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Spraying equipment SPRAY EQUIPMENT
Alumina spraying equipment, plasma spraying equipment
Plasma spraying equipment, alumina spraying equipment, ceramic coating spraying
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Product Description
Alumina spraying equipment, plasma spraying equipment
(Introduction to the Features of the SX-80 Plasma Spraying Equipment)
Introduction to Plasma Spraying Technology
Plasma spraying is a thermal spraying process that uses a plasma arc as the heat source and primarily employs spray powder materials.
① Steps of plasma spraying
During plasma spraying, a direct-current arc is generated between the cathode and the anode (nozzle). This arc heats and ionizes the introduced working gas, transforming it into a high-temperature plasma that is ejected from the nozzle, forming a plasma jet. Powder particles are fed into the plasma jet by a powder-feeding gas, where they are melted, accelerated, and sprayed onto the substrate material to form a coating. The working gas can be argon, nitrogen, or a mixture of these gases with hydrogen added; alternatively, a mixed gas of argon and helium can also be used.
② Characteristics of plasma spraying
(1) Capable of spraying a variety of coating materials, especially high-melting-point and refractory materials such as refractory metals, ceramics, metal-ceramics, and other special functional materials;
(2) Inert gases can be selected as the working medium to reduce oxidative reactions of spray particles during their flight.
(3) The coating exhibits high bonding strength and low porosity; fine coatings can be prepared by controlling process parameters.
③ Main equipment for plasma spraying
Including the spray gun, powder feeding mechanism, rectifier current, air supply system, water cooling system, and control system.
Introduction to the Configuration of the SX-80 Plasma Spraying Equipment
The SX-80 plasma coating equipment was developed successfully based on the introduction and absorption of plasma spraying equipment such as the PT-A3000 and METCO-9M. Its overall performance level is comparable to that of the METCO-9M.
The device includes: ① Main power supply ② Human-machine interface intelligent Control System ③ Transfer box ④ Powder feeder ⑤ Gas and Electricity Safety Center ⑥ The system consists of a spray gun, a heat exchanger, piping connections, and other components.
1. Imported SG-100 plasma torch (imported)
The SG-100 plasma torch is a 100-kW-class, multi-mode torch that is widely used in thermal spraying applications. Thanks to its versatile performance, the SG-100 can coat virtually any type of material—ranging from highly dense, wear-resistant carbide coatings to thermally insulating coatings with controllable porosity.
Features:
The unique design of the SG100 allows it to employ either internal or external powder feeding. Material specialists can develop a reasonable powder-feeding mode based on the coating performance requirements. Additionally, the two internal powder-feed ports of the SG100 can be used independently; when used simultaneously, they can achieve a higher spraying speed and enable the simultaneous mixing of different materials within the plasma jet. The external powder-feed port can also replace the internal one, and the internal and external feed ports can be used in combination as well.
By adding optional accessories, the SG100 can be easily assembled into an extended-nozzle spray gun suitable for 2086 and 2700 models. It can also be modified into a 90° SG-100 spray gun, enabling spraying of internal bores with different diameters to meet various application requirements. Below is a diagram of the 90° SG100 plasma gun.
The components of the SG-100 plasma torch can operate continuously for up to three times longer than those of other torches. Thanks to the SG-100’s fewer components and its self-calibrating design, assembly time is reduced and accuracy is enhanced, enabling the torch to meet even the most stringent and demanding GE acceptance criteria.
Other features: automatic calibration, wear-resistant nozzle components with a longer service life, reduced operational and assembly costs, and the ability to operate even at a power output of 100 kW.
Applicable nozzle:
The SG-100 can be used in three spray modes—subsonic, Mach 1, and Mach 2—and depending on the specific requirements, different anode and cathode configurations as well as gas distribution ring setups can be selected.
2. The SX-80 human-machine interface intelligent control system serves as the control center for the entire equipment set.
Features of the SX-80 Human-Machine Interface Intelligent Control System:
The SX-80 human-machine interface intelligent control system, leveraging cutting-edge technology, provides automatic control over the entire spraying system. The plasma spraying system boasts advanced performance comparable to similar foreign products, offering superior functionality and ease of operation. The control cabinet features a PLC-based touch-screen control terminal that integrates operation, settings, help functions, display, process monitoring, and fault alarm surveillance into a single unit. This simplifies panel design, making the system convenient to use and ensuring even simpler, more intuitive operation.
