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Thermal Spray

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Thermal Spray

Thermal spray is a general term for a variety of industrial coating processes that use a heat source to melt metallic or nonmetallic materials and spray them onto a solid surface or component. It is used to resurface new or worn components so that their physical properties are enhanced or restored.

The gases used for thermal spray vary depending on the type of coating material and process used. The carrier gas used to feed wire or powder coating material is usually an inert gas such as argon or nitrogen. For arc spraying, air is used as an atomizing gas, and for the conventional flame spraying process and the relatively newer high velocity oxy-fuel (HVOF) spraying process, where combustion results from the reaction between oxygen and fuel, the fuel gases used can be acetylene, propane, hydrogen, propylene, propane, and natural gas, as well as liquid fuels such as kerosene. Whether utilizing high pressure cradles or liquid cylinders for thermal spray processing, the CONCOA 632 Series pressure differential enables higher flow capacities from multiple liquid or high-pressure cylinders feeding a common 6700 Series manifold regulator. Integration with the Altos 2 remote alarm with intrinsic safety barriers provides audible and visible notification of cylinder depletion at a remote location. For bulk pipeline applications, the rugged 6790 Series heavy-duty, high flow regulator, with a variety of outlet pressures and flow ranges, provides steady and reliable pressure control.

In any environment where large flows of inert gas are used, gas detection equipment should be employed. CONCOA oxygen deficiency monitors provide continuous detection and alert if high concentrations of oxygen-depleting gases should threaten respiration. For safe usage with flammable gases used in various thermal spray applications, CONCOA recommends integrating automated safety control features. The 580 Series flammable gas detectors permit continuous monitoring of combustible gases and notification before an emergency. Additionally, the CONCOA 585 Series emergency shut-off controller is designed to automatically shut down up to eight independent gas sources for maximum facility and worker safety.

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