Advantages of the Newly Upgraded SX-90 Plasma Spraying Equipment

The plasma spraying system produced by Guangzhou Sanxin Metal Technology Co., Ltd. has the following distinct advantages:

1. The SX-90 plasma control cabinet is controlled by imported Alicat mass flow meters from the USA.

2. Equipped with imported SG-100 plasma spray guns.

3. Specially configured with one Water, Gas & Electricity Safety Center.

4. 100% of the main core components are imported brand parts, eliminating customers' after-sales concerns.

1. The SX-90 Plasma Control Cabinet is Controlled by Imported Alicat Mass Flow Meters from the USA

The SX-90 plasma control cabinet adopts the most advanced touch control terminal to date, simplifying the original button operation mode. As the control core of the entire SX-90 plasma spraying system, it realizes automatic control of the whole system with state-of-the-art technology.

Features of the US-Imported Alicat Mass Flow Meter Adopted in the Plasma Control System

Control via Alicat mass flow meters effectively solves the problems of unstable plasma flame flow (fluctuating size) and voltage (fluctuating high and low) caused by unstable gas pressure and flow during operation, thus stabilizing the output power and achieving closed-loop control of all parameters. The SX-90 control cabinet is equipped with a touch control terminal that can record and save spraying parameters for different powders in the form of recipes. It also allows viewing of alarm information in case of equipment abnormalities. The system access is divided into administrator and operator channels: administrators can modify and save spraying parameters, while operators can only adjust them. Reserved interfaces are also provided for extended use.

Brief Introduction to US Alicat

Alicat (USA) is the world’s fastest manufacturer of mass flow meters, mass flow controllers and pressure controllers! With a device response speed as fast as 5 milliseconds, fast delivery and technical support, Alicat always provides customers with innovative flow and pressure solutions promptly. All Alicat mass flow meters, mass flow controllers and pressure controllers are equipped with NIST-traceable calibration certificates and an industry-unique conditional lifetime warranty. Alicat flow and pressure equipment has become the first choice in the industry for both scientific research and various industrial applications.

2. Imported SG-100 Plasma Spray Gun

Features

A. The unique design of the SG100 enables internal or external powder feeding. (For internal powder feeding, coating powder is atomized after passing through the plasma arc core, resulting in significantly better coating performance and higher energy efficiency compared with external powder feeding.)

See the attached figure for the principle analysis of a conventional external powder feeding spray gun, from which the superiority of the internal powder feeding spray gun can be concluded.

B. Material engineers can formulate a reasonable powder feeding mode according to coating performance requirements. In addition, the two internal powder feeding ports of the SG100 can be used independently; simultaneous use delivers higher spraying speed and enables mixed use of different materials in the plasma beam. The external powder feeding port can replace the internal ones, and internal and external ports can also be used in combination.

C. One set of SG100 equipment can generally work continuously for about 200 hours. Under specific operating conditions, the service life of SG100 plasma spray gun components is up to three times that of other spray guns. Thanks to its fewer components and self-aligning design, the SG100 features quick and precise assembly, meeting the strict even harsh acceptance standards of GE.

Other features: Including automatic calibration and wear parts with a longer service life, all reduce its operation and assembly costs. It can even operate at a power of 100KW.

Applicable Nozzles

The SG100 can be used in three spraying modes (subsonic, Mach I and Mach II), and different anode/cathode and gas distribution ring configurations can be selected according to different needs.

Summary of SG100 Plasma Spray Gun Features

1. Optional internal/external powder feeding modes (or mixed use) and multi-angle powder feeding to meet diverse requirements;

2. Long continuous working time;

3. Easy component maintenance, long service life of spray gun anodes and cathodes, and automatic calibration to reduce operation and assembly costs;

4. CE certified.

With low consumable costs, easy maintenance and long service life of key components, the SG100 is undoubtedly a cost-effective spraying tool.

3. The SX-90 Plasma Spraying System is Specially Configured with One Water, Gas & Electricity Safety Center

Special Note: Hydrogen (H₂) is a flammable and explosive gas, and mass flow meters are electrical components that may generate electric sparks, leading to combustion and explosion risks. Therefore, our independently developed and manufactured Water, Gas & Electricity Safety Center provides safety protection for the equipment during operation.

Functional Features

A. Leakage detection system for three gases (H₂, N₂, Ar);

B. Gas leakage alarm device;

C. Quick cut-off device for air intake pipelines;

D. Spray gun backfire prevention and flameout device;

E. Leakage protection, cut-off and alarm device;

F. Current overcurrent protection device;

G. Voltage overvoltage protection device;

H. Water flow and leakage pressure sensing device;

I. Water temperature overhigh warning and shutdown system;

J. Dust concentration monitoring, alarm and shutdown device.

4. 100% of Main Core Components are Imported Brand Parts

The coverage rate of imported parts for core components in Sanxin’s series of spraying equipment reaches 100%. Among domestic equipment, our spraying equipment ranks first in domestic sales, and we are also the manufacturer using the most imported brand parts in the thermal spraying equipment industry. All our raw materials and internal components are procured from regular manufacturers with production licenses, and core and main components are selected from world-renowned imported products with strict product inspection. More than a decade of operation results show that the equipment produced by our company features stable and reliable performance with a good reputation among customers!

