Newly upgraded SX-90 plasma spraying equipment

新升级的SX-90等离子喷洒设备的优势

广州三新金属科技有限公司生产的等离子喷涂系统具有以下显著优势：

1. SX-90等离子体控制柜由进口的美国Alicat质量流量计控制。

1. 装备进口SG-100等离子喷枪。

1. 特别配置了一个水、燃气和电力安全中心。

1. 主要核心零部件100%为进口品牌零件，消除了客户售后顾虑。

1. SX-90等离子控制柜由进口的美国Alicat质量流量计控制

SX-90等离子控制柜采用了迄今为止最先进的触控终端，简化了原有的按钮操作模式。作为整个SX-90等离子喷洒系统的控制核心，采用先进技术实现全系统自动控制。

美国进口的Alicat质量流量计在等离子体控制系统中采用的特点

通过Alicat质量流量计的控制有效解决了运行过程中气体压力和流动不稳定引起的等离子体火焰流动（大小波动）和电压（高低波动）的问题，从而稳定输出功率，实现所有参数的闭环控制。SX-90控制柜配备了触摸控制终端，可记录并保存不同粉末的喷涂参数，以配方形式呈现。它还允许在设备异常时查看报警信息。系统访问分为管理员和操作员通道：管理员可以修改和保存喷洒参数，操作员只能调整。还提供保留接口以支持长时间使用。

美国Alicat简要介绍

Alicat（美国）是全球最快的质量流量计、质量流量控制器和压力控制器制造商！设备响应速度高达5毫秒，交付速度快且技术支持迅速，Alicat始终为客户提供创新的流量和压力解决方案，时间紧密。所有Alicat质量流量计、质量流量控制器和压力控制器均配备NIST可追溯校准证书及业界独有的条件性寿命保修。Alicat流与压力设备已成为行业中科学研究和各种工业应用的首选。

1. 进口SG-100等离子喷枪

特色

A.SG100独特的设计支持内部或外部供药。（对于内部粉末供料，涂层粉末通过等离子弧芯后被雾化，因此相比外部粉末送料，涂层性能显著优越，能效更高。）

请参见附图，了解传统外置火药供弹喷枪的原理分析，由此可得出内部供药喷枪的优越性。

B. 材料工程师可以根据涂层性能要求制定合理的粉末供给方式。此外，SG100的两个内部供药口可以独立使用;同时使用可获得更高的喷雾速度，并允许在等离子体束中混合使用不同材料。外部供药口可以替代内部供药口，内部和外部供药口也可以组合使用。

C. 一套SG100设备通常可连续工作约200小时。在特定操作条件下，SG100等离子喷枪组件的使用寿命可达其他喷枪的三倍。由于零件数量更少且具备自对准设计，SG100 拥有快速且精准的组装能力，符合通用电气严格甚至严苛的验收标准。

其他特点：包括自动校准和使用寿命更长的耐磨部件，这些都降低了其运行和组装成本。它甚至可以以100KW的功率运行。

适用喷嘴

SG100可采用三种喷雾模式（亚音速、马赫I和Mach II），并可根据不同需求选择不同的阳极/阴极和气体分配环配置。

SG100等离子喷枪功能总结

1. 可选的内部/外部供粉方式（或混合用途）和多角度供药以满足不同需求;

1. 长时间连续工作;

1. 元件维护简便，喷枪阳极和阴极寿命长，自动校准以降低运行和组装成本;

1. CE认证。

凭借低消耗成本、易于维护和关键部件长寿命，SG100无疑是一款性价比高的喷涂工具。

3. SX-90等离子喷洒系统特别配置了一个水、燃气和电力安全中心

特别说明：氢气（H₂）是一种易燃且易爆的气体，质量流量计是电气元件，可能产生电火花，导致燃烧和爆炸风险。因此，我们独立开发制造的水、气与电力安全中心在设备运行过程中提供安全保护。

功能特征

A. 三种气体（H₂、N₂、Ar）的泄漏检测系统;

B. 气体泄漏报警装置;

C. Quick cut-off device for air intake pipelines;

D. Spray gun backfire prevention and flameout device;

E. Leakage protection, cut-off and alarm device;

F. Current overcurrent protection device;

G. Voltage overvoltage protection device;

H. Water flow and leakage pressure sensing device;

I. Water temperature overhigh warning and shutdown system;

J. Dust concentration monitoring, alarm and shutdown device.

4. 100% of Main Core Components are Imported Brand Parts

The coverage rate of imported parts for core components in Sanxin’s series of spraying equipment reaches 100%. Among domestic equipment, our spraying equipment ranks first in domestic sales, and we are also the manufacturer using the most imported brand parts in the thermal spraying equipment industry. All our raw materials and internal components are procured from regular manufacturers with production licenses, and core and main components are selected from world-renowned imported products with strict product inspection. More than a decade of operation results show that the equipment produced by our company features stable and reliable performance with a good reputation among customers!

