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SX-HVAF8000 Air Supersonic Spray System
The SX-HVAF8000 supersonic spraying system is a newly designed, independently patented HVAF supersonic spraying system that builds on Sanxin New Materials’ many years of experience in operating imported HVAF equipment. It features low cost, high efficiency, and exceptional stability.
Product Description
SX-HVAF8000
Air Supersonic Spraying System
Introduction to SX-HVAF8000 Supersonic Spraying System
• Development Background of SX-HVAF8000 Supersonic Spraying System
• Composition of SX-HVAF8000 Supersonic Spraying System
• Performance Characteristics of SX-HVAF8000 Supersonic Spraying System
• Advantages of SX-HVAF8000 Supersonic Spraying System
• Features of SX-HVAF8000 Spray Gun
• Coating Performance Test of SX-HVAF8000 Spraying
• Typical Applications of SX-HVAF8000 Supersonic Spraying System
Development Background of SX-HVAF8000 Supersonic Spraying System
SX-HVAF8000 Supersonic Spraying System is a newly designed HVAF supersonic spraying system with independent intellectual property rights, low cost, high efficiency and high stability, developed on the basis of Sanxin New Materials' decades of process experience in using imported HVAF equipment!
- Long procurement cycle of imported equipment VS Fast delivery by Sanxin
- Slow after-sales response of imported equipment VS Rapid response by Sanxin
- High procurement cost of imported equipment VS Low cost by Sanxin
- High spare part cost of imported equipment VS Low cost by Sanxin
- Sanxin shares the rich and reliable thermal spraying process experience accumulated over more than 30 years with users with almost complete transparency.
As a carrier of the company's decades of HVAF process application experience, SX-HVAF8000 came into being as a supersonic spraying system with core competitiveness tailored for you!
System Composition
- Supersonic spraying equipment
- Enclosed sound-insulating coating processing chamber
- 11-axis 9-linkage spraying robot
- Conveying system (product processing turntable and conveying system)
- Control system
- Waste gas treatment system
- Gas supply system
- Public power pipelines, circuit materials and connections
- Fire protection, environmental protection and safety facilities
Fixed Brand of Outsourced Components
- Adopt Siemens human-machine interaction system → High reliability
- Imported pneumatic control components → High stability and repeatability of process parameters
- Mankal V1.0 control software → Strong expandability; Easy integration
- Independent gas circuit design → High safety
- Built-in gas leakage sensor → High safety
- Hydrogen elimination → High safety
- Unique gas dilution design → High safety
- Diverse spray gun configurations → Wider process applications
- Unique SX-HVAF8000 spray gun → Higher quality coating, higher efficiency and lower energy consumption
- Unique SX-HVAF8000 powder feeder → High precision and repeatability even under low carrier gas parameters
- Self-designed robot quick switching module → Safe, flexible, efficient and automatic switching
Comparisons with HVOF
- HVOF requires a large amount of oxygen (850L/min), with high storage safety requirements and high costs;
- SX-HVAF8000 adopts air combustion support, no oxygen required means higher safety, and only the electricity cost of air compressor is consumed; the operating cost is extremely low compared with the oxygen for HVOF;
- The optimized SX-HVAF8000 spray gun has extremely low spare part consumption: combustion chamber (200h+); gas ignition plate (500h+); gun barrel (100h+); powder injector (200h+);
- The optimized SX-HVAF8000 spray gun can spray with an extremely high powder feed rate (WC up to 300g/min) without affecting coating performance; the deposition efficiency of sprayed tungsten carbide coating is as high as 50%;
- The optimized SX-HVAF8000 spray gun is equipped with sandblasting function without obvious wear on the gun barrel (sandblasting consumption: 0.5kg/m²), thus saving the construction cost of sandblasting room and sandblasting system, and reducing the process transfer time and potential safety hazards.
Comparisons with Imported HVAF
- Fast delivery cycle; low equipment procurement and spare part costs; fast after-sales service response;
- Comprehensive and open technical support for process application;
- In particular, the spray gun gas circuit is designed through fluid finite element analysis based on simulation software, resulting in more sufficient combustion. High flame flow and powder particle flight speed can be obtained with relatively low input of compressed air and propane fuel; the powder particle flight speed can reach 1000-1200m/s; ultra-high powder particle speed equals ultra-high quality coating performance.
SX-HVAF8000 Spray Gun
- Working Principle: It can generate high-speed spray beams through the combustion of compressed air and fuel gas to heat and accelerate various metal, alloy or cermet powders, thus obtaining high-density coatings. Propane is used as fuel. Compressed air and propane pass through the mixing chamber and enter the combustion chamber through the gas ignition plate, which is ignited by a spark plug for combustion. The gas ignition plate ensures continuous and stable combustion; powder is axially injected into the combustion chamber to be heated, and then accelerated after entering the nozzle, realizing the separation of powder heating and acceleration sections, thus achieving precise control of powder particle temperature and speed. High-temperature and high-speed particles impact the substrate surface to form a coating.
