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Plasma Product Line

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Plasma Spray Systems

Conventional Plasma Equipment:

Low end manualModel 3710 Controller with SG-100

Semi-automaticModel 3620 Controller with SG-100

SG-100

3620

3710

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Plasma Spray Systems

New & Unique Technology:

Model 7700 Universal PlasmaClosed loop - Net Energy Controlled plasma spray system

Global Tasking System (GTS)Universal thermal spray controller

PlazJet high energy plasmaUnique technology for rapid production of high density coatings

PlazJet

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Plasma Spray Systems

Model 3710 Plasma

Control Console:

Most economically priced Outstanding value

‘Jewel’ critical orifice gas flow control Highly accurate and repeatable

gas flow control = consistency No need for routine calibration

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Plasma Spray Systems

Model 3710 Plasma

Control Console:

Built-in PC-100 power supply controller with digital displays Easy to set and operate

Two powder feeder control (either / or) Bond coat -- top coat changeover made

easy Time consuming feeder clean-outs can

be eliminated

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Plasma Spray Systems

Model 3620 Plasma

Control Console:

Built-in PC-100 power supply controller with digital displays Easy to set and manipulate

Two powder feeder control (either / or / both at the same time) Bond coat -- top coat

application Graded coating application

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Plasma Spray Systems

Model 3620 Plasma

Control Console:

Microprocessor based semi-automatic control

‘Jewel’ critical orifice gas flow control Highly accurate - repeatable

gas flow control Relatively insensitive to back

pressures like other gas flow control devices

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Plasma Spray Systems

Model 3710 and 3620

Plasma Control Consoles: Safety interlocks

Prevent gun operation in case of other equipment failure

NFPA type “Z” purging with alarm in case of failure Safe design

24 VDC purge circuit Remote E-stop box Stainless steel plumbing for flammable

gas

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Model 7700 -Net Energy™

Closed loop control of process and coating

Net Energy™ provides complete control over system parameters based on input recipes and control limits. PLC utilizes a sophisticated algorithm that captures process variables in ‘real time’ and adjusts as necessary to produce desired results.

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Real time control of coating structure

Net Energy™ algorithm compensates for process variables like part wear and cable life by real time process control of plasma energy levels

Model 7700 -Net Energy™

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Net Energy™ Coatings

Consistent and repeatable Aircraft proven High DEs High density Uniform structure Cleaner coatings High bond strengths Less oxides High hardness

Cr3C2-NiCr

Ni-5Al

T-800

WC-12Co

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Secondary Gas Module

Primary Gas Module

Carrier Gas Module

Touch-screen PC

Water Module/ Heat Exchanger

Power Supply

High Frequency Unit

Model 7700 Universal Plasma Controller

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Features & Benefits

PLC based process control Minimal operator involvement Expandable via Devicenet®

Real time process control Consistent, reproducible

coatings Cool for troubleshooting

Coating device flexibility Multiple gun configurations

for application-specific coatings

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Features & Benefits

Ergonomic design Minimum floor space

required Module placement

flexibility

Safe design Minimizing process

hazards

Data acquisition Records storage Process monitoring Quality control

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Features & Benefits

Intuitive controls Graphic user interface

(GUI) gives on-screen display of important process variables

Constant process monitoring

Navigational ease Intuitive operation and

training

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Net Energy™ Performance Less downtime

Completely automated Recipe storage Real time monitoring helps

schedule maintenance Multiple powder feeding

options

Longer production runs Longer hardware life Multiple feeding options

Quick changeovers Multiple coating sequences

Preheat, bond coat, top coat, graded coatings

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Global Tasking System (GTS)

Advanced multi-process control technology

Allows multiple thermal spray processes to be operated from a single work station cell. Utilizes PLC control, point-and-click or touch screen operation, and intuitive screens for simple operation of sophisticated tasks.

GTS Screen

Electrical Cabinet

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One system runs:

PlazJetNet Energy 5500-2000JP-8000 HVOF9000 Arc SprayCombustion Spray gunsAutomation

And any other thermal spray process you need or want

GTS Capabilities

GTS with JP-5000, 2700 I.D. gun and 9000

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One work station for multiple spray systems

One spray cell for any number of processes

Efficient space utilization Control options: closed loop

to semi-automatic Pre-programmed recipes

The ultimate in efficiency, control and total capability

GTS Features & Benefits

GTS for plasma, HVOF, arc and flame spray

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High Energy Plasma

PlazJet is a new plasma technology utilizing very high energy (kW) levels to generate extremely high plume temperatures and velocities. The result is the unique ability to produce very dense coatings very quickly, regardless of whether you spray Chrome Oxide, Yttria-stabilized Zirconia or any other plasma powder.

