For a thermal spray coating process to be successful and produce the best results possible, you need to invest in reliable, unparalleled thermal spray equipment and materials. By carefully choosing the best thermal spray spare parts, spray systems, and consumables for your operations, you can achieve consistent, quality coatings every time.
EPC knows how important it is for companies that perform thermal spray processes to have a reliable supplier to support their operations. We offer a huge range of first-class spare parts and consumables for you to choose from, including but not limited to:
- Gun parts
- Nozzles
- Electrodes
- powder injectors
- Barrels
- Air caps
- Wire guides
- Powder feeder parts
- Powder disks
- Suction/spreaders
- Stirrers
- Injectors
- Seal packages
HVOF Liquid Fuel
Liquid fuelled HVOF thermal spray coating processes offer certain advantages over processes that are fuelled by gas, such as the easy availability and handling of fuel plus the resulting dense coatings with higher bond strengths. At EPC, we stock two liquid fuel HVOF spray guns and their relevant spare parts: the eGun™ and the JP-5000 gun.
EGUN™ HVOF SPRAY GUN
The eGun™ is a liquid fuel HVOF torch that is fuelled by ethanol and capable of operating at combustion chamber pressures up to 13 bar (188 PSI) – which is 3-5 bar (43-73 PSI) more than conventional kerosene HP-HVOF systems. This higher combustion chamber pressure is proven to generate a higher flame velocity, which in turn generates higher particle velocity, which then results in improved coating density and better overall coating integrity. The eGun™ is also very economical to run as well as being eco-friendly; ethanol is an easy-to-obtain, low-cost fuel that provides repeatable and reproducible coatings, and burning ethanol results in 30% less toxic emissions than kerosene.
When the eGun™ is in operation during the thermal spray coating process, ethanol and oxygen are injected, mixed, and atomized in the pre-chamber before being ignited and partially burned to create a combustible fuel oxygen mixture. This mixture then enters the combustion chamber where efficient, clean combustion occurs (oxygen consumption is reduced by 30-50% in comparison with conventional kerosene combustion processes). After leaving the combustion chamber, the gasses pass through a carefully engineered nozzle creating a supersonic flame. At the end of the combustion chamber, the powder is radially injected into the interconnector, where it is mixed, heated, and accelerated to very high speeds resulting in a high-quality coating when it hits the surface material.
Key features and benefits of the eGun™:
- 30%-50% reduction in oxygen usage
- Ability to run very fuel-rich, creating new coatings and application opportunities
- Coating exhibit excellent wear resistance
- Compressive stresses in the coating
- Consistent fuel
- Dual-port, radially fed powder injection
- Easy smooth system starts and ramp-ups
- Environmentally friendly with minimal toxic fumes
- High-density coatings with minimal porosity
- Larger window of operation compared to kerosene (meaning better control over the balance between kinetic and thermal energy of the particles)
- Low impurities and oxides levels
- High coating integrity and uniformity
- Higher combustion chamber pressure results in higher particle speed
- Machine-mount for use with robots
- No ash formation
- Safe and reliable design
- Simple design means it’s easy to maintain
- Smooth “as-sprayed” surface finishes
- Superior microhardness compared to other thermal spray technologies
- Thick coatings, up to or exceeding 6mm (0.25 inch) are possible
- Up to 50% reduction in required cooling power
- Very high bond strengths, typically exceeding 80 MPa (10000 psi)
JP-5000 HVOF SPRAY GUN
The JP-5000 HVOF gun is often regarded as the benchmark for liquid-fuel HVOF guns, and it is designed to use kerosene fuel to create thick, high-quality coatings that protect the surface from corrosion and wear. This spray gun has a simple, rugged design utilizing robust components, making it low maintenance and capable of surviving long spray runs in the harshest of spray environments.
Kerosene and oxygen are fed into the JP-5000 spray gun, where they are atomized by the coaxial stabilizer and ignited in the combustion chamber, resulting in a supersonic flame. Then, any thermal spray powders are fed into the supersonic flame through two powder ports positioned directly after the combustion chamber. The stream is accelerated through a specialized nozzle at supersonic speed, coating the surface of the part being sprayed.
