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Spraying equipment SPRAY EQUIPMENT
SX-HVAF5000 Supersonic Flame Spraying System
The SX-HA 5000 HVAF supersonic flame equipment manufactured by Sanxin Company is equipped with an SX-HA 5000 HVAF supersonic torch delivering 200 kW of power and featuring an internally-diameter torch. It is suitable for coating deposition on cemented carbides and metals. The SX-HA 5000 HVAF coatings exhibit high hardness and high density, while also demonstrating excellent ductility. Thanks to the efficient utilization of combustion energy, this system offers high quality at a low cost.
Product Description
Introduction to the Composition of SX-HA 5000 HVAF Supersonic Flame Spraying System
Working Principle
The SX-HA 5000 HVAF supersonic flame spraying equipment manufactured by Sanxin is equipped with a 200kW SX-HA 5000 HVAF supersonic spray gun and an inner-diameter spray gun, which can be used for coating deposition of cemented carbides and metals. The SX-HA 5000 HVAF coating features high hardness, high density and good ductility at the same time. Thanks to the efficient use of combustion energy, the system is characterized by high quality and low cost.
- Oxidant and cooling gas: Compressed air
- Fuel: Propane, propylene, propane-butane mixture, natural gas
The combustion temperature of the air-fuel mixture is relatively low, allowing spray particles to be axially injected along the narrow combustion chamber. Inside the combustion chamber, the low gas velocity ensures sufficient heating time for the particles. The particles complete the acceleration process in the large-diameter nozzle. Meanwhile, the large nozzle diameter provides a passage for a large amount of nitrogen in the air and prevents the inner wall of the nozzle from interacting with powder particles. This makes it possible to increase the acceleration speed of powder by extending the nozzle, which can usually reach over 400–1000 m/s. The catalytic ceramic plate in the combustion chamber helps provide a wider range of more stable spraying parameters.
Coating Quality
The combustion temperature of the air-fuel mixture is 1000 degrees Celsius lower than that of the oxygen-fuel mixture. This temperature reduction results in a temperature equivalent to or slightly higher than the metal melting point, which is ideal for the gradual heating required for spraying cemented carbide and metal powders. In comparison, the initial oxygen content in the HVAF process is at least 50% lower than that in HVOF. These two factors (low temperature and low oxygen) prevent powder oxidation and carbide decomposition in the alloy, and retain the ductility of the raw powder material even when the hardness of the cemented carbide coating is as high as 1600 HV300.
High Efficiency
Powder particles are heated by high pressure in the combustion chamber, where heat conduction is most effective. The size of the combustion chamber ensures that powder particles can stay for a long time to be heated. Therefore, the energy transfer efficiency of the HVAF process is significantly increased compared with other high-speed spraying methods. High heating efficiency is also the primary factor for the cost reduction of AcuKote HVAF coatings.
Acceleration Efficiency
The large diameter of the nozzle eliminates the so-called length limitation of other spray guns. Spray particles can be accelerated to the gas flow velocity.
Consistency of Coating Quality
The diameter of the spray powder stream is only a fraction of the nozzle diameter. Therefore, the influence of the nozzle inner wall on the velocity of spray particles is almost negligible, which provides uniform acceleration for the particles and improves the consistency of the coating structure.
- SX-HA 5000 Supersonic Spray Gun
- Oxidant and cooling medium: Compressed air with an inlet pressure of 9+ Bar
- Fuel: Propane, propylene, propane-butane mixture, natural gas with an inlet pressure of 7+ Bar
- Sprayable materials: Cemented carbide, metal, cermet powder
Spray Gun Model | Power (kW) | Spraying Efficiency (kg/hour) | Air (SLPM) | Propane (SLPM) |
SX-HA 5000
| 200 | 33+ | 9900 | 95-150 |
Due to its relatively low heat input, it is more suitable for coating applications such as mud pumps. Its performance is as follows:
SX-HA5000 spray gun
200 kW HVAF spray gun
Notes about nozzle use with WC-Co (Cr)
- Nozzle 3L: Hardness 1200 HV300, Deposition Efficiency (DE) 55%
- Nozzle 5L: Hardness 1350 HV300, Deposition Efficiency (DE) 45%
- Nozzle 5E: Hardness 1450 HV300, Deposition Efficiency (DE) 38%
- HVAF Control System
- PLC automatic control
- Control of electrical module, air/nitrogen module and fuel module
- Air control: Electronic pressure valve
- Fuel control: Electronic pressure valve, differential pressure flow meter for monitoring
- Carrier gas (nitrogen) control: Mass flow controller
- Pressure monitoring of combustion chamber and nitrogen cleaning pipeline
- Adjustable spray gun ignition settings
- Adjustable alarm and safety shutdown alarm settings
- Fully remote control of powder feeder and adjustable powder startup parameters
- Automatic pressure release of powder tank can be set after spray gun shutdown
- Download and upload of spraying parameters in the "Recipe" window
- Hydrogen injection control: Manual flow meter or mass flow controller
- Communication ports with external equipment (robot, host computer, etc.)