To ensure stable and reliable quality of the equipment during long-term operation and minimize failure rates, 100% of the main core components of our newly upgraded SX-90 Plasma Spraying Equipment are imported brand parts, eliminating customers' after-sales concerns.

List of Importers and Manufacturers of Main Components

Supplementary List of Key Imported Components

SX-90 Plasma Spraying Equipment (Equipped with Imported SG-100 Spray Gun)

Plasma spraying is a thermal spraying method that uses a plasma arc as the heat source and spraying powder materials as the main raw material.

① Steps of Plasma Spraying

During plasma spraying, a DC arc is generated between the cathode and anode (nozzle). The arc heats and ionizes the introduced working gas into high-temperature plasma, which is ejected from the nozzle to form a plasma flame. Powder is fed into the flame by powder feeding gas, 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, as well as a mixture of argon and helium.

② Features of Plasma Spraying

1. Capable of spraying a variety of materials, especially high-melting-point refractory materials such as refractory metals, ceramics, cermets and other special functional materials;

2. Inert gas can be selected as the working medium to reduce the oxidation reaction of spraying particles during flight;

3. High coating bonding strength and low porosity; fine coatings can be prepared by controlling process parameters.

③ Main Equipment for Plasma Spraying

Including spray gun, powder feeding mechanism, rectifier power supply, gas supply system, water cooling system and control system.

Configuration Introduction of SX-90 Plasma Spraying Equipment

The SX-90 Plasma Spraying Equipment is successfully developed on the basis of introducing and absorbing PT-A3000 and METCO-9M plasma spraying equipment, and its overall level is equivalent to METCO-9M.

The equipment consists of: ① Main Power Supply; ② Intelligent Human-Machine Interface Control System; ③ Transfer Box; ④ Powder Feeder; ⑤ Water, Gas & Electricity Safety Center; ⑥ Spray Gun; ⑦ Heat Exchanger and pipeline connection systems.

1. SX-90 Intelligent Plasma Control Cabinet

The control core of the entire plasma spraying equipment

Features of SX-90 Intelligent Control System

The SX-90 plasma control cabinet adopts the most advanced touch control terminal to date, simplifying the original button operation mode. As the control core of the entire SX-90 plasma spraying system, it realizes automatic control of the whole system with state-of-the-art technology.

Control via Alicat mass flow meters effectively solves the problems of unstable plasma flame flow (fluctuating size) and voltage (fluctuating high and low) caused by unstable gas pressure and flow during operation, thus stabilizing the output power and achieving closed-loop control of all parameters. The SX-90 control cabinet is equipped with a touch control terminal that can record and save spraying parameters for different powders in the form of recipes. It also allows viewing of alarm information in case of equipment abnormalities. The system access is divided into administrator and operator channels: administrators can modify and save spraying parameters, while operators can only adjust them. Reserved interfaces are also provided for extended use.

Parameter Table of SX-90 Plasma Control Cabinet

2. Imported SG-100 Plasma Spray Gun

The SG100 plasma spray gun is a 100KW multi-mode spray gun widely used in thermal spraying applications. Its multi-functionality enables it to spray all types of current coatings, from high-density wear-resistant carbide coatings to thermal barrier coatings with controllable porosity.

Basic Data of SG-100 Plasma Spray Gun

Features

The unique design of the SG100 enables internal or external powder feeding, and material engineers can formulate a reasonable powder feeding mode according to coating performance requirements. In addition, the two internal powder feeding ports of the SG100 can be used independently; simultaneous use delivers higher spraying speed and enables mixed use of different materials in the plasma beam. The external powder feeding port can replace the internal ones, and internal and external ports can also be used in combination.

By adding accessories, the SG100 can be easily assembled into a 2086/2700 mode bore extension spray gun, and can also be transformed into a 90° SG-100 spray gun for spraying bores of different diameters to meet diverse needs. (See the figure for 90° SG100 plasma spray gun below.)

90° SG100 Plasma Spray Gun

One set of SG100 equipment can generally work continuously for about 200 hours. Under specific operating conditions, the service life of SG100 plasma spray gun components is up to three times that of other spray guns. Thanks to its fewer components and self-aligning design, the SG100 features quick and precise assembly, meeting the strict even harsh acceptance standards of GE.

Other features, including automatic calibration and wear parts with a longer service life, all reduce its operation and assembly costs. It can even operate at a power of 100KW.