- The SX-HVAF8000 spray gun is a newly designed high-performance spray gun with extremely simple and reliable structure, elaborately developed based on fluid dynamics, finite element analysis and years of HVAF spray gun application experience;
- The spray gun has a very simple structure, and workshop assembly can be completed with simple tools;
- Extremely few wearing parts;
- Specially developed for handheld spraying!
Coating Prototype Testing Service
Customers are welcome to conduct coating prototype testing before ordering equipment or coatings, and can track the sample production in the whole process!
Applicable Materials and Coating Functions of SX-HVAF8000 Supersonic Spraying
SX-HVAF8000 supersonic spraying can spray more than 100 kinds of materials, and the coatings can realize the following surface functions on substrates:
1. Manufacturing (Coating parts during manufacturing or before use)
- Wear-resistant coatings under various working conditions
- Corrosion-resistant coatings under various working conditions
- High-temperature resistant coatings under various working conditions
- Coatings with integrated wear, corrosion and high-temperature resistance under various working conditions
- Other functional coatings (Coating processes can be developed with customers according to their working conditions)
2. Maintenance/Remanufacturing
Repair parts that cannot be used due to friction, wear and corrosion through coating and machining.
3. Cost Reduction
Parts originally made of expensive alloys can be replaced with ordinary materials and coated with functional coatings to achieve the same service effect as alloy parts.
Replacement of Traditional Electroplating Process
The electroplating industry uses a large number of strong acid, strong alkali, heavy metal solutions and even toxic and harmful chemicals such as cyanide. These toxic and harmful substances are discharged into the environment through wastewater and waste residue, making it a heavily polluting industry.
Although the traditional HVOF process is environmentally friendly, its cost is 7 times higher than that of electroplating (hard chrome plating), making it difficult to replace the electroplating process.
Two Basic Conditions for the New Process
- Quality equivalent to or higher than electroplated coatings
- Cost close to or lower than electroplating process
The spray gun of SX-HVAF8000 supersonic spraying system is elaborately designed based on fluid dynamics, finite element analysis and years of HVAF spray gun application experience. It can spray ultra-fine tungsten carbide powder with a particle size of 2-10μm to form a thin coating with low roughness, extremely high density and excellent wear resistance, which can replace hard chrome plating. Traditional supersonic spraying usually uses raw material powder with a particle size of 15-45μm or 20-53μm, and the sprayed coating has high roughness and relatively low density.
Coating Performance Comparison
Performance Index | Traditional Supersonic Tungsten Carbide | SX-HVAF8000 Supersonic Tungsten Carbide | Hard Chrome Plating |
Porosity (%) | <1% | <0.5% | <0.2% |
Roughness (Ra μm) | 4.5-5.8 | 1.0-1.6 | 1.2 |
ASTM G65 (mm³) | 1-2 | 0.8-1.5 | 4-7 |
Cavitation wear (mm³) | 0.1-0.3 | 0.05-0.25 | 0.05 |
Micro hardness HV0.3 | 1170-1350 | 1300-1500 | 750-950 |
Innovation Strengths
Core Advantages: Unique internal component design of spray gun; Intelligent system software; High-quality coating process service
- Unique multi-process spraying system
- Spraying deposition efficiency is 5-6 times higher than traditional HVOF
- Replacement of traditional electroplating process
- At least 50% reduction in cost input compared with imported equipment
Core Technologies: Intelligent System
Intelligent Spraying Control System
High-quality Components and Stable Control System
- SX-HVAF8000 air supersonic spraying system with independent intellectual property rights;
- Self-designed and developed fully enclosed dust-proof robot external axis system for thermal spraying;
- Adopt Siemens human-machine interaction system → High reliability;
- Imported pneumatic control components → High stability and repeatability of process parameters;
- Sanxin V2.0 control software → Strong expandability; Easy integration.
Higher Quality Coating Preparation
Multiple Options for Spraying Power
Cost Advantages
- Suitable for internal hole spraying with an inner diameter of 80 mm or above;
- High-power spray gun is suitable for spraying all materials on large workpieces; carbide spray gun is suitable for spraying all workpieces;
- Handheld spray gun is suitable for spraying small workpieces and workpieces with complex geometry;
- Replacing traditional HVOF equipment with our HVAF can save 1.04 million RMB per ton of sprayed tungsten carbide coating.
