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Combustion powder spray is suitable for maintenance, repair, restoration of machine parts, as well as abradable coatings used for clearance control applications.

It is a relatively flexible process in that it can be used to apply metals, alloys, carbides, polymers and even some ceramic powders. 

Key benefits of this process 
  • Equipment investment costs can be low
  • Greater flexibility of feedstock choices compared to Combustion Wire Spray
  • Coatings can be machined to final dimensions and finish

Typical applications

  • Crank shafts
  • Sucker rod couplings
  • Gas turbine shrouds for clearance control
  • Dimensional restoration of worn or mismachined parts

Process description

The feedstock material, in powder form, is continually fed into a fuel gas-oxygen flame where it is then melted by the heat of combustion. For most combustion powder spray systems, the powder is fed via a feeder using a carrier gas to transport it to the spray gun. The mixed gasses accelerate the melted particles onto the prepared workpiece surface where it rapidly solidifies to form a coating.

Graphic of combustion powder spraying

Process basics

  • Heat source: combustion 
  • Material: powder (metals, alloys, metallic blends or ceramics, ) 
  • Flame temperature: max. 3 100 °C (5 600 °F) 
  • Particle velocity: up to 50 m/s (165 ft/s) 
  • Approximate application rate: 35 to 150 g/min (4.5 to 20 lb/h) 

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