The Combustion Wire Flame Spray Process is basically the spraying of molten metal* onto a surface to provide a coating with the help of a gun. The material in wire form is melted in a flame (oxy-acetylene flame most common) and atomized using compressed air to form a fine spray. When the spray contacts the prepared surface of the substrate material, the fine molten droplets rapidly solidify forming a coating. This flame spray gun process conducted out perfectly is called a "cold process" (relative to the substrate material being coated) as the substrate temperature can be kept low during processing avoiding damage, metallurgical changes, and distortion to the substrate material.
The metal spray gun is a gun in which the feedstock is put inside the gun where feed is molted down. This is being sprayed on the surface of the subject. A Metal spray gun is used for the thermal coating process which uses a single wire, cord, and powder as a raw material for coating. This feed material is melted in an oxygen fuel gas flame or with the help of an electric arc. This molten metal is atomized by compressed air and impinges on the surface of the substrate.
In this process, the basic principle of the heat source is the same as wire spray gun except that powders or Rod are fed through a flame and propelled by high-velocity oxygen or air onto a substrate Compressed air is concentrated around the flame spray gun, atomizing the molten material into fine spherical particles which propels these particles at high velocity onto a substrate. In this process, we utilize two metallic wires that are electrically charged with opposing polarity for the coating feedstock. In this process, we feed the spray material in wire form into a fuel gas-oxygen flame where it is melted by the heat (temperature up to 3000°C) of that combustion. This will cause mobility to them to throw a molten arc between each other. We will next inject inert gas or high-velocity air to trigger the atomization of the now-molten material and propel onto the substrate to form the coating.
Wire flame spray Gun Metco 12E (Metco Metalizing Gun) uses a single wire that is entered in a jet flame. The temperature is close to 10,100 K, melting the wire. The air stream from the jet atomizes the molten particles, falling them onto the substrate. The technological parameters, such as feedstock, flame spray gun gas composition, and flow rate, and energy input, play an important role in the relationship between the particles and the substrate.
The copper spray metalizing (copper spray gun) is used for a thermal spray of copper over the surface of the substrate. The copper coating thermal spray gun is used for coating after the sandblasting process. Before the copper spray metalizing with the copper thermal spray gun surface finishing is done with the sand blasting machine.
The zinc spray gun is used for the coating process on the surface of the substrate to prevent rust. In a zinc spray gun, zinc and zinc alloys are sprayed over the surface of the component after melting it. To melt the zinc wire and zinc wire alloys oxygen and acetylene are used with compressed air.
The aluminum spray gun is used for the coating process with aluminum wire on the surface of the substrate to avoid the risk of rust and oxidation. Aluminum wire is sprayed in an aluminum spray gun is sprayed across the surface of the component after melting it. In this process to melt, the aluminum wire oxygen and acetylene, or sometimes LPG gas is used with compressed air. Sometimes Oxygen and acetylene melt the aluminum wire and compressed air is used to atomize the molten metal or semi-molten metal on the surface of the substrate. In aluminum spray gun rollers are used to push and pull the wire in forward and backward direction.
There are some spare parts used in a flame spray gun and Wire comes first in the siphon plug and then in the blasting nozzle, it completely holds the wire. The siphon plug should be cleaned occasionally. Wipe out the grooves and clean out the holes with the proper size wires from the cleaning wire kit. Do not wash the o-rings with a cleaning solvent. Examine them for damage and replace them if required. Do not stretch new o-rings more than necessary. Lubricate all o-rings before reassembling the siphon plug.
The gas flow meter is a highly accurate and reliable instrument for regulating and measuring the flow of both oxygen and fuel gas in a manual powder and wire thermal & arc spray gun. It has precision needle valves which are actuated by adjustment knobs on the front panel that controls the movement of gas through the meter. Flow unit readout is provided in both Metric (NLPM) and U.S. Customary (SCFH) units.
Boiler Tube Coating is a must for increase the life of boiler tubes. The Thermal spray gun on boiler tube coating technology to give high-temperature wear & corrosion protection coating on the boiler tubes. A broad type of coating materials such as mild steel or other metals or alloys is available. Therefore a proper coating can be utilized on the tubes to combat the specific queries without changing the tube material.