arc brochure

Arc Spray EquipmentSolutions

Arc spray solutions

Praxair Surface Technologies, Inc. is a world leaderin thermal spray equipment and materials and in coatings technology. Our focus is on providing the rightcoatings solution for any application. As a primary contributor to the development and commercializationof the arc spray process, Praxair continues to lead in advancing the technology. Arc spray is at the core ofwhat we do everyday, and we provide a complete family of products that reflects years of applicationknowledge with our history of equipment engineeringand coatings expertise.

As with any process, the selection of arc spray equip-ment is only the first step. At Praxair we believe that the development of arc spray wires, in additionto focusing on application technology, pushes the thermal spray process toward expansion into new areasof surface-enhancement solutions. We have dedicatedteams of engineers to work with you to develop solutions that expand the market for cost-effectivethermal spray applications. Let us work with you to select the best arc spray system and then help youmaximize your output and returns.

For more information, please contact you local repre-sentative or contact our U.S. headquarters:

Phone: 1-603-223-2100Fax: 1-603-225-4342E-mail: [email protected]/thermalspray The arc spray process is

used in multiple industriesfor many demandingapplications includingsome in the aerospaceindustry.

ProvenA long history of proven success

The arc spray process is at the very coreof Praxair Surface Technologies’ broadline of thermal spray equipment. This is because of Praxair’s historic develop-ment and pioneering of applicationsfocused on the arc spray process andour commitment to equipment designand commercialization. We provide acomplete family of arc spray products,each using tailored technologies for various coating solutions. The rangestretches from “push” to “pull” to“push/pull” wire-feed technologies andto innovative process enhancements like Internal Diameter (ID) spray exten-sion and the ArcJetTM spray attachment.In addition, we offer a variety of configu-rations that will support the mostdemanding applications.

Arc spray models

8830A true classic of the arc spray line whichfeatures an air-driven “pull” 350-ampgun and a control that is simple to operate, the 8830 has become a proveneconomical and reliable standard ofexcellence with thousands of applica-tions worldwide.

8835Adaptable to any spray environment, the 8835 features an electric motor “pull”350-amp gun and modular unbundledcontrol technology. The PLC controlscan be used in either automatic or man-ual mode, and the gun is flexibleenough to be handheld or roboticallymounted.

BP-400A versatile robust option, the BP-400features a lightweight point-and-shootgun utilizing “push” wire feed technology.Designed with a 350-amp output,the system provides both applicationand production flexibility with superior coating results.

CoArcTM systemA combination of the best-of-all-worldsin TAFA products, the CoArc systemfeatures the 9935 350-amp gun combining the robust 8835-type drivewith high air flow capability and a “pull”or “push/pull” wire delivery system.Designed with a variety of “state-of-the-art” features and options, it revolutionizesarc spraying by close-looping the sprayprocess.

The 9935 is a robust,machine mounted orhand-held gun combiningthe proven, rugged wiredrive of the 8835, with areliable DC servo motor,the high volume air flowcapability of the 9000 witha new improved nozzledesign to truly make the9935 the state-of-the-artarc spray gun.

Versatility

Praxair has modeled equipment strate-gies around reliability and versatility inuse, operation and application. The arcspray process itself provides the bestcombination of reliability and versatilityof all thermal spray processes, and the 8830 and 8835 have a reputation for great performance and reliable operation in thousands of applicationsthrough the years. The guns aredesigned to perform with minimumoperator adjustment, assuring qualitycoatings time and time again. Processset-up includes only loading wire, settingthe voltage, and pushing the “On” but-ton. No other adjustments are needed.

The 8835 offers the same properties asthe 8830, but also includes the versatilityof modular design. It can be unbundled– the console and the wire feed cartcan be separated from the power supply to add more range of use. The8835’s PLC controls are designed forhand or robotic operation and provideconsistently repeatable coatings througha multitude of application and controloptions.

8830 and 8835 features• “Pull” wire feed design utilizing either

an air drive (8830) or electric drive(8835) with:

– Optimum energy transfer tip/tubeassembly

– Error-proof alignment housing

– Permanent arc shield protection• Double yoke wire feed unit• 350-amp 100% duty cycle power supply

Robust spray systems

Our engineering team integrates thermal sprayautomation, such as thisrobot-mounted multiple gun arc spray configurationdeveloped for a large automotive OEM.

The “pull” design of the8830 and 8835 gunsallows for consistent wirefeeding and repeatablecoatings.

Reliability

Designed with reliability, robustness andflexibility in mind, the BP-400 can handlea variety of applications without compro-mising coating quality. Lightweight,portable and easy to use, the BP-400offers one-touch, point-and-shoot opera-tion. Based on a highly engineered“push” wire delivery system, the BP-400virtually eliminates drive mechanismmaintenance. This leads to lightweightgun design, fewer worries, and reliableoperation.

