All you need to know about a flame spray gun!

Flame spray guns are used for providing a coating on metallic surfaces of various parts and products. These products have wide-ranging industrial uses in the fields of aviation, automotive, and electrical & electronics. 

An oxy-fuel flame is used in the Flame Spray Gun method to melt the wires. After being melted, the molten metal is atomized using compressed air to produce a spray stream that coats the target surface. Uses for the flame spray gun include spraying ferrous and nonferrous materials. Restoration of tattered components, conductivity, and anti-corrosion coating are major uses.

Flame spray coating

A plastic powder is filled using a flame spray coating technique, which causes the powder to partly melt and fuse as it comes into contact with the substrate. The flame preheats the component's surface. 

To manage the temperature, it is customary to only coat a few square meters at a time. After then, the flame is altered. The powder is turned off when the coating is finished, and the coating is then post-heated using a flame. Spraying with flames is very beneficial for covering objects whose surfaces are too vast to be heated in an oven. The issues with an open flame and the requirement for competent operators to apply the coating are drawbacks.

The process

A gun nozzle is used in the century-old technique known as a flame spray to inject a fuel combination, such as acetylene, propane, or hydrogen, together with oxygen. To produce a flame outside the nozzle, the gas mixture is burned in the front of the nozzle. The temperature of the flame varies between 3000 and 3300°C (5430 to 5970°F), depending on the oxygen-to-fuel ratio. 

The coating substance, which might be in the form of wire or powder, will determine the nozzle choice. To regulate the spray pattern, a cold air sheath is employed to collimate the flame. The coating material is gravity fed to the cannon from a hopper in the powder feed system. The powder is carried across the flame by aspirating gas. 

During their passage through the flame, the powder particles melt and deposit on the metal. A roller drive mechanism in the wire feed system continuously feeds the wire tip into the flame. By injecting compressed air, the molten material at the wire's tip is broken up and sent toward the substrate. The coating qualities are determined by the wire diameter and feed rate, air and gas flow rates, flame temperature, and gas pressure.

Benefits and advantages of using a flame spray gun

• Technical advantages: As these coatings contain less oxide, they may be simpler to apply technically. An advanced design of a flame spray gun works fast. It saves time while accomplishing the task at the optimal level. 

• Benefits to operations: The non-conductive wires needed for spraying by this equipment. Moreover, they produce far less dust when the machine is operating. Explosion and fire incidents are hence significantly less likely. These devices may be transported to several site sites for spraying because they are very lightweight, portable, and convenient.

• Economic advantages: Using wire for spray coating is frequently more cost-effective than using powder. Moreover, initial equipment or machine purchases need far fewer expenditures than other processes.

A drive unit with a motor and rollers for feeding the wire, a gas head with valves, a gas nozzle, and an air cap that controls the air of the flame are the components of the wire flame spray gun. 

One thing is certain: These machines are employed in a variety of sectors today and have gained popularity because of their design, low weight, cost-effectiveness, clean operation, and quick mechanism. IMC provides a flame spray gun that meets international standards and performs well. They are manufacturing flame spray guns as per industry standards.