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Spraying equipment SPRAY EQUIPMENT
SX-LP60 Cold Spray System
Cold spraying (CS) is a novel thermal spray technology that operates on the principles of aerodynamics. It utilizes high-temperature, high-pressure gas to carry powder particles axially into a Laval nozzle within 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, causing plastic deformation and depositing onto the substrate surface to form a dense coating.
Product Description
SX-LP60 Cold Spray System
Cold spraying ( CS is a novel thermal spraying technique that, based on aerodynamic principles, uses high-temperature, high-pressure gas to carry powder particles axially into the Laval nozzle of the spray gun, generating a supersonic flow. After being accelerated by the spray gun to speeds ranging from 500 m/s to 1200 m/s, the powder particles impact the substrate in a fully solid state, causing plastic deformation and depositing onto the substrate surface to form a dense coating.
It can be used to prepare coatings with high thermal conductivity and high electrical conductivity; has minimal thermal impact on the substrate; exhibits extremely slow grain growth (potentially maintaining a nanoscale microstructure); closely resembles forged microstructures (with higher hardness compared to conventional coatings); and features stable phases and chemical composition. Coating thickness can reach 10 cm or more.
Its main advantages include a coating that is virtually free of oxides, excellent density, high deposition efficiency, and broad applicability to various materials.
It is applicable to plastic-deformable metal powders and composite powders containing plastic-deformable material components; the spraying range of metals extends from low-melting-point zinc to high-melting-point titanium and niobium.
Technical parameters for cold spray equipment:
Reserve a material feeding port and a powder feeding port.
Available working gases: nitrogen, helium, or mixed gases.
Work pressure: 0-3.5Mpa
Operating temperature: 0-400℃
Gas flow: Nitrogen, Helium -2500L/min
Powder feed rate (copper powder): 20-200g/min
Powder particle size: 1-50um
Jet range: 5-50mm
Power consumption: 15-55KW
1. Spray Gun & Nozzle
The core of the cold spray system is the spray gun and its Laval nozzle.
Our company uses a variety of precision manufacturing proprietary technologies to produce a series of high-precision standard nozzles. The spray gun with nozzles has passed long-term operational tests to meet the cold spray production requirements of manufacturing and R&D. The standard nozzle adopts an integrated structure, enabling quick nozzle replacement as shown in the figure on the right.
- The inlet side of the spray gun is equipped with a main gas inlet, powder feeding gas inlet, pressure measurement and temperature sensors, meeting the control requirements of gas flow, pressure and temperature for production.
- Maximum power of the heated spray gun: 22.5 kW.
- High-temperature resistant materials are used to ensure a long service life of the spray gun and nozzle.
- The spray gun, nozzle and cooling accessories can be selected according to different cold spray processes and materials.
- The main gas metal high-pressure hose (resistant to 800℃, 4.5 MPa) is wrapped with thermal insulation materials to avoid heat loss, covering the hose and connectors.
- The powder feeder delivers powder through a fine high-pressure hose with a metal inner lining.
- The main gas and powder-laden feeding gas are fully mixed and preheated in the pre-mixing chamber of the spray gun, then injected into the Laval nozzle and accelerated toward the substrate.
2. Main Control Cabinet & Operation Control Display
- The left cabinet houses the main power supply control, heating control power supply and power regulator. Specially developed for cold spray applications, the heating control power supply and power regulator deliver an output power exceeding 50 kW, and are equipped with ventilation fans to meet long-term heat dissipation requirements.
- The right cabinet is equipped with a Siemens Simatic S7-300 CPU, I/O modules, control relays and terminal blocks, along with circuit breakers and power supplies for 24 V and 220 V.
- The right cabinet also manages three gas paths: main gas (nitrogen), auxiliary gas (helium), and powder feeding gas (nitrogen). Each path is configured with a mass flow controller and safety valve, which opens slowly and closes rapidly. In case of failure, sudden pressure drop or power outage, the system shuts down immediately. The control unit emits an audible alarm and displays error messages.
- Independent nitrogen and helium control loops meet the requirements of single-gas and mixed-gas operation. The mass flow controller settings for main gas, auxiliary gas and powder feeding gas can be adjusted to suit different gas requirements.
- The operation control display uses a 10-inch touchscreen to control the entire system. The touchscreen integrates interfaces for connection to external computers, printers and networks.
Main Control Cabinet Technical Parameters
- Voltage: 380 VAC, 50 Hz, three-phase five-wire
- Input Power: 55 kW
Gas Requirements
| Gas | Flow Rate | Pressure | Pressure Fluctuation (30s) |
|---|---|---|---|
| Nitrogen | 2500 L/min | 4.5 MPa | 0.01 MPa |
| Helium | 750 L/min | 4.5 MPa | 0.01 MPa |
| Powder Feeding Gas (Nitrogen) | 250 L/min | 4.8 MPa | 0.01 MPa |
- Gas Purity: Nitrogen 97.7%, Helium 99.995%
Parameters Controlled & Monitored on the Display Screen
- Powder consumption
- Gas consumption
- Main gas temperature (heater outlet gas temperature)
- Heater heating element temperature
- Heater control power supply output power
- Main gas pressure
- Powder feeding gas consumption
- Powder feeding gas pressure
- Nozzle gas temperature
- Nozzle pressure
Main Gas Temperature Regulation
- The heater is made of high-temperature resistant materials and placed in a thermal insulation chamber, which ensures continuous operation without overheating the outer shell.
- A closed cooling system prevents electrode overheating by transferring heat from the electrodes to a heat exchanger, maintaining constant temperature control of the electrode cable assembly.
- The main heater is suitable for continuous production.
Main Heater Technical Parameters
- Heating Power: 22.5 kW
- Heating Capacity (at 4.5 MPa, nozzle diameter φ2mm):
| Gas | Maximum Temperature Rise | Remarks |
|---|---|---|
| Nitrogen | 850℃ | - |
| Helium | 850℃ | - |
3. Powder Feeder
- Powder-laden gas flows into the spray gun through a flexible hose and is injected into the main gas jet stream. The powder feeding gas entering the nozzle compression chamber without passing through the preheating chamber is controlled by a mass flow controller, ensuring stable flow, high powder feeding accuracy and uniform coating. The volumetric metering method minimizes changes in powder feed rate throughout the spraying process.
- Powder feed rate repeatability complies with DIN EN 1395-7 standard.
Powder Feeder Technical Parameters
| Model | DWPF-5 | DWPF-1 |
|---|---|---|
| Powder Feed Rate (Standard Copper Powder) | 20~250 g/min | 20~250 g/min |
| Powder Particle Size | 1~150 μm | 1~150 μm |
| Effective Powder Hopper Volume | 4.44 L | 0.37 L |
| Maximum Stirring Speed | 30 rpm | 30 rpm |
| Maximum Powder Feeding Gas Pressure | 4.8 MPa | 4.8 MPa |
| Control | Main Control Cabinet | Main Control Cabinet |
Schematic Diagram of the Overall Layout of the Cold Spray System Equipment
Schematic diagram of the main heater
Schematic diagram of a spray gun nozzle
Schematic diagram of the powder feeder
Prev: SX LP-20 Supersonic Cold Spray Equipment
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