3. Gas Safety Center
Special Note: Since H2 gas is a flammable and explosive hazardous gas, and the mass flow meter used is an electrical component that could generate sparks, posing a risk of combustion and explosion, our company has specially designed and developed an independent “Water, Electricity, and Gas Safety Center” to provide safety protection during equipment operation.
4. SX-80 Main Power Supply
SX-80 Main Power Supply Silicon-controlled rectifier with a maximum input power of 85 kW and a duty cycle of 100%. The maximum output power is 80 kW, and it can operate normally under grid voltage fluctuations of ±15%. The current fluctuation range is ±1% to ±2%.
External dimensions: 1200mm (length) × 800mm (width) × 900mm (height)
Weight: approximately 300 kg
The SX-80 plasma main power supply provides a DC power source for the torch, featuring intelligent module control and modular rectification. It employs soft arc starting and can operate continuously for 24 hours without failure—making it currently the most advanced plasma power supply available in China.
5. SX-80 Adapter Box
The transfer center of the entire spraying system connects the power supply, control cabinet, heat exchanger, and spray gun together. The enclosure is equipped with high-frequency ignition, water circuit, and air circuit control and alarm devices. The enclosure is mobile, and the length of the water cable is 5 meters (standard model).
External dimensions: 950mm (length) × 580mm (width) × 1700mm (height)
Weight: approximately 85 kg
6. SX-80 Powder Feeder
Introduction to the Technical Advantages of the Newly Upgraded Intelligent Dual-Powder-Feeding System:
1. Parameters are set using a PLC and touch screen to precisely control the powder feeding accuracy and feeding speed.
2. The system features two independent powder-feeding units: the large hopper has a capacity of 20 liters and uses a blade-type conventional powder feeder capable of delivering up to 150 grams per minute. The small hopper employs a rotary drum feeder, making it suitable for handling various ultrafine powders as well as difficult-to-feed mixed powders.
3. It features a fully enclosed plastic steel enclosure that is unaffected by external environmental factors such as temperature and humidity. The panel has a transparent glass door, providing a clear view of the powder-feeding status at a glance.
4. Optional features include a powder feeding vibration device, a powder tank heating device for powders, and a metering and weighing device.
SX-80 Plasma Powder Feeder Features ：
Provide one (dual-barrel) powder feeder.
Powder particle size range for delivery: 5–200 μm; repeatability error in powder delivery is less than ±1%.
Two hoppers can deliver powder simultaneously, with a powder delivery rate ranging from 8 to 250 g/min.
A device used to store spray powder and deliver it to the spray gun according to process requirements. The main air supplied to the spray gun serves as the powder-transporting gas. As the powder-transporting scraper disc rotates, it conveys the spray powder to the outlet of the powder feeder. Under the pressure of the gas, the powder is then ejected from the powder hopper and enters the spray gun. By adjusting the potentiometer on the control cabinet panel, the speed of powder delivery can be regulated.
7. Chiller unit (refrigeration system)
The cooling unit consists of a high-pressure water pump, a chiller, and a large stainless steel chilled-water tank. The high-pressure water pump operates at a pressure of 12 kg, the chiller has a capacity ranging from 5 to 10 HP, and the chilled-water tank has a capacity of 3 tons.
Note:
1. The cooling capacity is based on the following conditions: chilled water inlet and outlet temperatures of 12℃/7℃, and cooling water inlet and outlet temperatures of 30℃/35℃.
2. Operating Range: Chilled water temperature range: 5℃ to 35℃; chilled water inlet-outlet temperature difference: 3℃ to 8℃. To be used in environments where the condensing temperature does not exceed 35℃.
3. Unit Conversion: 1 kW cooling capacity = 860 kcal/hr; 1 RT = 3,024 kcal/hr; 1 kcal/hr = 3.969 BTU/hr. 1 metric horsepower (HP) = 0.735 kW
Prev: Application of Thermal Spraying Technology in Aero-Propulsion and Gas Turbines
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