New Atomization Process to Achieve High Production Rates During Thermal Spraying of Thick Coatings

Because of their characteristic spray geometry, pressure-gas-atomizers can be used to create thick coatings from molten metal. Production rates of pressure-gas-atomizers are substantially higher compared to conventional Thermal Spraying (100 – 200 kg/h based on molten tin). The shape of the spray cone can be designed by the geometry of the atomizer. The mean particle sizes and velocities (molten tin and tin-copper alloys) are controlled by the gas flow. Powder products and coatings of several millimeters on steel substrates were investigated. The average density of the layer was higher than 99%.