Equipment

Advanced Equipment for Thermal Spraying of Protective Coatings and Plasma Treatment of Materials

Plasma spraying equipment

PLAZER-40

This is the plasma spraying machine with 40 kW power plasmatrons for spraying of coatings on external and internal surfaces. It is intended for spraying of powder and wire materials. Plasmatron is made with a single inter-electrode insert and recuperative cooling, and can operate in the sub- and supersonic modes. Plasma gas is air + methane. The machine consists of a power source, control panel, powder feeder, wire feed mechanism, plasmatron, and service lines.

Specifications:

Mains voltage – 3 х 380 V

Open circuit voltage - 320 V

Operating voltage - 140 - 250 V

Operating current - 100 - 250 А

Gas mixture flow rate - 3 - 10 m3/h

Plasmatron efficiency - 90 %

Deposition efficiency:

         metals – 10 kg/h

         Al2O3 - 5 kg/h

PLAZER-80

This is the plasma spraying machine equipped with 80 kW power plasmatron, with separate (or common, by Customer’s request) feed of gases. It is intended for operation as part of automated and mechanized complexes. It can be equipped with independent cooling unit. Plasma gas is air + methane (propane-butane).

Specifications:

Mains voltage – 3 х 380 V

Open circuit voltage - 300 V

Operating voltage - 200 - 270 V

Operating current - 100 - 300 А

Plasmatron efficiency - 70%

Deposition efficiency:

         metals – 25 kg/h

         Al2O3 - 10 kg/h

PLAZER-180

This is the 180 kW plasma spraying machine, which can operate in the sub-and supersonic modes. It is intended for operation as part of automated and mechanized complexes, and can be used in all cases where it is necessary to produce high-quality coatings at high productivity. Plasma gas is air + methane.

Specifications:

Mains voltage – 3 х 380 V

Operating voltage - 250 - 400 V

Operating current - 200 - 400 А

Gas mixture flow rate - 10 - 30 m3/h

Plasmatron efficiency - 70%

Deposition efficiency:

         metals – 50 kg/h

         Al2O3 - 15 kg/h

PLAZER-15-AVM

This is the plasma spraying machine with 15 kW plasmatron. It is intended for electric-arc wire spraying in a shielding atmosphere of argon with supersonic air blowing. The machine consists of a control panel with built-in upgraded inverter VDUCh-500, plasmatron unit, and wire feed mechanism. It is intended for operation as part of automated and mechanized complexes, and can be used in all cases where it is necessary to produce high-quality coatings of wire materials.

Specifications:

Mains voltage – 3 х 380 V

Operating voltage - 45-55 V

Operating current - 150 - 300 А

Argon flow rate – 1,0 – 1,5 m3/h

Air flow rate - 30 - 40 m3/h

Deposition efficiency:

   Steel wire - 8-20 kg/h

   Spraying wire diameter – 1,2 - 2,0 mm

Plasma equipment for high-speed surface hardening

PLAZER-80-LU

It is intended for local hardening of steel and cast iron parts. Hardening depth is 2.5-3.0 mm, width of the hardened zone is 25-35 mm, and hardness and structure are set by the technology. The machine can be equipped with microprocessor controller. Working gases: air + methane (propane-butane). The machine is fitted with plasmatron and is designed for operation as part of automated and mechanized complexes.

Specifications:

Mains voltage – 3 х 380 V

Open circuit voltage - 320 V

Operating voltage - 180 - 220 V

Operating current - 150 - 250 А

Gas mixture flow rate - 3-7 m3/h

Plasmatron efficiency - 70 %

Hardening speed - 1-3 1-3 cm/s

Equipment for supersonic electric-arc metallizing

PLAZER-10-SM

It is intended for electric-arc spraying of wire materials in a supersonic flow of hot air + methane combustion products. The machine consists of a metallizing unit with built-in supersonic torch, control panel, wire feed mechanisms, and arc power supply. It is designed for operation as part of automated and mechanized complexes, and can be used in all cases where it is necessary to produce high-quality coatings of wire materials.

Specifications:

Mains voltage – 3 х 380 V

Operating voltage - 35-45 V

Operating current - 150 - 400 А

Gas mixture flow rate – 30-40 m3/h

Air flow rate – 30-40 m3/h

Deposition efficiency:

   Steel wire - 8-20 kg/h

   Spraying wire diameter – 1.2-2.2 mm

Equipment for supersonic flame spraying

PLAZER-100-SG

It is intended for spraying of powder materials. It consists of a control panel, powder feeder, and direct-flow supersonic torch with transpiration cooling and return injector. It can be applied to produce high-quality coatings of powder materials. Working gases: oxygen + methane (propane-butane).

Specifications:

Deposition efficiency:

         metals – 7 kg/h

         Al2O3 - 3 kg/h

Gas mixture flow rate – 30-40 m3/h

Porosity of coatings – 0-3 %

Powder losses - 20%

Steam-plasma machines

PLAZER-100-P
PLAZER-200-P

Specialized steam-plasma units PLAZER-100-P with 100 kW power plasmatron and tungsten cathode flown about with shielding gas, and PLAZER-200-P with 200 kW power plasmatron and hollow copper electrodes are designed for the equipment for high-efficiency pollution-free steam-plasma disposal of medical and other dangerous wastes with simultaneous production of alternative power supplies, as well as for steam-plasma conversion of carbon-containing materials. The units provide generation of steam-plasma jets with preset composition and parameters (plasma environment of variable concentration – pure air and water steam).