Coating Performance Comparison (MKE-HVAF 19T vs Traditional HVOF)
Performance Index | Traditional Supersonic Tungsten Carbide | Hard Chrome Plating | US Unique Coat | SX-HVAF8000 Supersonic Tungsten Carbide (Our Product) |
Porosity (%) | <1% | <0.2% | <0.5% | <0.5% |
Roughness (Ra μm) | 4.5-5.8 | 1.2 | 1.0-2.0 | 1.0-1.6 |
ASTM G65 (mm³) | 1-2 | 4-7 | 0.7-1.4 | 0.8-1.5 |
Cavitation wear (mm³) | 0.1-0.3 | 0.05 | 0.06-0.27 | 0.05-0.25 |
Micro hardness HV0.3 | 1170-1350 | 750-950 | 1300-1450 | 1300-1500 |
Leading Performance
Our equipment combines the technologies of spraying gun body, gas control system and ignition system with traditional supersonic equipment, and pioneered the research and development of SX-HVAF8000 supersonic spraying system. The above core technologies are the first in China with the following advantages:
Multiple Spraying Power Options
SX-HVAF8000 supersonic spraying system provides high-power spray guns, low-power spray guns and internal hole spray guns. This multi-power performance can spray a wider range of powder materials, thus helping customers realize coating applications in more fields. However, some domestic supersonic equipment only has one power and configuration with a relatively small spraying "window".
High Safety
SX-HVAF8000 supersonic spraying system adopts Siemens human-machine interaction system, independent gas circuit design, built-in gas leakage sensor and unique gas dilution design. On the premise of ensuring coating quality, the safety is greatly improved compared with traditional supersonic systems.
High Spraying Deposition Efficiency
The optimized SX-HVAF8000 supersonic spraying system can spray with an extremely high powder feed rate (WC up to 300g/min) while maintaining excellent coating performance, which is 3 to 4 times the deposition efficiency of traditional supersonic systems. At the same time, the deposition efficiency of the optimized SX-HVAF8000 supersonic spraying system is 1.3 times that of traditional supersonic systems. Comprehensively, under the premise of the same coating quality, the spraying time of MKE-HVAF19T supersonic spraying system is only 50% of that of traditional supersonic systems.
Excellent Coating Performance
The spray gun gas circuit of SX-HVAF8000 supersonic spraying system is designed through fluid finite element analysis based on simulation software, resulting in more sufficient combustion. High flame flow and powder particle flight speed can be obtained with relatively low input of compressed air and propane fuel; the powder particle flight speed can reach 1000-1200m/s; ultra-high powder particle speed will obtain ultra-high quality coating performance. The sprayed coating has higher hardness, high density, low porosity and higher bonding strength (the bonding strength of traditional supersonic coating is about 10000psi, while that of SX-HVAF8000 supersonic coating ＞12000psi), making the coating more reliable.
Two Processes (Sandblasting & Spraying) Realized by One System
Traditional Supersonic Spraying Process
Workpiece inspection and cleaning → Masking of non-spraying areas of workpiece → Workpiece sandblasting → Workpiece spraying → Coating post-treatment
SX-HVAF8000 Supersonic Spraying Process
Workpiece inspection and cleaning → Masking of non-spraying areas of workpiece → Integrated sandblasting & spraying → Coating post-treatment
SX-HVAF8000 supersonic spraying system can realize the quick and easy switching between sandblasting and spraying processes, while traditional supersonic spraying equipment can only realize the spraying process. The sandblasting process requires an additional sandblasting system and a lot of switching time. Figures 3 and 4 are photos of on-line sandblasting and spraying of SX-HVAF8000 supersonic spraying system.
Workpiece being sandblasted | Workpiece being sprayed
Comprehensive Cost Advantages
Equipment Investment Cost
High localization rate of components, the cost is only about 30% of that of similar foreign products.
Operating Cost
SX-HVAF8000 adopts air combustion support, with extremely low operating cost compared with the oxygen for traditional supersonic spraying; in addition, the high deposition efficiency and high powder feed rate of SX-HVAF8000 make the spraying time of SX-HVAF8000 supersonic spraying system only 50% of that of traditional supersonic systems under the premise of the same coating quality requirements, thus further greatly reducing production costs.
Spare Part and Consumable Cost
100% of the spare parts of HVAF8000 supersonic system are self-designed domestic parts, and the price is only 30%-40% of that of foreign products.
After-sales Service Cost
Compared with foreign after-sales service, our company has a faster response speed and more convenient communication. After selling a complete set of spraying equipment, we can also provide special coating "turnkey" services. Based on 30 years of spraying experience, we can provide personalized customized services for customers, especially for military and aerospace project customers, and can quickly and accurately help customers pass the coating system certification of end customers.
Easy Upgrade
Our equipment adopts a modular design, with general components in stock all year round, and users enjoy 24-hour on-site maintenance by a professional team; based on the modular design, our company can not only continuously research and develop to improve quality, but also conveniently provide customers with corresponding upgrade requirements.
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