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Guangzhou Sanxin independently develops cold spray equipment.

Guangzhou Sanxin independently develops cold spray equipment.

Cold spraying (CS) is a novel thermal spray technology that, based on aerodynamic principles, uses high-temperature, high-pressure gas to carry powder particles axially into a Laval nozzle of 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.

Category:

Coating spray equipment

Cold spray equipment

Industry Application Classification

Key words:

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Product Description

SX-LP80 Cold Spray System of the Type (cold spray system)

Cold spraying ( CS ) is a new type of thermal spraying technology that, based on aerodynamic principles, uses high-temperature, high-pressure gas to carry powder particles axially into the Laval nozzle of the spray gun. Laval nozzle ) Generates supersonic flow, and powder particles are accelerated by the spray gun to... 500 m/s – 1200 m/s Subsequently, upon impact with the substrate in a fully solid state, plastic deformation occurs, and the material is deposited onto the substrate surface to form a dense coating.

It can be used to prepare coatings with high thermal conductivity and high electrical conductivity; causes minimal thermal impact on the substrate; exhibits slow grain growth (potentially maintaining a nanoscale microstructure); closely resembles forged microstructures (with higher hardness compared to conventional coatings); features stable phases and chemical composition; coating thickness can reach... 10cm The above.

Principle of Cold Spray

Cold spraying ( CS ) It is a new type of thermal spraying technology, from the 20th century. 80 In the mid-1980s, by the Soviet Institute of Theoretical and Applied Mechanics Papyrin Proposed by him and his team, it is based on aerodynamic principles and uses high-pressure gas to carry powder particles axially into the Laval nozzle of the spray gun. ( Laval nozzle ) The nozzle generates a supersonic airflow, and powder particles ( 1-50um ) Accelerated to by a high-speed airflow 500 m/s–1200 m/s Subsequently, upon impact with the substrate (such as metal, ceramic, or glass) in a fully solid state, the material undergoes plastic deformation and is deposited onto the substrate surface, forming a dense coating. The gas typically used is nitrogen, ammonia, or a mixture of both.

Advantages of cold spraying

What distinguishes cold spraying from other spraying methods is that it does not melt the coating material; instead, it relies on a physical process for shaping. Compared to arc spraying and plasma spraying, HVOF Compared to spray coating, cold-spray coatings have virtually no oxides and feature a dense coating structure. The electrical conductivity of cold-spray pure copper coatings can reach that of cast bulk materials. 90%, and the flame-sprayed coating and HVOF The electrical conductivity of the spray-coated layer is lower than that of the as-cast bulk material. 50%。

* High deposition efficiency (for certain materials, it can reach) 95% Above); low oxide content;

* Coating density:

* Coatings with high thermal conductivity and high electrical conductivity can be prepared (with thermal and electrical conductivities reaching those of the corresponding bulk materials). 90% The above);

* Has a small thermal impact on the substrate;

* Grain growth is negligible (and the nanoscale microstructure can be maintained);

* Close to the forged microstructure (with higher hardness compared to conventional coatings), the spraying process does not cause changes in phase or chemical composition.

* Different nozzle shapes are available, and the cross-sectional area of the spray jet can... 20 mm — 60 mnm ；

* Short spray distance (can be less than 10mm );

* Coating thickness can reach 10cm Above;

- The powder is collectible and reusable (high powder utilization rate).

Cold spray application Use

Metal powders that undergo plastic deformation, as well as composite powders containing components of materials capable of plastic deformation, are suitable for cold spraying. The range of metals that can be sprayed extends from low-melting-point zinc to high-melting-point titanium and zirconium. Like thermal spraying, cold spraying is carried out in a soundproof chamber equipped with an air-suction and dust-collection system. Its noise level is significantly lower than that of thermal spraying. HVOF Spraying.

The cold spray system consists of the following components: the main control cabinet and operator control display, the main heater, the spray gun and nozzle, the powder feeder, and the gas piping circuit.

Overall layout diagram of cold spraying

Schematic diagram of cold spray structure

Main Technical Parameters of Cold Spray Equipment

Available working gases: nitrogen, helium, or mixed gases.

Work pressure: 0-3.5Mpa

Operating temperature: 0-950℃

Gas flow: Nitrogen, Helium -3000L/min

Powder feed rate (copper powder): 20-200g/min

Powder particle size: 1-50um

Jet range: 5-50mm

Power consumption: 15-55KW

1 Control cabinet and operation control display screen

* The left cabinet houses the main power control, heating control power supply, and power regulator. . The heating control power supply and power regulator, developed for cold spray applications, deliver an output power exceeding... 50 kW, It is also equipped with a ventilation and adjustment fan to meet long-term heat dissipation requirements.

* The right cabinet is equipped with main gas—nitrogen, auxiliary nitrogen, and powder-supply nitrogen. Each gas line is fitted with a mass-controlled flow controller and a valve. The valve is designed to open slowly under control and close rapidly. In the event of a malfunction, a sudden pressure drop, or power failure, the system will shut down quickly.

