Thermal spray gun, a combination of film coating methods in which finely distributed metallic or nonmetallic elements are collected in a molten or semi-molten state to form a coating. The thermal spray coating element may be in the form of powder, ceramic rod, wire, or molten materials. The thermal spray gun process is predicated on an equivalent method of heating and melting a feedstock material, usually within the sort of powder or wire before accelerating it to a high velocity then allowing the particles to strike the substrate surface. The main feature of all thermal spray gun coatings is their lamellar grain structure resulting from the rapid solidification of small globule particles, flattened from striking a chilly surface at high velocities. The coating is made when many particles are deposited on top of every other. These bits are mechanical or metallurgical attached to the substrate. There are various types of thermal spray guns available by which different coating of certain materials can be coated on the substrate.
Types of Thermal Spray Gun
- Wire flame spray gun
- Powder flame spray gun
- Electric arc spray gun
- Plasma arc spray coating
- High-velocity oxy-fuel (HVOF) spray gun.
1. Wire Flame Spray Gun
Wire Flame spray gun is a thermal spraying technique that uses an oxygen-fuel gas flame as a heat source for melting the wire (coating material). Here, Compressed air is used for atomizing and propelling the material to the workpiece. The method of flame spraying using wire is known as metalizing wire spray or wire flame spray.
2. Powder Flame Spray Gun
The powder flame spray gun method uses self-flux alloys in powder patterns as its spraying materials and oxygen or acetylene as its heat source. Self-flux alloys involve alloys with a low melting time of around 1,000?, containing nickel and/or cobalt as the base metal, and boron and silicon as its fluxing materials. After the sprayed coating reaches the specified thickness, it's applied fusing treatment to hide open pores and forms an alloy layer with the substrate, which provides high adhesiveness like welding. In the fusing and hardening process, the coating puts a solid layer of borides and carbide, which combines excellent wear resistance to the coating. In addition to those features, the coating has outstanding resistance to corrosion of most chemical solutions, erosion and cavitation erosion, and hot hardness characteristics.
3. Electric Arc Spray Gun
In the electric arc spray gun method, 2 wires of the material turned on electricity at the nozzle of spraying gun square measure liquefied with short-circuited arc, then the liquefied materials square measure fine-grained and sprayed onto the themes with compressed gas. Electric arc spraying and flame spraying square measure jointly known as wire processes. All metals and alloys in wire kind square measure out there for arc spraying material.
4. Plasma Arc Spray Gun
The plasma spray coating method involves spraying a substrate with melted or semi-molten material to make a tough coating that protects against oxidization and corrosion wear caused by environmental and operative conditions. The coatings are dense and powerful, creating plasma coating a positive possibility for equipment protection and refinishing. Plasma spray coatings are applied to employ a high-temperature method that involves injecting fine coating material into a plasma flame. The fabric is rapidly heated and so accelerated toward the substrate. Once it reaches the surface it begins to chill, forming a tough coating on the substrate. The high temperatures concerned in plasma coating permit the use of ceramics and different materials that have a high freezing point.
5. High-Velocity Oxy-Fuel (HVOF) Spray Gun
High-Velocity Oxygen Fuel (HVOF) coating, a thermal spray coating method used to improve or restore a component’s surface properties or dimensions, therefore extending instrumentation life by considerably increasing erosion and wear resistance and corrosion protection. Molten or semi-molten materials area unit sprayed onto the surface by the heat(high temp.), the high-speed gas stream, manufacturing a dense spray coating which may be ground to an awfully high surface end. The utilization of the HVOF coating technique permits the appliance of coating materials like metals, alloys, and ceramics to supply a coating of outstanding hardness, outstanding adhesion to the substrate material, and giving strong wear resistance and corrosion security.
Thermal Spray Gun Advantages
- Reduced Cost:- The cost of repairing the component is a smaller amount than buying a replacement one. Often, the coating actually lasts longer than the first material used.
- Low Heat Input:- Among some exemptions, the thermal spray process drops the component’s thermal past alone.
- Versatility:- Almost any metal, ceramic, or plastic is often thermally sprayed.
- Thickness Range:- Depending on the fabric and spray system, coatings are often sprayed from 0.001 to quite 1 inch thick. The thickness typically ranges from 0.005-0.1 inch.
- Processing Speed:- The spray rates range from 3-60 lb/hr counting on the fabric and therefore the spray system. Typical rates for material application are 1/2 -2 lb of fabric per square foot per 0.01-inch thickness.
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