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Thermal Spraying
Thermal Spraying
In recent years, thermal spraying has become increasingly important, both in the manufacturing of new parts and in the repair of existing parts. Thermal spraying is a surface coating technology which combines a variety of positive characteristics. Numerous base and coating material combinations High grade materials coating onto lower cost base materials Repair instead of replace expensive components Many thermal and mechanical energy process combinations for just the right effect.
Two types of energy are required to spray on a coating: thermal and kinetic. Both of these energies are generated trough gases. The move towards dense layers has resulted in equipment where the kinetic energy rises in line with reduced thermal input. The evolution of high-velocity thermal spray methods has led to Cold Gas Spraying where the surface material is propelled and plasticized as it hits the substrate, thus combining with the basic material. This procedure is similar to explosion welding. Spraying is a real money saver and easy to carry out. For an exact surface finish, all you need is a flame, an electric arc/plasma or laser and the right coating material. It improves resistance to wear, corrosion and heat. You can even use this process to increase or decrease friction or change the electrical properties of the surface. Damaged surfaces can be repaired and faulty parts can be redimensioned. In most cases, the surface can easily be post treated.
In the plasma transferred arc (PTA) process, the surface of the work piece is surface melted. A high density plasma arc serves as the heat source and the metal powder as the surfacing material. The arc is formed between a non-consumable electrode and the work piece. The plasma is generated in the plasma gas, between the central tungsten electrode and the water-cooled anode. The entire process takes place in the atmosphere of a shroud gas
Cold Spray
In cold spraying, the kinetic energy (particle velocity) is increased and the thermal energy reduced. In this way it is possible to produce spray coatings which are virtually free of oxides. Laboratory investigations show that cold spray coating have extremely high bond strengths and are exceptionally dense. In cold spray processes the powder requires a temperature of only a few hundred degrees. Coated substrates reveal no material changes due to thermal influence. Applications are still being developed. Current uses are found in the automobile industry, anti-corrosion protections and electronics, for example
Supply System for Cold Spray Applications, DESY 300/100 In this system, the nitrogen is compressed up to 4000psi (275 bar) in the liquid state. After the DESY 300/100, the liquid nitrogen is evaporated in a high pressure evaporator. For pressure requirements over 4000psi, an additional booster operated with very low energy consumption can be used. Main advantages of the system are: Very low energy requirements due to cost-effective liquid compression The DESY 300/100 pumps exactly the quantity of nitrogen which is required by the user, even when strong fluctuations in demand occur Unchangingly high quality of the injection moulded parts because of the very pure and oil-free nitrogen
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