Key features and benefits of the JP-5000:
- Can be mounted onto a machine for use with robots
- Coatings demonstrate excellent wear resistance
- Compressive stresses in the spray coating
- Different barrel lengths available for specific thermal spray materials/coating results
- Dual-port, radially fed powder injection
- Economical process
- Highly polished barrel IDs to minimize build-up of material in the barrel
- High-density coatings with minimal porosity
- Low impurities and oxides levels
- Safe and reliable remote ignition design
- Simple, low-maintenance design
- Smooth “as-sprayed” surface finishes
- Superior microhardness compared to other thermal spray technologies
- Allows thick coatings, up to or exceeding 6mm (0.25inch)
- Very high bond strengths, typically exceeding 80MPa (10000psi)
JP-5000 HVOF Spray Gun spare parts
HVOF gas fuel
The gas fuel HVOF process is popular because it can create corrosion- and wear-resistant coatings that are hard, thick, dense, and have fine, homogeneous structures. Here at EPC, we can supply 3 gas fuel spray torches and their relevant spare parts to suit your needs: the DJ2600, the DJ2700, and the JetKote 3000.
DJ2600 HVOF torch
The DJ2600 HVOF thermal spray torch has been developed to produce high integrity coatings of metals, alloys, superalloys and carbides. The DJ2600 uses Hydrogen as the fuel. Coatings sprayed with the DJ2600 exhibit high density, low oxide content, good microhardness and high bond strengths with excellent machinability.
The DJ2600 process uses oxygen, fuel gas (Hydrogen) and air to produce a high-pressure flame, which provides uniform heating of the injected spray material. The gas stream is accelerated through a converging/diverging nozzle to supersonic speeds, forcing the powder particles towards the substrate where they deform upon impact, tenaciously bonding the coating to the substrate.
These coatings are very dense, with low porosity, predictable chemistries and fine, homogeneous microstructures. The axial powder injection focuses the coating material within the centre of the flame, reducing coating material build-up on the walls of the extended air cap and minimizing nozzle wear. As the Diamond Jet® process operates at high pressure, controllers and powder feeders are specifically designed for this HVOF process.
Key Features and Benefits of the DJ2600:
- Axial powder feed reduces coating material build-up on the extended air cap, increasing service life
- Coatings are dense and low in oxides, and they have low residual stress within the coating structure
- Coatings have very high bond strengths of up to 75 MP (10,000 psi)
- Easy to maintain with modular gun hardware that is simple to remove and replace without additional tools
- Generally accepted in the aerospace industry
- Produces coatings that protect against wear and corrosion, prolonging the life of the surface component
- Smooth “as-sprayed” surface finishes can be used as-is for many applications and reduce processing when post-coat machining is necessary
- Surfaces can be machined to high finishes and tight dimensional tolerances
- Water consumption for water-cooled guns is minimal
DJ2700 HVOF torch
The DJ2700 HVOF spray torch was specifically developed to produce high-integrity coatings of metals, alloys, superalloys, and carbides, using either natural gas, ethylene, propane, or propylene as fuel. The coatings this torch creates have a high density, a low oxide content, excellent microhardness and high bond strengths. The DJ2700 process uses oxygen, the fuel gas, and air to produce a high-pressure flame, which then heats the injected spray material. The gas stream is accelerated through a converging/diverging nozzle to supersonic speeds, propelling the powder particles towards the substrate where they bond to form a dense coating.
Key Features and Benefits of the DJ2700:
- Axial powder feed reduces coating material build-up on the extended air cap, increasing service life
- Coatings are dense and low in oxides, and they have low residual stress within the coating structure
- Coatings have very high bond strengths of up to 75 MP (10,000 psi)
- Easy to maintain with modular gun hardware that is simple to remove and replace without additional tools
- Produces coatings that protect against wear and corrosion, prolonging the life of the surface component
- Smooth “as-sprayed” surface finishes can be used as-is for many applications and reduce processing when post-coat machining is necessary
- Surfaces can be machined to high finishes and tight dimensional tolerances
- Water consumption for water-cooled guns is minimal
JetKote 3000 HVOF Gun
The JetKote 3000 HVOF gun delivers coatings with outstanding qualities thanks to its clever design that provides an axial powder injection.