To ensure stable and reliable quality of the equipment during long-term operation and minimize failure rates, 100% of the main core components of our newly upgraded SX-90 Plasma Spraying Equipment are imported brand parts, eliminating customers' after-sales concerns.

List of Importers and Manufacturers of Main Components

Supplementary List of Key Imported Components

SX-90 Plasma Spraying Equipment (Equipped with Imported SG-100 Spray Gun)

Plasma spraying is a thermal spraying method that uses a plasma arc as the heat source and spraying powder materials as the main raw material.

① Steps of Plasma Spraying

During plasma spraying, a DC arc is generated between the cathode and anode (nozzle). The arc heats and ionizes the introduced working gas into high-temperature plasma, which is ejected from the nozzle to form a plasma flame. Powder is fed into the flame by powder feeding gas, melted, accelerated, and sprayed onto the substrate material to form a coating. The working gas can be argon, nitrogen, or a mixture of these gases with hydrogen, as well as a mixture of argon and helium.

② Features of Plasma Spraying

1. Capable of spraying a variety of materials, especially high-melting-point refractory materials such as refractory metals, ceramics, cermets and other special functional materials;

1. Inert gas can be selected as the working medium to reduce the oxidation reaction of spraying particles during flight;

1. High coating bonding strength and low porosity; fine coatings can be prepared by controlling process parameters.

③ Main Equipment for Plasma Spraying

Including spray gun, powder feeding mechanism, rectifier power supply, gas supply system, water cooling system and control system.

Configuration Introduction of SX-90 Plasma Spraying Equipment

The SX-90 Plasma Spraying Equipment is successfully developed on the basis of introducing and absorbing PT-A3000 and METCO-9M plasma spraying equipment, and its overall level is equivalent to METCO-9M.

The equipment consists of: ① Main Power Supply; ② Intelligent Human-Machine Interface Control System; ③ Transfer Box; ④ Powder Feeder; ⑤ Water, Gas & Electricity Safety Center; ⑥ Spray Gun; ⑦ Heat Exchanger and pipeline connection systems.

1. SX-90 Intelligent Plasma Control Cabinet

The control core of the entire plasma spraying equipment

Features of SX-90 Intelligent Control System

The SX-90 plasma control cabinet adopts the most advanced touch control terminal to date, simplifying the original button operation mode. As the control core of the entire SX-90 plasma spraying system, it realizes automatic control of the whole system with state-of-the-art technology.

Control via Alicat mass flow meters effectively solves the problems of unstable plasma flame flow (fluctuating size) and voltage (fluctuating high and low) caused by unstable gas pressure and flow during operation, thus stabilizing the output power and achieving closed-loop control of all parameters. The SX-90 control cabinet is equipped with a touch control terminal that can record and save spraying parameters for different powders in the form of recipes. It also allows viewing of alarm information in case of equipment abnormalities. The system access is divided into administrator and operator channels: administrators can modify and save spraying parameters, while operators can only adjust them. Reserved interfaces are also provided for extended use.

Parameter Table of SX-90 Plasma Control Cabinet

1. Imported SG-100 Plasma Spray Gun

The SG100 plasma spray gun is a 100KW multi-mode spray gun widely used in thermal spraying applications. Its multi-functionality enables it to spray all types of current coatings, from high-density wear-resistant carbide coatings to thermal barrier coatings with controllable porosity.

Basic Data of SG-100 Plasma Spray Gun

Features

The unique design of the SG100 enables internal or external powder feeding, and material engineers can formulate a reasonable powder feeding mode according to coating performance requirements. In addition, the two internal powder feeding ports of the SG100 can be used independently; simultaneous use delivers higher spraying speed and enables mixed use of different materials in the plasma beam. The external powder feeding port can replace the internal ones, and internal and external ports can also be used in combination.

By adding accessories, the SG100 can be easily assembled into a 2086/2700 mode bore extension spray gun, and can also be transformed into a 90° SG-100 spray gun for spraying bores of different diameters to meet diverse needs. (See the figure for 90° SG100 plasma spray gun below.)

90° SG100 Plasma Spray Gun

One set of SG100 equipment can generally work continuously for about 200 hours. Under specific operating conditions, the service life of SG100 plasma spray gun components is up to three times that of other spray guns. Thanks to its fewer components and self-aligning design, the SG100 features quick and precise assembly, meeting the strict even harsh acceptance standards of GE.

Other features, including automatic calibration and wear parts with a longer service life, all reduce its operation and assembly costs. It can even operate at a power of 100KW.

