Plasma Spray System
　　Whether you need simple, reliable spray equipment or sophisticated, robust computerized plasma controls, we have a solution for you. We offer a broad range of plasma guns that operate at power levels ranging from 2 kW to 100 kW and are versatile for most ID and OD applications. Critical-orifice gas flow controlled to mass-flow, PLC controlled and easy-view touch screen control digital shows spray parameters would be your option. For more information on our plasma system, please view the linked below.

　　1.Low Power Consumption and High Efficiency plasma spraying
　　2.High enthalpy bi-anode plasma torch
　　3.ID plasma torch

Low Power Consumed and High Efficiency Plasma Spraying (LE-15)
　　Conventional atmosphere plasma spraying applied such powder-injecting method shown as the figure below. Powders were vertically injected into the plasma jet from the outside of the nozzle by carrier gas. Plasma spraying applying this powder-injecting method exists following disadvantages.
　　1.Energy consumption is large (40-200 kW) but deposition efficiency of powder is low.
　　2.High temperature of the plasma jet brings great heat effect on the substrate, resulting in the thermal deformation and oxidation of the substrate. Lengthening spray distance, however, leads to an inferior quality of the coating due to the oxidation of the powder.
　　3.Serious electrode erosion exists when using nitrogen or hydrogen as working gas under a large arc current.
　　4.The equipment is very huge and noise pollution and ultraviolet pollution are all serious.

Conventional plasma spraying,
In order to overcome such problems we have designed and manufactured a high-efficiency and low-power-consumption plasma spraying system containing such advantages as below:

Low power consumed plasma spray system
FEATURE
　　1.Sprayed powders are injected into the region in front of the cathode tip from inside of the torch. Powders were heated and accelerated effectively because their flight contrails consist with plasma jet flow.
　　2.Power consumption ranges from 2.5 to 10 kW (50-200A, 50-70V) and deposit efficiency of the powder can get up to 70% for most commercial powder.
　　3.Heat effect on the substrate is significantly decreased and spray distance can reduce to 30-80mm. The torch has a small size and can be applied to spray the internal surface directly, given the inner diameter is larger than 140mm.
　　4.Spraying operation is simple. Do not need acoustic treatment for the low noise in the spraying process (<85dB). DC power supply and gas flow controller can be integrated together. All these advantages make it easy to operate in industrial locale or be set in laboratory.



Internal powder feed lower power plasma spraying

Internal powder feed lower power plasma spraying

Spraying parameters for some materials

  Materials

Spraying parameters

Properties of the coatings

 Current (A)

Voltage (V)

Gas

Powder feed(g/min)

Porosity (%)

 Hardness (Hv.3)

Al2O3

100

70

Ar/H2

35

3

>1200

ZrO2-8Y2O3

150

60

Ar/H2

40

3-5

500-700

Cr2O3

150

70

Ar/H2

40

2-4

1400-1600

WC-14CoCr

70

50-60

Ar/N2

70

 5

 600

NiCrAlY

50

60

Ar/H2

50

 3

 320
High Enthalpy Bi-anode Plasma Spray (HP-100)
　　　Plasma thermal efficiency is a key factor for reducing the coating cost which was influenced by the configuration of the gun, the thermal efficiency most commercially employed plasma torch are lower than 40% such as SG-100，F4 or Metco 9M and owing to instable arc jet by the movement of arc root resulting a poor quality of the coating. Here, we offer HP-100 Plasma Gun for you to increase thermal efficiency and improve the quality of the coating.
FEATURE

　　1.The torch consists of a cathode and two anodes nozzle in different distance to the cathode tip. The arc can be lengthened to work in a very high voltage up to 200V. In the input power up to 100kW, its efficiency is much higher than conventional torches.
　　2.The voltage fluctuation is little, the power output is steady, and the sprayed coating is more uniform with lower porosity rate.
　　3.Super-sonic plasma jet increased the spraying efficiency and the coating quality. The torch can compare with three-cathode plasma torch in the coating quality.
　　4.The torch works in a high voltage and low current, which prevents the appearance of copper melting in the anode nozzle
　　5.The torch is suitable to spray high-density coatings such as the coating of laser engraved anilox roll with an efficiency 20% higher than that of Metco 9MB.
　　6.H2,N2 or air can be introduced as working gas
　　7.Size: Ф70x120mm weight: 1kg
HP-100 plasma jet
Thermal efficiency in the plasma jet

ID Plasma Spray Gun
The torch was specially designed for the spraying of internal surface.
　　1.ID Plasma-60: mini-type of conventional plasma torch that can spray the internal surface directly, given the diameter of bore is large than 60mm.
　　2.ID Plasma-35: the torch and the plasma jet have an included angel of 45°. The torch can spray the bore with a diameter as small as 35 mm.
　　3.Standard connecting length of torch is 450 mm, which can be lengthened to 1000mm.
　　4.Its power supply, water-cooling system and powder feeder are all interchangeable with low power consumption and high efficiency plasma spraying
　　5.Inner-powder-feeding is applied. Input power ranges from 2 to 20 kW. The spraying has high depositing efficiency.
ID Plasma-35
ID Plasma-60
Plasma Controller

The system applied most advanced mass flow controller to adjust mass flow rate and composition of the working gas. Man-machine dialog system comprising a touch-screen computer and PLC simplifies the spraying operation. It main properties are stated as below:
The controller has functions of auto-monitor water temperature, water pressure, gas-flow rate and gas pressure, auto-alarm and auto-stop.
Spraying parameters are digitally displayed. Programmable control can simplify the spraying operation and guarantee the coating quality. Import electronic components make the control advanced in the world.
Manual or automatic operation is selectable.
A on-off switch is installed closed to the torch to realize remote control.
　　
 Cooling System

Cooling system, mainly consisting of a stainless water pump and a compressor, applies deinonized water as cooling medium and Freon as coolant. It provides the spraying torch high-pressure and constant-temperature cooling water to guarantee the long-term running of plasma spraying.
Powder Feeder

Electronic controlled powder feeder with high precision can keep the error of powder feed rate under 2g/min in a maximum powder feed rate of 150g/min. Powder feed rate is digitally displayed and the remained powder can be observed from the window on the top of the feeder. Import apparatus were employed in the central part of the feeder to keep powders following into the torch smoothly. Powder feed ratio is independent of the carrier gas flow.
DC Power Supply

Closed-loop power supply adopted silicon-controlled rectifier to ensure a constant current output. Stability control of the arc in low power can minimize the voltage fluctuation. Integration of high-voltage and high-frequency generators realized miniaturization of the equipment. overload protection guarantees the safety of the spraying system. The arc current is set up in the screen and the set value is obtained automatically after the arc is ignited, which makes the system immune to the impact of start trigger current.
Application of Plasma Spraying
Coatings of NiCrAlY(under coat),Al2O3(top coat)for wear resistant at elevated temperature.
Spindle with WC-12Co coating.
Coating of mechanical seal
ZrO2-8Y2O3 coating on the laminose alumina.
   
Coating of Al2O3
Coating of mechanical seal