BP-400 features• “Push” wire feed design• Lightweight gun with no moving parts• Synchronous dual wire feeding • 350-amp 100% duty cycle power supply• Handheld or machine mounted

Offering all the benefits of the other arcspray models plus much more, the 9935 gun when used with the CoArcTM

system provide modularity, and robust-ness. Advanced controls make theCoArc system the ultimate in flexibilityand ease-of-use. The CoArc system hasthe option of supplying the wire with“push/pull” technology and when combined with the optional closed-loopcontrol of gun head’s voltage and air pressure, truly revolutionizing the arcspray process to ensure consistent,reproducible coating quality.

CoArc system features• Touch-screen operator interface• Monitoring of spray head voltage and

air pressure• Recipe storage• Simple, modular design• Advanced power supply

Dependable and consistent

Simple to operate yetrobust, the BP-400 arcspray system produceshigh-quality metallic coatings.

The CoArc system isdesigned for automatedspraying yet offers optional hand sprayingcapability. The 9935 gun incorporates high-flow air design that when combined with theoptional closed-loop control feature ensuresconsistent, reproduciblecoating quality.

The flexibility of the BP-400 is such that it canfunction in hand-held orfully automated configura-tions in applications suchas spraying varistors.

8830

Equipment solutions Arc spray solutions for excellent coatings

8830 system

8835

8835 system

A proven, reliable and economical arc spray classic

Features:

“Pull” wire feed design

Air motor driven

1.6mm or 2mm wire feed capability

Robust construction

Rated for operation up to 350 amps

Designed for handheld operations

8830 system components and options

350-amp power supply

8830 control console

8830 gun

Optional ArcJetTM attachment

Optional anti-skid retrofit kit

Optional ID extension for straight-ahead or angled spray

An easy-to-operate, robust arc spray systemdesigned for maximum application flexibility

Features:


Electric motor driven

1.6mm or 2mm wire feed capability

PLC controlled

Built-in e-stop interface


Designed for automated operations

CE, UL and 3C certified

8835 system components and options


8835 control console

8835 gun

Built with ArcJetTM attachment

Modular, unbundled construction

Optional anti-skid retrofit kit

Optional fan spray air cap

Optional ID extension for straight-ahead orangled spray

Optional robot gun mount

BP-400 CoArcTM

BP-400 system CoArc system

Simple, lightweight, and durable arc spraysystem with a proven track record

Features:

“Push” wire feed design

1.6mm, 2mm and 1/8-inch wire feed capability


Simple construction

Designed for handheld or machine-mounted operation

CE certified

BP-400 system components and options


BP-400 control console

BP-400 gun

Optional high-velocity conversion kit

Optional fan spray conversion kit

Optional 2.3mm conversion kit

Optional ID extension for straight-ahead or angled spray

Optional robot gun mount

High-tech, modular arc spray system withadvanced control features for reproducible andexceptional coating quality

Features:


1.6 mm and 2mm wire feed capability

PLC controlled


“Touch-screen” operator interface

Spray head monitoring of voltage and air pressure

CE, UL, and 3C certified

CoArc system components and options

350-amp enhanced power supply

CoArc control console

9935 gun

Recipe storage

Maintenance scheduling

Optional “push/pull” wire feed

Optional closed-loop control of head voltage and pressure

Optional wire counter / “out” indicator

Optional Data acquisition capability

Optional remote OIT / unbundled capability

Optional 8830 capability

DiversityBroad spectrum of wireapplications

Proud of our role in the emergence andgrowth of the arc spray process, wecontinue to develop and refine not onlyequipment and consumables but also arc spray applications. Arc spraycoatings are becoming more and moreaccepted in applications around theworld due to the quality, low cost, easeof use, and repeatability of the process.

Praxair has worked closely with industryto develop arc spray solutions for some of the most demanding coatingapplications. While most arc spray coatings still utilize metallic alloy compo-sitions, the advent and growth ofengineered, composite cored wiresbroadens the use of arc spray technolo-gy. For coatings ranging from simpledimensional restoration, to engineeredsolutions for complex surface treatmentrequirements, arc spray provides competitive, high quality answers toproblems.

Wear resistanceCored wire technology has broadenedthe spectrum of arc spray applications.With a tailored chemistry of cored wires,including carbide-bearing compositions,it is possible to produce coatings withexcellent sliding wear resistance as wellas abrasion resistance.

Aircraft component repairMost major aircraft engine manufactur-ers specify the use of the arc sprayprocess for repairs of many aircraft en-gine components. Coatings are appliedto various components for dimensionalrestoration, hot temperature erosionresistance, and as bond coats.

Corrosion protectionArc sprayed coatings are used widely tofight both high and low temperature corrosion. These coatings have proventheir excellence in challenging environ-ments such as boilers, by providingoxidation and heat resistance. Arcsprayed coatings also provide excellentresistance to atmospheric corrosion and are used on bridges and otherinfrastructural components.

Part restorationThe forgiving nature and flexibility of thearc spray process enables economicalapplication of thick coatings without sig-nificant loss of bond strength. For thisreason, arc spray has become theprocess of choice for part restoration inapplications where the replacementcosts are high or the part has to berefurbished on-site.

Mold makingThe mold-making industry uses arcspray to produce thick coatings duringthe mold process. The coating charac-teristics help improve yields from themolds, and the efficiency of the processhas also helped in rapid tool prototypingtechnology.

