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Oxygen - PowerPoint PPT Presentation

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Gun Head. Air Envelope. Shock Diamonds due to Supersonic Speeds of the Particles. Compressed Air. Oxy - Propylene. Powder With Nitrogen Carrier Gas. Sprayed Material. Combustion Zone. Molten Powder Particles. Oxy-Fuel Flame at a Maximum Temperature of 2760 o C. Forming Die.

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Presentation Transcript

Gun Head


Shock Diamonds due to Supersonic Speeds of the Particles

Compressed Air


Powder With

NitrogenCarrier Gas

Sprayed Material

Combustion Zone

Molten Powder Particles

Oxy-Fuel Flame at a Maximum Temperature of 2760oC

Forming Die

Air control unit


Flow meter unit

Compressed air

Powder feed unit

Spray booth

Cooling nozzles


Electric control box





HVOF (High Velocity Oxy-Fuel) Thermal Spray ProcessDr. Joseph Stokes and Dr. Lisa LooneyMaterials Processing Research Centre, Dublin City University, Dublin 9, Ireland


The HVOF thermal spraying system at DCU uses propylene as the combustion gas in combination with oxygen and compressed air. Powder material is transported to the flame of a combustion zone in the spray gun, where it becomes molten or semi-molten, at temperatures between 2300 and 3000°C. These particles are then propelled from the gun nozzle at supersonic velocities towards a substrate or forming die, where the material deposits.

The Cross-Section of Diamond Jet Spray Gun

Development of the System:

Modifications to the existing system were needed to improve process control and to ensure repeatability of experiments. These included installation of a linear traverse unit to automate movement of the spray gun, and incorporation of a carbon dioxide system for forced cooling.

Schematic of the HVOF Thermal Spray Process

Fabricated Free Standing Components using the HVOF Process


The production of free standing engineering components using the HVOF process is being examined. Research is focused on WC-Co material, commonly used to produce cutting tool inserts and other wear parts. Carbide solid components are generally produced by powder compaction followed by sintering. Spray forming does not incur the high costs of powder compaction, sintering and finishing by grinding. However, difficulties in forming high thickness components arise due to the build up of residual stress.