Air Plasma Spray

 

Our Plasma Arc Flame Spray is a high-energy spray process that allows for applying High Volume and High Temperature Coatings. Surface treatments and hard facing with Tungsten Carbides or Chrome Carbides provide excellent wear properties for Aerospace as well as Industrial requirements. These coatings provide dense smooth coatings with industry standard Rockwell hardness values.

 

Other materials enhance surface requirements utilizing a Ceramic Coating. These materials include:

 

• Aluminum Oxide
• Zirconium Oxide
• Titanium Dioxide
• Chromium Oxide
• Magnesium Zirconate
• High Velocity Oxygen Fuel Spray

 

These coatings have low thermal conductivity combined with a high melting point that can be recommended as a Thermal Barrier Coating or resistant to wear by abrasive grains. They can resist particle erosion and cavitation in low, and with some materials, high temperatures such as combustion chambers of diesel and jet engines.

 

Additional exotic materials, such as Tantalum, Niobium, and Molybdenum, are best suited for the Plasma Flame Spray process as well. Practically, any powered material can be served through the metal spray processes to produce a variety of coatings for a myriad of Industry applications and engineered purposes.

 

Description of Plasma Flame Spray

 

Plasma Flame Spray coatings are used extensively for a wide range of industrial applications. The technique generally involves the spraying of molten powder through a plasma arc stream.

 

The plasma arc machine can best be defined as follows: a gun operating on a direct current, which sustains a stable non-transferable electric arc between a thoriated tungsten cathode and an annular water-cooled copper anode. An Inert gas (generally argon) complimented by a few percent of an enthalpy enhancing gas (such as hydrogen) is introduced through the electric arc in a swirling vortex fashion. The pressurized gases are ionized through the electric arc and exit the nozzle of the gun. The plasma arc flame, which axially rotates due to the vortex momentum, exits the gun effectively in excess of 15,000K for a typical dc torch operating at 40kW.

 

A variety of materials can be used for the Plasma Flame Spray process. Because of the high enthalpy energy ceramic materials can easily be sprayed with great success. The powder particles are accelerated and melted in the flame to the substrate surface being coated at high speeds from 100-300 M/sec. Upon impact the molten particles, coupled with the kinetic energy, undergo a rapid solidification that forms the coating deposit, which is built-up by successive impingement of these individual flattened particles or “splats”.

 

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