PlazJet -- Unique Technology

PlazJet Gun

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Dense YSZ

Porous YSZChrome oxide

PlazJet Coatings

High density High DEs Uniform structure High hardness Clean coatings High bond strengths Low oxides Produced rapidly

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PlazJet Console PLC - Mass flow control Data acquisition

PlazJet Gun Self-aligning components Powder injection

flexibility

Power Supply Constant current (± 2%) Stable, low ripple plasma High voltage / low amps Up to 270 kW power level

PlazJet Key Components

PlazJet

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High spray rates =

high productivity High gas velocities =

denser coatings High coating reproducibility Closed-looped control Long life gun components Flexible gun configurations Designed for automation

integration

PlazJet Features & Benefits

Yttria stabilized Zirconia

Alumina

Chromium Oxide

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SG-100Power: 80 kW

Plasma Spray Guns

SG-200Power: 40 kW

PlazJetPower: 270 kW

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Plasma Spray Systems

SG-100 Gun -- the key component

Up to 80 kW

Maximum flexibility for melting and range of coating structures

3 Modes of Operation (Subsonic, MACH I and MACH II)

Able to apply coatings with wide range of materials and sizes with one set-up

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PlasmaEquipment

Thermal source Plasma arc

Key elements Anode, cathode, gas injector D.C. rectifiers, water cooling,

gas supply, material feed,

Material delivery powder feeder, carrier gas

Controls net energy, DC current, water cooling, arc gas flows, powder feed rate,

manipulation

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PlasmaSpray

Spray stream

Anode Cathode

Cooling water &DC power +

Gas injector

Cooling water &DC power -

Arc gas in

Powder gas & powder in

Plasma arc

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SG-100 -- the key component

Features and benefits

Powder injection flexibility Internal and/or external -- flexibility for optimized coating structure Forward, 90º, backward -- flexibility for optimized coating structure

Air jet assembly No coating contamination from over spray

Self-aligning components Easy and quick hardware changes Proper geometric spacing for assured gun performance

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SG-100 -- the key component

Long hardware life (up to 500 hrs)

Coating consistency Low downtime Faster turn-around of jobs High productivity

Internal injection Deposit efficiencies in excess of

60% Engineered dwell time Optimum energy transfer Denser coatings

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SG-100 Plasma Spray Gun

Unsurpassed coating qualityRegardless of system controller

3 Operation modes to 80 kW (Subsonic, Mach I and Mach II)

Refined coatings solutionsDEs in excess of 60%

Designed for flexibilityInternal +/or external injectionQuick hardware changeoversSelf-aligning components

Long hardware life (to 500 hrs)

Unique ID extension capability Easy conversion to 2700 /

2086A

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SG-100

SG-100HardwareOptions

Mach I

-145

-175

-165

-129

-113

Sub Sonic

-358

-155

-355

-112

-113

Mach II

-110-104

-100

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SG-100 -- a versatile tool

Model 2086-A

ID size > 2.5” (62.5 mm)

Model 2700

ID size > 1.5” (37.5 mm)

ID Extensions

External Feed Plate

Air-Jet Assembly

SG-100

Accessories

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ID Extension Guns

Model 2086-A

ID size > 3” (75 mm)

Model 2700

ID size > 1.5” (37.5 mm)

ID Extensions

Easy adaptability with the SG-100 Gun

Robust designs Self-aligning components 45º, 60º, Straight-ahead

spraying

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ID Extension Guns

Model 2086A ID Coatings- diameters

3” (75 mm) and up Up to 40 kW power level

Model 2700 ID Coatings- diameters

1.5” (37.5 mm) and up Up to 30 kW power level

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SG-200

SG-200 40 kW Machine mount

applications True 90 degree ID

coatings

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SG-100 on Net Energy 5500-2000 System

SG-100 Features & Benefits

Outstanding coatingsOptimum energy transfer Engineered dwell timeMetals, oxides or carbides

High productivityHigh deposit efficiencies Minimal downtime Faster turn-around of jobs

Multiple gun capabilitiesPowder injection optionsHardware optionsID capability

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Plasma System Performance

Our complete family of systems provides a number of advantages:

Unsurpassed coating quality Tailored to the application

Increased throughput High spray rates Reliable equipment / less downtime

Higher efficiencies Versatile gun configurations Internal powder feed option Less powder required per job

IGT blade PlazJet-coated with ZrO2

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Plasma System Performance Advanced system controls

Mass flow gas controls Closed loop feedback control -

Net Energy™ Critical orifice options

Engineered for consistency Automation compatibility Recipe storage Real time monitoring Diagnostic capabilities

Longer production runs Longer hardware life Multiple feeding options

2086A I.D. gun spraying liner2086A I.D. gun spraying liner