* The control unit emits an audible warning signal and displays an error alarm message.

* Independent nitrogen and nitrogen-control circuits meet both single-gas and mixed-gas application requirements. The mass flow rate control settings for the main gas, auxiliary gas, and powder-supply gas can be adjusted according to different gas usage requirements.

* The operation control display adopts 10 A Siemens touch screen controls the operation of the entire system. The touch screen features integrated interfaces for connecting to external computers, printers, and networks.

Operation Control Interface

* The main interface displays the system’s overall process.

* Monitoring data can be displayed on the operation interface, and the data will change accordingly when temperature and pressure fluctuate.

* During the work process, you can input and view the parameters of the components used.

Control cabinet

Main Control Cabinet Technical Parameters

• Voltage: 380VAC50Hz Three-phase five-wire

Input power: 55kW

Gas demand:

Gas	Gas	Gas	Pressure fluctuations ( 30s )
Nitrogen	2500L/min	4.5 MPa	0.01 MPa
Ammonia	750L/min	4.5 MPa	0.01 MPa
Powder delivery gas (nitrogen)	250L/min	4.8 MPa	0.01 MPa

Gas quality: Nitrogen 97.7%, Ammonia 99.995%

The operation screen displays the following control and monitoring parameters:

* Powder dosage

* Gas consumption

* Main gas temperature (gas temperature at the heater outlet)

* Heater heating element temperature

* Heater control power output power

* Main gas pressure

* Powder delivery gas flow rate

* Powder delivery gas pressure

* Gas temperature at the nozzle

* Nozzle pressure

2 Main heater

Main heater temperature adjustment

The main heater is the core component of the cold spray system. The main heater can... 1 One 2 Heat the main gas to within minutes. 800°C Left and right. Use protective technology to safeguard the heater components and prevent overheating damage.

The heater is made of high-temperature-resistant materials and is housed in an insulated chamber. The insulated chamber ensures continuous operation without causing the outer casing to overheat.

A closed cooling system prevents electrical overheating. The cooling device transfers the heat conducted to the electrical components into a heat exchanger, maintaining constant temperature control of the electrical cable assembly.

The main heater is suitable for continuous production.

Main Heater Technical Parameters

* Heating power: 22.5kW

* Heating capacity (in 4.5Mpa Next, nozzle diameter cm 2mm Temperature rise at the time)

Gas	Temperature rise ()	Note
Nitrogen	850°C
Helium	850°C

3 Spray gun and nozzle

An important component of the spraying system is the spray gun and its Laval nozzle. (Laval nozzle) Nozzle.

Our company employs a variety of manufacturing technologies to produce a series of high-precision, high-standard nozzles. Nozzle-equipped spray guns,

After extensive use and testing, it meets the production and research needs of cold spray processes. The standard nozzle features an integrated design, allowing for quick nozzle replacement. As shown in the figure below.

*The input side of the spray gun is equipped with a main air inlet, a powder-supply air inlet, and pressure- and temperature-sensing devices to meet the gas flow rate and heating power requirements for production. 22.5 kW»

*Uses high-temperature-resistant materials to ensure a longer service life for the spray gun and nozzle.

*Select the spray gun, nozzle, and cooling accessories based on the cold spray process and the material used.

*Main gas metal high-pressure hose (800°C 、 4.5 MPa) To prevent heat loss, wrap hoses and fittings with thermally insulating materials.

*The powder feeder delivers powder through a thin, high-pressure hose with a metal liner.

*The primary gas and the powder-laden carrier gas are thoroughly mixed and preheated in the spray gun’s premixing zone, then injected into the Laval nozzle and accelerated toward the substrate.

4 Powder feeder

Powder feeder

The powder feeder is specially designed for cold spray systems, and the powder feed rate is controlled by adjusting the speed of the rotary metering disc.

The powder in the powder delivery airflow enters the spray gun through a flexible hose and is then injected into the main gas jet stream. The powder delivery airflow, which passes through the preheating chamber and into the nozzle compression chamber, is controlled by a mass flow controller. , The flow rate is stable, which ensures excellent powder-feeding accuracy and results in a uniform and consistent coating. The volumetric metering system maintains a remarkably stable powder-feed rate throughout the entire spraying process.

Reproducibility of powder delivery DIN EN1395-7 Standard.

Powder Feeder Technical Parameters:

Model	DWPF-5	DWPF-1
Powder feed rate (standard copper powder)	20?9?1250 g/min	20?9?1250 g/min
Powder particles	1?9?1150 mm	1 ~ 150 Teacher
Effective volume of the powder bin	4.44L	0.37L
Stirring speed	30rpm	30rpm
Powder delivery gas pressure	4.8MPa	4.8MPa
Control	Main control cabinet control	Main control cabinet control