20-200g/min

Powder particle size: 1-50 micrometer

Jet range: 5-50mm

Power consumption: 15-55KW

1. Control cabinet and operation control display screen

*The left cabinet houses the main power control unit, the heating control power supply, and the power regulator. The heating control power supply and power regulator were specially developed for cold-spray applications, with an output power exceeding 50 kW and equipped with a ventilation-adjustable fan to meet long-term heat dissipation requirements.

*The right cabinet is configured with nitrogen as the main gas, helium as the auxiliary gas, and nitrogen as the powder-supply gas. Each gas line is equipped with a mass-flow controller for quality control and a safety valve. The safety valve is designed to open slowly under control and shut down rapidly. In the event of a malfunction, sudden pressure drop, or power failure, the system will shut down quickly.

The control unit emits an audible warning signal and displays an error alarm message.

*Independent nitrogen and helium control loops to meet both single-gas and mixed-gas application requirements: The mass flow controllers for the main gas, auxiliary gas, and powder-feeding gas can be adjusted according to different gas usage requirements.

*The operation control display features a 10-inch Siemens touchscreen that governs the entire system’s operation. The touchscreen is equipped with integrated interfaces for connecting to external computers, printers, and networks.

Operation Control Interface

*The main interface displays the system’s overall process.

*Monitoring data can be displayed on the operation interface, and the data will change accordingly when temperature and pressure fluctuate.

*During the work process, you can enter and view the parameters of the components used.

Control cabinet

Main Control Cabinet Technical Parameters

• Voltage: 380V AC, 50 Hz, three-phase five-wire

Input power: 55 kW

Gas demand:

Gas	Gas	Gas	Pressure fluctuation (30s)
Nitrogen	2500L/min	4.5 MPa	0.01 MPa
Ammonia	750L/min	4.5 MPa	0.01 MPa
Powder delivery gas (nitrogen)	250L/min	4.8 MPa	0.01 MPa

Gas composition: Nitrogen 97.7%, Ammonia 99.995%

The operation screen displays the following control and monitoring parameters:

*Powder dosage

*Gas consumption

*Main gas temperature (gas temperature at the heater outlet)

*Heater heating element temperature

*Heater control power output power

*Main gas pressure

*Powder delivery gas flow rate

*Powder delivery gas pressure

*Gas temperature at the nozzle

*Nozzle pressure

2. Main heater

Main heater temperature adjustment

The main heater is the core component of the cold spray system. The main heater can heat the primary gas to around 800°C within 1 to 2 minutes. Safety protection technology is employed to safeguard the heater components and prevent overheating damage.

The heater is made of high-temperature-resistant materials and is housed in an insulated, heat-insulating chamber. This insulation chamber ensures continuous operation without causing the outer casing to overheat.

The closed cooling system prevents the electrode from overheating. The cooling device directs the heat conducted to the electrode into a heat exchanger, maintaining constant temperature control of the electrode cable assembly.

Prev: Guangzhou Sanxin independently develops cold spray equipment.

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