Structure of the units and delivery sets:

The units consist of: 1 – rectifier, 2 – steam plasmatron with cable-hose pack, 3 – plasma unit control panel, 4 – cooling stack, 5 – intermediate water tank, 6 – vertical centrifugal pump, 5 – compressor station, 6 – electric steam generator, 7 – steam feeder, 8 – softened water tank, 10 – fine filter.

Specifications:

Mains voltage at (50 ?1) Hz frequency, V

Unit power consumption, kVA

Plasmatron power consumption, kW

Plasma gas

Air plasma gas flow rate, nm3/h

Water steam plasma gas flow rate, g/s

Mean temperature of steam plasma

Plasmatron cooling

Arc voltage regulation range, V

Open circuit voltage at plasmatron arc ignition, V

3 х 380 (+19; - 38)

300

60-200

air – water steam

15– 35

5 - 11

2500 – 3500 ?С

water

300 - 550

640

Semi-automatic spraying lines

1. Semi-automatic line for hardening of new high-capacity diesel crankshafts and repair of worn-out ones to improve their operational reliability and extend service life.

The line comprises metallizing and jet-abrasive blasting semi-automatic devices. They are designed for operation in a set with programmable controller and supersonic electric-arc metallizing unit PLAZER-10-SM or PLAZER-15-AVM.

Metallizing semi-automatic device is an assembly complex, which is composed of a metallizing chamber, aspiration device, control cabinet, electrical equipment, supersonic metallizing unit PLAZER-10-SM (PLAZER-15-AVM), and system of air ducts and enclosures. The metallizing chamber provides protection of attending personnel and environment from dangerous and harmful effects of the metallizing process.

The jet-abrasive semi-automatic device is an assembly complex composed of a jet-abrasive chamber, aspiration unit, control cabinet, electrical equipment, forced jet-abrasive unit, and system of air ducts and enclosures. The chamber provides protection of attending personnel and environment from dangerous and harmful effects of the process.

Jet-abrasive preparation of surfaces and spraying of crankshaft journals can be performed in the manual and automatic modes by assuring accuracy and reproducibility of all requirements of the technological process and, hence, quality indicators of the deposited coatings.

Metallizing semi-automatic device

2. Semi-automatic line for repair of journal necks of wheelset axles by spraying to improve their operational reliability and extend service life.

The line comprises movable metallizing and jet-abrasive treatment chambers, which are mounted on one frame with workpiece manipulator. The line is designed for operation in a set with programmable controller and supersonic electric-arc metallizing unit PLAZER-10-SM or PLAZER-15-AVM.

The metallizing chamber is an assembly complex, which is composed of plasmatron manipulator, system for forced cooling of workpieces, aspiration unit, and system of air ducts and enclosures. The metallizing chamber provides protection of attending personnel and environment from dangerous and harmful effects of the metallizing process.

The jet-abrasive chamber is an assembly complex, which is composed of manipulator of the jet-abrasive gun, aspiration unit, forced jet-abrasive unit, and system of air ducts and enclosures. The chamber provides protection of attending personnel and environment from dangerous and harmful effects of the process.

Movements of the chambers (metallizing and jet-abrasive) and axle rotation are controlled from one control cabinet.

Jet-abrasive preparation of surfaces and spraying of journal necks can be performed in the manual and automatic modes by assuring accuracy and reproducibility of all requirements of the technological process and, hence, quality indicators of the deposited coatings.

3.Semi-automatic line for hardening of new high-capacity diesel cylinder bushings and repair of worn-out ones to improve their operational reliability and extend service life.

The line comprises semi-automatic spraying and jet-abrasive blasting devices. The semi-automatic devices are designed for operation in a set with programmable controller and plasma spraying unit PLAZER-40 or PLAZER-15-AVM.

The spraying semi-automatic device is an assembly complex comprising a spraying chamber with workpiece rotator and forced cooling system, column with three-coordinate plasmatron manipulator, aspiration unit, control cabinet, electrical equipment, and system of air ducts and enclosures. The spraying chamber provides protection of attending personnel and environment from dangerous and harmful effects of the spraying process.

The jet-abrasive semi-automatic device is an assembly complex, which is composed of a jet-abrasive chamber with workpiece rotator and force cooling system, column with three-coordinate plasmatron manipulator, aspiration unit, forced jet-abrasive unit, control cabinet, electrical equipment, and system of air ducts and enclosures. The chamber provides protection of attending personnel and environment from dangerous and harmful effects of the process.

Jet-abrasive preparation of surfaces and spraying of cylinder bushings can be performed in the manual and automatic modes by assuring accuracy and reproducibility of all requirements of the technological process and, hence, quality indicators of the deposited coatings.