Applicable Nozzles

The SG100 can be used in three spraying modes (subsonic, Mach I and Mach II), and different anode/cathode and gas distribution ring configurations can be selected according to different needs.

SG100 Plasma Spray Gun Cathode | SG100 Plasma Spray Gun Anode

Summary

1. Optional internal/external powder feeding modes (or mixed use) and multi-angle powder feeding to meet diverse requirements;

1. Long continuous working time;

1. Easy component maintenance, long service life of spray gun anodes and cathodes, and automatic calibration to reduce operation and assembly costs;

1. CE certified.

With low consumable costs, easy maintenance and long service life of key components, the SG100 is undoubtedly a cost-effective spraying tool.

3. Water, Gas & Electricity Safety Center

Special Note: Hydrogen (H₂) is a flammable and explosive gas, and mass flow meters are electrical components that may generate electric sparks, leading to combustion and explosion risks. Therefore, our independently developed and manufactured Water, Gas & Electricity Safety Center provides safety protection for the equipment during operation.

Functional Features

A. Leakage detection system for three gases (H₂, N₂, Ar);

B. Gas leakage alarm device;

C. Quick cut-off device for air intake pipelines;

D. Spray gun backfire prevention and flameout device;

E. Leakage protection, cut-off and alarm device;

F. Current overcurrent protection device;

G. Voltage overvoltage protection device;

H. Water flow and leakage pressure sensing device;

I. Water temperature overhigh warning and shutdown system;

J. Dust concentration monitoring, alarm and shutdown device.

4. Plasma Inverter Power Supply (SX-90)

The inverter chopper power supply provides DC power for the spray gun and adopts dual-mode IGBT modules. The modules can operate in single or dual mode to reduce failure rates, with intelligent module control and water-cooled electrical modules. It features soft arc starting, small size, high efficiency and low power consumption. The air cooling + water cooling heat dissipation method ensures excellent heat dissipation performance and stable continuous operation for a long time, making it the most outstanding plasma power supply in China at present.

Parameter Table of Main Power Supply for SX-80 Plasma Spraying System

5. Water and Electricity Transfer Box

The transfer core of the entire spraying system, which connects the power supply, control cabinet, heat exchanger and spray gun together.

It mixes the water and electricity of the plasma equipment and delivers them to the spray gun, and at the same time provides the high-frequency pulse voltage required for spray gun arc starting, and detects the spray gun return water temperature and cooling water pressure. It is light and flexible for easy moving, with excellent arc starting performance, reducing the instantaneous current impact during nozzle arc starting.

Parameter Table

1. Powder Feeder

Technical Advantages of the Newly Upgraded Intelligent Dual Powder Feeding System

1. Adopts PLC and touch screen for parameter setting, digital display of powder feeding parameters, and precise control of powder feeding accuracy and speed.

1. The system includes two sets of independent powder feeding devices: the large tank has a capacity of 6.0L with scraper-type conventional powder feeding (speed up to 150g/min); the small tank adopts drum-type powder feeding, suitable for feeding various ultrafine powders and hard-to-feed mixed powders.

1. Adopts a fully enclosed plastic-steel cabinet to avoid interference from external environmental factors such as temperature and humidity; the panel is equipped with a transparent glass door for clear observation of powder feeding status.

1. Optional powder feeding vibration device, powder tank heating device and metering and weighing device.

Functions of SX-80 Plasma Powder Feeder

One single-barrel (or dual-barrel) powder feeder is provided.

Applicable powder particle size range: 5~200μm (0.01-0.25 mm); powder feeding repeat error is less than ±1%.

The two barrels can feed powder simultaneously with a feeding rate of 120~250g/min.

It is a device for storing spraying powder and delivering it to the spray gun according to process requirements. The main gas of the spray gun is used as the powder feeding gas. The spraying powder is delivered to the outlet of the powder feeder by the rotation of the powder feeding scraper disk, and the powder leaves the powder feeding barrel together with the gas pressure and enters the spray gun. The powder feeding speed can be adjusted by the potentiometer on the control cabinet panel.

Parameter Table of Powder Feeder for Plasma Spraying System

7. Cooling Unit (Refrigeration System)

Technical Parameters and Configuration of Air-Cooled Chiller

Model: LYK-20S

Notes:

1. Refrigerating capacity is based on: chilled water inlet/outlet temperature 12℃/7℃, cooling water inlet/outlet temperature 30℃/35℃.

1. Operating range: chilled water temperature range 5℃ to 35℃; chilled water inlet/outlet temperature difference 3℃ to 8℃. Used in an environment with condensation temperature not higher than 35℃.

1. Unit conversion: 1kw cooling capacity = 860kcal/hr; 1RT = 3024kcal/hr; 1kcal/hr = 3.969BTU/hr; 1 metric horsepower (HP) = 0.735KW.