Coating of industrial woven fabrics by wire flame spraying
GTV K2 spraying gun
GTV GLC spraying gun
5PII gun
6PII gun
These days the main product spectrum of GTV concerns HVOF and plasma spraying equipment and installations that are tailored to the desires of our customers and their specific applications.
Use of modern Siemens control units (S7 300U) combined with mass flow controllers guarantee the highest possible reproducibility concerning thermal spray coatings properties. GTV control units also feature easy and secure use as well as highest functional safety.
But our control units (type VIP6000) also attract customers due to their outer appearance. The reason is the increasing marketing conscience of job shops that want to demonstrate their customers that their high tech components are also coated with modern, high quality spraying equipment.
Besides the highest possible reproducibilty combined with the possibility of fast documentation of relevant data GTV control units also offer the opportunity to control multiple spraying guns of the same type for mass coating production or to control different types of spraying guns, e.g. HVOF and plasma spraying guns, that can be used in the same installation by switching between them. The acceptance of such installations is growing staedily. In both cases costs and potentially costly space is saved. Only a single SPS control unit with a single control panel, a slightly larger gas cabin and in some cases a heat exchanger with increased cooling capacity is needed. The alternative case would mean as many single components as the number of spraying guns.
Plasma Spraying
GTV plasma spraying equipment type MF-P1000 (100 kW, 1000 A, SPS- and mass flow controlled) consist mainly of components listed in the following table:
Plasma control panel type VIP 6000 with Siemens Operator Panel type MP270/PC677
Visualisation software: Protool or WinCC
Separate SPS cabin with Siemens SPS type S7 U300 control unit
Separate gas cabin with mass flow controllers
Jam Box: current water transition with cooling water control and HF ignition
100 kW chopper electrical power supply PPC 2002 with continuously variable current ranging from 20 A (!) up to 1000 A (up to 120 V (working) voltage)
GTV plasma spraying gun type F6 with fast connectors (other available guns: F1, F4, 3/7/9MB, P2, SG100, 3K Magnum, Delta)
GTV powder feeder PF2/2 (type Twin 10); closed-loop powder mass flow controlled powder feeders, also available powder feeders: Mark XV, Miller 1264
Heat exchanger type PC250/VWK320 or special solutions, also with energy recovering
Complete hose and cable set (length dependend on customers demands)
Detailed documentation
Of course, CE conformity is ascertained! Additional powder feed lines as well as alternative or additional plasma gas lines are imparted according to customers specifications. All gases (Ar, H2, He, N2) can be mixed as desired in order to e.g. increase deposition rate or efficiency.
GTV always loves to realise special customer demands or to provide options for increased flexibility!
Wire flame spraying equipment features relatively easy construction. GTV offers wire flame spraying guns type 11E, 12E, 15E as well as 7K.
Type 11E guns are provided with simple volumetric flowmeters for oxygen, azetylene or propane as well as pressure reducers and the according gas hoses with fast connectors. They are mainly applied for zinc coating production. Other low melting materials like aluminium or tin can be processed as well. The gun is handeled manually. Wire feeding is realized by means of a turbine powered by compressed air. Compressed air is also used to cool the spraying gun. If desired, a flowmeter for control of the compressed air flow can be purchased.
Component spectrum and handling of type 12E guns is equivalent to 11E guns. However, this gun contains a wire feed unit that is adapted for spraying of high melting materials like steels or molybdenum. Significantly lower feed rates compred to the type 11E gun are realized.
The type 15E gun is equipped with a wire feed unit that is powered by an electric motor. The wire feed rate can be adjusted continuously variable.
The type 7K wire flame spraying gun is tailored for mass coating production and needs to be moved by an automated handling system. It is only provided in combination with mass flow control of gas flows, automatic ignition, operator panel and SPS control unit. The construction concept is equivalent to GTV HVOF systems. However, there is no need for a heat exchanger, because the type 7K gun is cooled by compressed air.
Commonly wires from the GTV consumable material group 50 with 2.3 mm, 3.17 mm and 4.76 mm diameter are applied. Depending on the desired properties of coatings in use very low or very high porosity coatings can be produced.
GTV HVOF spraying equipment type MF-K-G 2000 (kerosene - 250 kW and gas fuel, SPS- and mass flow controlled) consist mainly of the components listed in the following table:
HVOF control panel type VIP6000 with Siemens operator panel type MP270B/PC6700
Separate SPS cabin with Siemens SPS type S7 U300 control unit
Separate gas cabin with mass flow controllers (Bronkhorst or Bürkert)
Separate kerosene pump unit for liquid fuels
GTV HVOF kerosene gun type GTV K2 GUN (other guns possible, if desired)
GTV HVOF gas fuel gun type GTV G GUN (other guns possible, if desired)
GTV powder feeder PF2/2, type Twin 10 (other powder feeders possible, if desired)
GTV 95 kW heat exchanger type VWK630 with CGC-free refrigerant type R407C
Complete hose and cable set (length dependend on customers demands)
Powder flame spraying equipment features relatively easy construction. GTV offers powder flame spraying guns type 5PII and 6PII as well as the complete UTP gun spectrum.
All powder flame spraying guns are provided with simple volumetric gas flowmeters for oxygen, acetylene or propane as well as the required pressure reducers and hoses with fast connectors. Generally, all kinds of powder materials can be processed. Depending on the coating material, choice of process parameters and nozzle configuration coatings show a more or less porous microstructure and according properties. Powder flame spraying is in the first place applied for spraying of so called self fluxing NiCrBSi alloys (GTV consumable material group 10) and self bonding materials (GTV consumable material group 20).
All spraying guns can be purchased with mass flow control, automatic ignition, SPS control and operator panel. The construction concept is equivalent to GTV HVOF systems. However, there is no need for a heat exchanger, because powder flame spraying guns are cooled by compressed air. For UTP spraying guns type F311 and Uni Spray Jet as well as 6PII according powder feeders are available. The 6PII gun can only be used in combination with a powder feeder.
Arc spraying features low investment costs and costs in use as well as high deposition rates and efficiencies. Therefore coating production is achieved particularly economical, if the desired coating material is available as electrically conductive wire. GTV offers type SPARC 400 systems that contain secondary chopped inverter power supplies that are already standard in the field of plasma spraying. In combination with the machine gun GIGASPARC that features particularly reliable push/pull technology for the wire feed unsurpassed process stability and also coating quality are achieved.
GTV arc spraying systems type SPARC 400 are delivered with heavy duty rolls in order to permit reliable mobility for on-site coating applications. The demountable display allows setting and monitoring of all relevant process parameters, while the spraying process is watched. There is possibility to save recipes of process parameter sets
Technical data:
Supply voltage: 3 x 400 V, 50 Hz
Power: 22 kVA
Efficiency cos.phi: 0.98
Mains fuse: 32 A
Supply wiring: 4 x 6 mm²
Output current: 400 A
Output volatge: 10 - 70 V
