What is Flame Spray Gun?

Flame Spray Gun

Flame Spray Gun is the kind of approach in which uses an oxy-fuel flame to melt the wires. After melting the molten metal and then it is atomized with compressed air to create a spray stream that applies the coating on the surface being sprayed. the flame Spray gun is a uses for spray both ferrous & nonferrous material. Major applications are restoring worn-out components, conductivity and anti-corrosion coating.

Flame Spray Process is basically the spray of molten metal like zinc, copper, aluminum on the surface for providing a coating. in this type of gun, Zinc is sprayed then called Zinc Spray Gun, Copper is Spraying then it's Copper Spray Gun, Aluminum is spraying then it will be Aluminum spray gun. The molten material can be wire form and powder form depend on the application. Coating wire or powder is melted in a gun and atomized with compressed air and deposit on the surface. The molten metal drops solidify on the surface of the substrate.

Flame Spray Coating:

Flame spray coating involves filling a plastic powder through a flame that partially melts the powder and fuses it as it contacts the substrate. The part's surface is preheated with the flame. The usual approach is to coat only a few square meters at a time, so the temperature can be controlled. The flame is then adjusted. When the coating is completed, the powder is shut off and the coating is post-heated with the flame. Flame spraying is particularly useful for coating products with surface areas too large for heating in an oven. Disadvantages are the problems associated with an open flame and the need for skilled operators to apply the coating.

Flame Spray Process:

Flame spray, a century-old process, consists of a gun nozzle in which a mixture of oxygen and fuel such as acetylene, propane, or hydrogen is injected. The gas mixture is combusted in the front of the nozzle to create a flame external to the nozzle. Depending on the ratio of oxygen to fuel, the temperature of the flame ranges between 3000 and 3300°C (5430 to 5970°F). The selection of the nozzle will be depending on the coating material, which can be in the form of either powder or wire. A cold air sheath is used to collimate the flame to control the spray pattern. In the powder feed system, the coating material is gravity fed to the gun from a hopper. Aspirating gas carries the powder through the flame. The powder particles melt during transition through the flame and deposit on the metal. In the wire feed system, the wire tip is continually fed into the flame by a roller drive mechanism. The molten material at the tip of the wire is fragmented and propelled to the substrate by compressed air injection. The wire diameter and feed rate, air and gas flow rates, flame temperature, and gas pressure define the coating characteristics.

Features and Benefits:

1.Effective:

Mounting stud: for machine mounted operation.
Rugged, built-in wire snubber: prevents the wire from accidentally being pulled out of the gun.
Flexible hardware choices that allow the gun to be configured for use with hard and soft wires in a variety of diameters.
Choice of fuel gases to suit plant operational requirements and economics.
Thumb-operated wire feed control provides simple wire feed start and stop.
Wire drive feeds wire reliably, consistently and uniformly,regardless of fluctuations in air pressure.
Metric threading: all standard nuts, screws, and mating
parts are supplied with metric threads, facilitating replacement where metric is used as the standard system of measurement.

2.Efficient:

The rugged design is built for long service life with limited maintenance.
The gas head valve handle provides a simple and quick set up of spray gas pressures and flows prior to gun ignition.
O-ring seals between nozzle and siphon plug ensure safe and reliable operation and simplify gun maintenance.
Simple maintenance and hardware changeover that things the nozzle, siphon plug, and front wire guide assemblies can be easily removed and replaced as a complete unit.
Simple operation is required insignificant operator training.

3. Economical:

Low maintenance design reduces operating costs
Long gear life: designed with large, rugged gears coupled with a circulating gear lubricant pump.
The unique universal gas head produces high spray rates with low gas consumption and is resistant to backfire.