Plasma Spray

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Plasma is the term used to describe gas which has been raised to such a high temperature that it ionises and becomes electrically conductive. In the case of Plasma spraying, the plasma is created by an electric arc burning within the nozzle of a plasma gun and the arc gas is formed into a plasma jet as it emerges from the nozzle. Powder particles are injected into this jet where they melt and then strike the surface at high velocity to produce a strongly adherent coating. Almost any material can be sprayed including metals, ceramics and plastics. The workpiece remains cool because the plasma is localised at the gun.

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PS50M Plasma Spraying System

While higher power systems are available, ranging up to 250 kW in some cases, it is a fact of life that probably 90% of all plasma coatings are deposited using 40 kW or less power. The Metallisation PS50M system is designed to meet the needs of this general market, as well as being suitable for aerospace applications, by providing a robust, easy to use, and inexpensive to run system.

The PS50M uses state of the art mass flow controls to precisely meter the flow of gases to the pistol. These gas controls are completely segregated from the electrical system and are freely vented to prevent any possibility of gas build up, which may be a concern when using hydrogen as a second gas. In addition the Metallisation system can be operated using Nitrogen as a secondary gas, avoiding any of the risks associated with Hydrogen.

The Metallisation PS50M system comprises six main elements:

• PLA5000 Pistol
• PS50M CU Control Unit
  (Optional Control Unit Pedestal)
  
• Refrigerated Heat Exchanger
• PF-MET Powder Feeder
• PS50M IPS PU Power Supply
  (Optional Control Unit Pedestal)

The whole system is integrated to provide reliable and reproducible results with simple to understand operation and a long life. Interconnections between the various components have been designed such that it is almost impossible to make a wrong connection. The control connection between the control panel and the gas controls are contained in a single umbilical cable. Hoses are color coded for ease of recognition and safety.

The PS50M guides the operator through the straightforward setting up and control of the system. An enunciator advises of the current status including the condition of the safety interlocks.

PS50M IPS & PS50M IPS-A Inverter Power Supply Units

This unit is an inverter power supply which gives a maximum power output of 50Kw @ 1000 Amps, with an open circuit voltage of 95V.

The D.C Power Supply Unit is designed to run off normal factory three-phase electrical supplies. This unit is capable of either medium or high current operation to enable it to be used with a variety of gases. Current is continuously adjustable from the control console.

Weight: 105Kg
Supplies: 3 Phase 380/480V 80A Phase
Dimensions: L 775mm x W 445mm x H 640mm

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Applications for plasma sprayed coatings can be found in all industries, ranging from scuff resistant coatings on piston rings, to thermal barriers on turbines and abrasion resistant coatings in the textile and paper industries.

Typical examples are:

• Turbocharger bearing areas running at 80,000 r.p.m.
• Mechanical seals and gland packing areas subject to corrosion and third body abrasion.
• Aircraft engine burner cases subject to flame impingement.