Electrical conductivity and resistivityArc sprayed aluminum, tin, zinc andother materials are used in applicationsrequiring good electrical conductivity.Aluminum coating on metal oxide varis-tors, for example, creates an electricalconductivity contact surface on the faceof the varistor.

AutomotiveThe arc spray process is used in theautomotive industry for coatings that provide corrosion protection, bodyrepairs, and weld-seam filling.

ConsistencyCoatings thatdeliver every time

Arc sprayed coatings areused for both electricalconductivity and resistivity.In the electronics industry,coatings such as tin areoften used on nonmetallicparts because of their ability to accept solders.

InnovationAdvanced options for elevated performance

ArcJet spray patternStandard spray pattern

Standard Arc Power SupplyFluctuation (± 10 V)

353 ECV Arc Power SupplyFluctuation (± 200 mV)

Praxair is committed to the developmentand advancement of arc spray equip-ment and applications. The innovation oftechnology such as the ArcJetTM attach-ment and ID extensions has continuedto drive the process forward.

The ArcJet attachment is a revolutionary,patented technology that has allowedthe arc spray process to rival the coat-ing quality of higher-end processes likeplasma spray. The ArcJet attachmentincreases particle velocities and con-centrates the spray pattern to producedramatically improved coating quality.Coatings are similar to plasma-sprayedcoatings; however, with the ArcJetattachment, these plasma-like coatingscan be produced in much less time and at a fraction of the cost.

Since the inception of arc spraying,power supplies used with the arc sprayequipment have been standard off-the-shelf or slightly modified welding powersupplies. Praxair has developed apower supply which minimizes the operating arc voltage. Lower operatingvoltage reduces the oxide levels withinthe coatings (improved particle size distribution) and increases deposit efficiency significantly depending on thematerial being sprayed. Importantly,the enhanced 353ECV power supply provides improved performance at lowervoltages than conventional power supplies by providing a more stable arcoutput. These benefits offer the usermaximum process reliability and flexi-bility, including a wider spray range.

Other advantages that the ArcJetattachment has over conventional arcspray configurations include:

• Higher deposition efficiency• Higher particle velocities• Denser coating• Focused, narrow spray pattern• Superior bond strength• Smoother as-sprayed coating• More uniform microstructure

For years, the arc spray process hasbeen limited in its ability to reach inter-nal diameters. The development of IDarc spray extensions has been a majorleap in improving process technology.Optional ID extensions, which are easilyadapted to existing guns, are availablein both straight-ahead and angle config-urations and come in a variety oflengths. In addition, highly engineerednozzles, tips and positioners have beendesigned for applications that demandmaximum durability.

SuperiorExceptional wires forsuperior coatings

Whether your application calls for a reli-able bond coat, dimensional restoration,or resistance to wear and corrosion,Praxair has a wire to meet the chal-lenge. All Praxair wires are engineeredand manufactured exclusively for thespecialized needs of thermal spray.Strict specifications and production con-trols are utilized so that each wire ismanufactured to a precise metallurgicalcomposition and is free from defectssuch as slivers or contaminants. Care isalso taken to ensure that our wires

have the proper physical properties forthermal spraying – tensile strength, hardness and surface finish – and thatthey are properly spooled for reliable performance.

When you search for the right thermalspray wire, remember the company that built its reputation on arc spray tech-nology: Praxair Surface Technologies. Let us work with you to continue to develop and perfect quality arc spraywires and coatings.

An extensive inventory ofwires, available in 25-or 30-pound spools aswell as bulk pay-off packs,assures prompt deliveryand reinforces our com-mitment to the growth and development of arcspray applications.

Quality thermal spraywires must be made to tight compositional tolerances, have theappropriate surface finish, and be spooled properly for consistentperformance.

© Copyright 2005 Praxair Technology, Inc.All rights reserved

Praxair Surface Technologies, Inc.1555 Main StreetIndianapolis, IN 46224USA

Telephone:1-317-240-2650

Fax:1-317-240-2596

Praxair Services GmbH & Co. KGAm Muhlbach 13D-87487 WiggensbachGermany

Telephone:+49-(0) 8370-9207-0

Fax:+49-(0) 8370-9207-20

www.praxair.com/[email protected]

Praxair, TAFA, the Flowing Airstream design, ArcJetand CoArc are trademarks or registered trademarks of Praxair Technology, Inc. in the United Statesand/or other countries.

The information contained herein is offered for use by technically qualified personnel at their discretion and risk without warranty of any kind.

Printed in the United States of America10-2005

TAFA IncorporatedA Praxair Surface Technologies company146 Pembroke RoadConcord, NH 03301USA

www.praxair.com/[email protected]

Telephone: 603-224-9585

Fax:603-225-4342

Praxair and TAFA are committed to continuous product improvement. Specifications, appearancesand dimensions are subject to change withoutnotice.

TAFA Incorporated is a Praxair Surface Technologiescompany.

All product photographs are not to scale and shouldbe used for information only. Photos might not represent the latest product revision and should notbe used for comparison purposes.

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