During the thermal spraying process, powder is injected downstream of the combustion nozzle so that it is well mixed, and the particles can impact with high kinetic energy and have a lower, more consistent temperature compared to many other HVOF guns. This unique combustion design results in high coating hardness and excellent coating integrity. What’s more, the JetKote 3000 allows powders with a larger particle size to be used, which in many cases can decrease the powder cost in comparison with systems that need to use a smaller particle size.
Key Features and Benefits of the JetKote 3000:
- Central injection
- Easy to maintain
- Easy to operate
- Safe remote ignition
Plasma Spare Parts
Plasma spraying is a popular thermal spray coating method that helps to protect components against corrosion, oxidization, and general wear and tear. At EPC, we stock a range of plasma spray guns and spare parts, including: the 9MB plasma spray gun, the 3MB plasma spray gun, the 3MBT ID-plasma spray gun, the F4 Plasma Spray Gun, the F1 ID-plasma spray gun, the SG-100 plasma spray gun, 2700 & 2086 ID-plasma extension spray gun, the cGun, and the F4-HBS.
9MB PLASMA SPRAY GUN
In the thermal spray industry, the 9MB plasma spray gun is renowned for its reliability, being made from high-performance hardware that provides high kW range capability while also offering extended component service life. This model of spray gun has also been carefully engineered to achieve optimum heat transfer through uniform distribution of the cooling water within the electrode and nozzle, resulting in reduced downtime and maintenance, increased productivity, and cheaper operating costs.
The 9MB spray gun is incredibly flexible in its design. It’s capable of depositing high-quality coatings of metal, metal alloys, carbides, composites, blends, cermets, abradable and ceramic powders, and it can operate efficiently with a single primary gas of pure argon or nitrogen and with multi-gas parameters of argon, nitrogen, hydrogen, and helium. What’s more, the 9MB has a modular construction allowing for easy maintenance of major gun components and is available in both machine mount (9MBM) and handheld (9MBH) configurations.
Key Features and Benefits of the 9MB Plasma Spray Gun:
- Dual gas capability (either argon or nitrogen can be used as the primary plasma gas)
- Easy to operate, maintain, and install
- Electrode design allows for water cooling into the critical tungsten tip area, resulting in improved electrode life
- Hardware design – allows easy replacement and changeover of nozzles, electrodes and gas insulator assemblies
- High heat output (up to 28832°F) and high power (80 kW @ 100% duty cycle)
- High particle velocities (up to 610 m/s) and high plasma gas velocity (up to 3050 m/s)
- High spray rates resulting in improved production time
- Long-life gas insulators made from heat-resistant ceramics (ensures durability and uniform gas flow at high power levels)
- Proven nozzle design – economical replacement cost
9MB Plasma Spray Gun spare parts FST
3MB PLASMA SPRAY GUN
The 3MB plasma spray gun produces high-quality, consistent and repeatable thermal sprayed coatings. Like the 9MB spray gun, the 3MB is well-known for its ruggedness and reliable performance in a variety of thermal spray coating applications.
The 3MB spray gun is designed to be flexible, having a modular construction that allows for easy maintenance of major gun components and is available in both machine mount (3MBM) and handheld (3MBH) configurations. This spray gun is able to create high-quality coatings made of metal, metal alloys, carbides, composites, blends, cermets, abradable and ceramic powders, and it can operate efficiently with a single primary gas of pure argon or nitrogen and with multi-gas parameters of argon, nitrogen, hydrogen, and helium.
Key Features and Benefits of the 3MB Plasma Spray Gun:
- Available as machine mount or handheld
- Compact, durable, flexible design
- Complete range of nozzle and powder port components
- Dual gas capability (either argon or nitrogen can be used as the primary plasma gas)
- Easy to operate, maintain, and install
- High heat output (up to 28832°F)
- High particle velocities (up to 610 m/s) and high plasma gas velocity (up to 3050 m/s)
- Powerful (40kW @ 100% duty cycle)
3MB Plasma Gun spare parts FST
3MBT ID-PLASMA SPRAY GUN
The 3MBT is a heavy-duty extension plasma spray gun used for a wide variety of thermal spray coating applications. Its modular construction allows for easy maintenance of major gun components, and it conveniently uses many of the same parts as 3MB series spray guns, including nozzles, electrodes, powder ports and O-rings.
