Combustion Spray uses an Oxygen/Fuel Gas Spray in either powder or wire form.  It is one of the oldest forms of metal spray we offer. Although many other metal spray processes have been developed and are superior to this technology, it is still the process of choice for a number or niche metal spray requirements.

 

One of these requirements is the jet engine design of a metallic air/oil seal commonly used for repair and over-haul of older engine parts. Usually a matrix of nickel or aluminum and graphite this material is a process specific coating system just for these jet engines.

 

Additionally, the application of aluminum to composite material for either lightning strike protection or EMI (Electro Magnetic Interference) and RFI (Radio Frequency Interference) Shielding is best applied by the combustion process for better temperature control against over-heating the light weight composite materials.

 

Most materials that can be made into a powder or wire form can be used in this basic process of metal spray.

 

Description of Combustion Powder Spray

 

Powder flame spraying is probably the simplest of all the spray processes to describe - feed a powder through the center bore of a nozzle where it melts and is carried by the escaping oxy-fuel gases to the work piece. Unfortunately, this approach yields coatings high in oxides and with void contents approaching 20 volume percent (v/o). However, coating quality can be improved by feeding air to the nozzle through a small jet, which reduces the pressure in a chamber behind the nozzle. This chamber is connected to the powder feed hopper. In this way a gentle stream of gas is sucked into the gun and carries powder with it.

 

Description of Combustion Wire Spray

 

The Combustion Wire Spray consisted of a nozzle in which a fuel gas is mixed with oxygen and burned at the nozzle's face. A stream of compressed air surrounding the flame atomized and propelled the liquefied metal. Process continuation depends on feeding the wire at a controllable rate so it melted and was propelled in a continuous stream. An air turbine or electric driven gears and drive rolls push the wire into the flame, melt and atomize it and deposit the molten droplets to form an adherent coating.

 

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