Combustion powder spray is suitable for maintenance, repair, restoration of machine parts, as well as abradable coatings used for clearance control applications.
It is a relatively flexible process in that it can be used to apply metals, alloys, carbides, polymers and even some ceramic powders.
Key benefits of this process
- Equipment investment costs can be low
- Greater flexibility of feedstock choices compared to Combustion Wire Spray
- Coatings can be machined to final dimensions and finish
Typical applications
- Crank shafts
- Sucker rod couplings
- Gas turbine shrouds for clearance control
- Dimensional restoration of worn or mismachined parts
Process description
The feedstock material, in powder form, is continually fed into a fuel gas-oxygen flame where it is then melted by the heat of combustion. For most combustion powder spray systems, the powder is fed via a feeder using a carrier gas to transport it to the spray gun. The mixed gasses accelerate the melted particles onto the prepared workpiece surface where it rapidly solidifies to form a coating.
Process basics
- Heat source: combustion
- Material: powder (metals, alloys, metallic blends or ceramics, )
- Flame temperature: max. 3 100 °C (5 600 °F)
- Particle velocity: up to 50 m/s (165 ft/s)
- Approximate application rate: 35 to 150 g/min (4.5 to 20 lb/h)