Key Features and Benefits 3MBT ID-Plasma Spray Gun:
- Applies high-quality TBC ceramics and associated bond coats
- Coats internal geometries as small as 100 mm (4”)
- Flexible spray angle of 90° or 30°
- Inexpensive operation cost using low-cost nitrogen as the plasma spray gas
- Powerful (40 kW @ 100% duty cycle)
- Uses many of the same spare parts as 3MB series guns, reducing the number of spare parts to stock
- Uses standard 3MB series plasma spray parameters for many applications, reducing parameter development time
- Versatile coating choices using a full complement of spray coating materials for practically any application
F4MB-X PLASMA SPRAY GUN
The F4MB-X is a machine-mounted, multi-purpose air plasma spray gun designed to be used in external thermal spray coating applications to produce reliable coatings. Engineered for reliable, effortless operation, the F4MB-X is capable of working at power levels up to 55 kW to deposit high-quality coatings of plasma-sprayed metals, metal alloys, carbides, composites, blends, cermets, abradable, and oxide ceramics. It can also be operated with combinations of argon, hydrogen, and helium plasma gases.
The F4MB-X nozzles are lined with tungsten for durability, as well as being designed to form a stable plasma that leads to high deposition efficiencies and minimal overspray during the coating process. The standard 6 mm nozzles mean that virtually all spray parameters can be met, minimizing hardware changes, while specialist nozzles are also available for use with nitrogen and nitrogen-hydrogen plasma gas mixtures.
Options and accessories:
- Air jet assembly
- F4MB-X centering tool
- F4MB-X injector gauge set
- F4-HBS plasma gun
- Hoses and cable made to length
- Parts, spare parts, and consumables
- Various powder injector assemblies
F1 ID-PLASMA SPRAY GUN
The F1 ID-plasma gun is recognized as a reliable gun that produces excellent results in the application of thermal spray coatings in internal surfaces of 75mm (3”) diameters or greater. This efficient spray gun is built to work power levels up to 25 kW in continuous operation, and is available in two spray angle configurations: 90° and 45°. Last but not least, the F1 benefits from a tungsten-lined nozzle similar to that used in the F4 spray gun, maximizing its life and minimizing part change-outs and production costs.
Key Features and Benefits of the F1 ID-Plasma Spray Gun:
- Able to operate with nitrogen as the primary fuel gas
- Easy to operate, maintain, and install
- Compact gun head design for small diameter applications
- Ideally suited for general purpose and advanced coating applications
- Inert gun head material that eliminates electrical shorting if the gun head contacts metallic components
- Low maintenance costs
- Long spray campaigns – long-life hardware allows longer spray periods without the need for change out
- Proven nozzle design with an economical replacement cost
- Reliable coating results – powder injector and gun head design ensure repeatable coatings
- Robust hardware configuration – sprays a wide range of coating materials with a single nozzle/electrode configuration
- Tungsten-lined nozzle for long-life performance
- Well-positioned powder injector holders that ensure proper injection angles and distances
F1 ID Plasma Spray Gun spare parts FST
SG-100 PLASMA SPRAY GUN
The SG-100 is a high-power (80 kW) multi-purpose plasma spray gun suitable for both high volume production applications and low volume applications where system flexibility is required. The SG-100’s unique design accepts internal or external powder injection, which both offer a variety of injection angles, and its limited number of components and self-aligning design makes rebuilding the gun a quick and easy task to complete when necessary.
The combination of dual internal and external powder injection makes the SG-100 the most versatile and efficient plasma spray gun on the market. The gun is very capable of operating in a range of spray velocities and modes, including subsonic, Mach I, and Mach II at up to 80 kW. This gun’s versatility also means it can work by utilising a variety of process gases including argon, nitrogen, helium, and hydrogen.
Key Features and Benefits of the SG-100:
- 90º adaptor
- Extended life anodes and cathodes
- High deposit efficiencies
- High power (80 kW)
- Internal diameter torch options (2700, 2086)
- Range of powder port hardware configurations
- Self-aligning components
SG-100 Plasma Spray Gun spare parts FST
2700 & 2086 ID-PLASMA EXTENSION SPRAY GUNS
The 2700 and 2086 plasma extension guns are versatile spray guns specifically designed for internal diameter thermal spray coating applications. The 2700 is designed to operate at power up to 30 kW, while 2086 can operate up to 40 kW. Both extension guns are supplied with 45º hardware (standard): configurations for 60º spray angles are also available for the 2086. Simplified anode design offers long hardware life and economical operation.