Applicable Nozzles

The SG100 can be used in three spraying modes (subsonic, Mach I and Mach II), and different anode/cathode and gas distribution ring configurations can be selected according to different needs.

SG100 Plasma Spray Gun Cathode | SG100 Plasma Spray Gun Anode

Summary

1. Optional internal/external powder feeding modes (or mixed use) and multi-angle powder feeding to meet diverse requirements;

2. Long continuous working time;

3. Easy component maintenance, long service life of spray gun anodes and cathodes, and automatic calibration to reduce operation and assembly costs;

4. CE certified.

With low consumable costs, easy maintenance and long service life of key components, the SG100 is undoubtedly a cost-effective spraying tool.

3. Water, Gas & Electricity Safety Center

Special Note: Hydrogen (H₂) is a flammable and explosive gas, and mass flow meters are electrical components that may generate electric sparks, leading to combustion and explosion risks. Therefore, our independently developed and manufactured Water, Gas & Electricity Safety Center provides safety protection for the equipment during operation.

Functional Features

A. Leakage detection system for three gases (H₂, N₂, Ar);

B. Gas leakage alarm device;

C. Quick cut-off device for air intake pipelines;

D. Spray gun backfire prevention and flameout device;

E. Leakage protection, cut-off and alarm device;

F. Current overcurrent protection device;

G. Voltage overvoltage protection device;

H. Water flow and leakage pressure sensing device;

I. Water temperature overhigh warning and shutdown system;

J. Dust concentration monitoring, alarm and shutdown device.

4. Plasma Inverter Power Supply (SX-90)

The inverter chopper power supply provides DC power for the spray gun and adopts dual-mode IGBT modules. The modules can operate in single or dual mode to reduce failure rates, with intelligent module control and water-cooled electrical modules. It features soft arc starting, small size, high efficiency and low power consumption. The air cooling + water cooling heat dissipation method ensures excellent heat dissipation performance and stable continuous operation for a long time, making it the most outstanding plasma power supply in China at present.

Parameter Table of Main Power Supply for SX-80 Plasma Spraying System

5. Water and Electricity Transfer Box

The transfer core of the entire spraying system, which connects the power supply, control cabinet, heat exchanger and spray gun together.

It mixes the water and electricity of the plasma equipment and delivers them to the spray gun, and at the same time provides the high-frequency pulse voltage required for spray gun arc starting, and detects the spray gun return water temperature and cooling water pressure. It is light and flexible for easy moving, with excellent arc starting performance, reducing the instantaneous current impact during nozzle arc starting.

Parameter Table

4. Powder Feeder

Technical Advantages of the Newly Upgraded Intelligent Dual Powder Feeding System

1. Adopts PLC and touch screen for parameter setting, digital display of powder feeding parameters, and precise control of powder feeding accuracy and speed.

2. The system includes two sets of independent powder feeding devices: the large tank has a capacity of 6.0L with scraper-type conventional powder feeding (speed up to 150g/min); the small tank adopts drum-type powder feeding, suitable for feeding various ultrafine powders and hard-to-feed mixed powders.

3. Adopts a fully enclosed plastic-steel cabinet to avoid interference from external environmental factors such as temperature and humidity; the panel is equipped with a transparent glass door for clear observation of powder feeding status.

4. Optional powder feeding vibration device, powder tank heating device and metering and weighing device.

Functions of SX-80 Plasma Powder Feeder

One single-barrel (or dual-barrel) powder feeder is provided.

Applicable powder particle size range: 5~200μm (0.01-0.25 mm); powder feeding repeat error is less than ±1%.

The two barrels can feed powder simultaneously with a feeding rate of 120~250g/min.

It is a device for storing spraying powder and delivering it to the spray gun according to process requirements. The main gas of the spray gun is used as the powder feeding gas. The spraying powder is delivered to the outlet of the powder feeder by the rotation of the powder feeding scraper disk, and the powder leaves the powder feeding barrel together with the gas pressure and enters the spray gun. The powder feeding speed can be adjusted by the potentiometer on the control cabinet panel.

Parameter Table of Powder Feeder for Plasma Spraying System

7. Cooling Unit (Refrigeration System)

Technical Parameters and Configuration of Air-Cooled Chiller

Model: LYK-20S

Notes:

1. Refrigerating capacity is based on: chilled water inlet/outlet temperature 12℃/7℃, cooling water inlet/outlet temperature 30℃/35℃.

2. Operating range: chilled water temperature range 5℃ to 35℃; chilled water inlet/outlet temperature difference 3℃ to 8℃. Used in an environment with condensation temperature not higher than 35℃.

3. Unit conversion: 1kw cooling capacity = 860kcal/hr; 1RT = 3024kcal/hr; 1kcal/hr = 3.969BTU/hr; 1 metric horsepower (HP) = 0.735KW.