- Electronic metering control of powder feeder and other functions
- The control cabinet is the control core of the supersonic spraying system. It adopts state-of-the-art technology to realize automatic control of the entire spraying system. The air supersonic spraying system reaches the advanced level of similar foreign products, with superior performance and easy operation.
Parameter Table of SX-HA 5000 Air Supersonic Flame Spraying System Control Cabinet
Serial No. | Item | Basic Parameter |
1 | Control Type | PLC + Touch Control |
2 | Input Power | 550W |
3 | Fuel Pressure/Flow | MPa, m³/H |
4 | Air Pressure/Flow | MPa, m³/H |
5 | Carrier Gas Pressure/Flow | MPa, m³/H |
6 | Overall Dimension of Control Cabinet (mm) | 7509001650 |
7 | Weight of Control Cabinet | 259Kg |
- SX-HV 5000 Supersonic Powder Feeder
(The newly upgraded powder feeder is equipped with a Siemens PLC touch screen. Functions such as powder feeding flow, frequency and thickness are linked with the main control system to realize free programming with a high degree of automation.)
The SX-07 air supersonic powder feeder is a device for storing spray powder and delivering it to the spray gun in accordance with process requirements. Nitrogen is used as the powder feeding gas. The spray powder is atomized and vibrated by the powder feeding gas, which delivers the powder to the outlet of the powder feeder. The powder then leaves the powder feeding barrel together with the powder feeding gas and enters the spray gun. The powder feeding speed can be adjusted via the touch screen on the control cabinet panel.
Parameter Table of Powder Feeder for SX-HA 5000 Air Supersonic Spraying System
Serial No. | Item | Basic Parameter |
1 | Powder Feeding Method | Scraper Pneumatic Type |
2 | Dual-Barrel Volume | 3.5 (7.0) L |
3 | Powder Feeding Gas | Nitrogen |
4 | Powder Feeding Gas Pressure | 1.1-1.3MPa |
5 | Powder Feeding Speed | 0~220g/min |
6 | Powder Feeding Accuracy | ≤±1% |
7 | Powder Feeding Gas Flow | 400~800L/h |
8 | Overall Dimension of Powder Feeder (mm) | 5605301130 |
9 | Weight of Powder Feeder | 138Kg |
4. Cooling System
Driven by twin compressors, it reduces the overall volume of the equipment and saves your space. It is mainly used to effectively cool the nozzle and sealing ring, so as to extend their service life.
Parameters of Cooling System
Serial No. | Item | Basic Parameter |
1 | Overall Dimension of Unit (mm) | 1330×780×1310 |
2 | Circulating Water Tank Capacity | 250KG |
3 | Refrigerating Capacity | 35KW |
4 | Outlet Water Temperature Fluctuation | 5℃ |
5 | Power Supply | 3P AC380 50HZ/60HZ |
6 | Compressor | Twin Compressors, Origin: Sanyo (Japan, Joint Venture) |
7 | Outlet Water Pressure | 4---8Kg (Adjustable), Outlet Water Flow: 6 m³/h |
8 | External Circulating Pump | Rated Power: 1.1KW, Rated Current: 1.5A |
9 | Refrigerant Injection Quantity | 11Kg, Refrigerant: F22 |
10 | Fan Power | 85W×2 |
11 | Total Input Power | 13.5KW |
12 | Weight | 450Kg |
Coating Performance
Gas Requirements for System Installation
1. Inlet Pressure
- Air: 100-130PSI (100HP air compressor recommended)
- Fuel gas: 90-180PSI (fuel gas vaporizer recommended)
- Hydrogen: 90-120PSI
- Nitrogen: 100-180PSI
2. Air Compressor System Parameters
- Air displacement of air compressor: 14 m³/min
- Maximum working pressure: 10 bar
- Motor power: 90Kw
- Air handling capacity of freeze dryer: 15 m³/min
- Air storage tank: 3m³-10bar
Notes
- The setting of the hydrogen regulating valve shall not exceed 120PSI!
- Note: The control console will not allow start operation or will shut down automatically if the inlet pressure of either nitrogen or air is lower than 70 PSI.
- Power supply: 210-240 V AC, 1-phase, 50/60 Hz, 8 Amps
- Note: The control cabinet is equipped with a 14AWG 3-wire connection cable. Workshop wiring and any extended power cords shall use wires with a grounding conductor of at least 14 AWG.
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