Both the 2700 and the 2086 are based on the proven SG-100 plasma spray gun design, so many of their components are interchangeable between the 2700, the 2086, and the SG-100. This is very convenient for operators because it means they can quickly convert the 2700 and 2086 into the more powerful SG-100 if necessary, which is able to operate at up to 80 kW.
Key Features and Benefits of the 2700 and 2086:
- Able to spray ID applications down to 1.5″ (for the 2700) or 3” (for the 2086)
- Available in 12″ and 24″ standard lengths (other lengths upon request).
- Available spray patterns are 45° or 60° angles
- Easy to maintain
- Repeatable coatings
- Self-aligning assembly
- Suitable for production and research
- The 2700 has a 30 kW capability and the 2086 has 40 kW capability
2700 & 2086 ID plasma spray gun
2086 SG-100 ID Plasma Gun Extension spare parts FST
CGUN
EPC’s sister company, FST, has begun to develop the cGun™, which is a high-voltage cascaded plasma torch. Conventional torches and systems come with some disadvantages including rifting and instability of plasma parameters (resulting in inconsistent coatings), low deposit efficiency, and high operating costs (including high flow rates of expensive plasma gases and the relatively short life of electrodes). It is predicted that the new cGun™ will overcome these challenges and offer a fresh way to conduct plasma spray coating processes.
Potential Key Features and Benefits of the cGun™:
- A wide operating window provides with presently unavailable, attractive new plasma parameters and related advanced coatings
- Cost reduction thanks to higher deposit efficiency, lower energy consumption and plasma gas flow rate, inexpensive gases, longer life of replaceable electrodes/parts, and higher production rate (due to higher spray rate and DE)
- Process stability results in coating consistency, a minimum level of rejected parts
F4-HBS PLASMA SPRAY GUN
The F4-HBS is a machine-mounted, multi-purpose air plasma spray gun used for external coating applications. The gun has been made to produce a reliable quality spray coating every time on metals, metal alloys, carbides, composites, blends, cermets, abradables, and oxide ceramics. Designed with reliable, stress-free thermal spray coating operations in mind, the F4 is capable of working with combinations of argon, hydrogen and helium plasma gases at power levels up to 55 kW.
The F4’s standard 6 mm nozzles mean that virtually all spray parameters can be met, minimizing hardware changes, and special nozzles are also available for use with nitrogen and nitrogen-hydrogen plasma gas mixtures. The gun’s nozzles are also lined with tungsten, meaning they have an extended life and are able to form a uniform and stable plasma that results in high deposition efficiencies and contributes to minimal overspray.
Options and Accessories:
- Air jet assembly
- F4 centering tool
- F4 injector gauge set
- Hoses and cable made to length
- Parts, spare parts, and consumables
- Various powder injector assemblies
Arc Wire Spray
Arc wire thermal spraying is a flexible process that can be used in a wide spectrum of industrial applications. At EPC, we stock the AWS-400 arc spray gun and the relevant spare parts to ensure you get great results every time.
AWS-400 ARC SPRAY GUN
The AWS-400 delivers optimal airflow and atomization with a variety of air caps that are designed to produce the correct spray pattern for any job, from the high-velocity air cap (featuring converging and diverging air chamber geometry) to the fan spray air cap (which provides the largest spray pattern).
The AWS-400 has no moving drive components, which reduces its weight significantly and virtually eliminates maintenance costs and downtime. Furthermore, no air cap or front wire guide adjustments are required with this spray gun, so you can expect repeatable, high-quality coatings year after year.
Key Features and Benefits of the AWS-400 Arc-Spray Gun:
- 6mm (1/16”) standard hardware
- Dead-man switch for handheld applications
- Easy to maintain with a longer life expectancy (no moving components)
- Full-function point and shoot trigger
- Lightweight design (less than 3 lbs.)
- Self-aligning air cap and wire guides
- Simple interface to an external controller