Energy & Power, Heating, Cooling & Drying

Cooling Solution Helps Prevent Metal and Thermal Spraying Meltdown

Phil Black - PII Editor 14/04/2015

239 2 minutes read

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Thermal spraying is a process of applying a coating to a product, to enhance the performance and functionality of a substrate or component. The method can be used in a variety of industries including engineering, automotive, aerospace and aviation. The spraying process can often reach temperatures of up to 1200°C. Temperature control specialist, ICS Cool Energy, has launched its new i-Chiller range to ensure that equipment used in the spraying process is not compromised by extreme heat, and can continue to function efficiently.

Thermal spraying
ICS Cool Energy has recently provided a stable cooling solution to a Middle East and European thermal spraying specialist to prevent its devices from melting in excessive heat during operations.

The process involves a product being surrounded in a plasma, or HVOF (High Velocity Oxygen Fuel) gas, which changes the surface of that product to provide enhanced performance characteristics and ultimately improve its functionality. Due to the intense heat from gas coating (with temperatures in excess of 1200°C), the spray device gets extremely hot and would fail without a means to keep it cool.

Kevin Whyte, Sales Director at ICS Cool Energy, explains: “Our engineers designed and installed a number of temperature control units, the largest being a powerful 96kW iC-535 chiller. The unit features process pumps capable of providing variable pressures up to 10barG, with the capacity to keep its temperature where it needs to be. The new i-Chiller unit provides a long-term reliable solution which integrates with the existing equipment on site.”

Metal spraying
Whyte continues, “Similarly we have worked with a company who specialises in advanced metal spraying equipment who required a stable temperature control system to make sure its equipment didn’t melt in the 1200°C at which it operates.

“The metal spraying process involves a product being coated with strengthening, non-corrosive properties which provide enhanced performance characteristics and ultimately improves functionality. The coating is applied with a spray gun which needs to keep the coating at around 1200°C – any lower and the mixture used to coat the metal will clot and not fuse with the surface. Yet at this temperature, it’s important that the spray gun is cooled after use to retain its structure and form.”

ICS Cool Energy provided a solution which supplies water to the spray gun at 17°C with a return temperature of 56°C. In order to maintain the process temperature, the solution also comprised a packaged i-C412 with each thermal spray system.

Whyte continues, “The metal spraying equipment is now effectively cooled, preventing it from overheating and ensuring the process runs smoothly. Our range of powerful i-Chillers offers a higher standard of process cooling, providing reliable and consistent temperatures.”