High-power hypersonic plasma spray gun

Abstract

The invention belongs to the field of plasma spray guns, and particularly relates to a high-power hypersonic plasma spray gun which comprises an anode, a cathode rod insulator is installed in the anode, one end of the cathode rod insulator extends to the left side of the anode, and the outer side of the cathode rod insulator is sleeved with a water channel head. A distribution ring is installed between the water channel head and the cathode rod insulator, an anode cap is installed between the water channel head and the anode, a nozzle is installed in the water channel head, one end of the nozzle and one end of the water channel head are sleeved with the same nozzle cap, and a powder feeding frame is installed on the outer side of the nozzle cap through a detachable structure. Two powder feeding nozzles matched with the nozzles are installed on the powder feeding frame, and electrode tips matched with the nozzles are installed in the cathode rod insulator. The device is reasonable in design, high-temperature plasma flame flow can be generated through unique structural design, various kinds of powder can be melted more easily, the device is particularly suitable for spraying high-melting-point ceramic and other materials, and the spraying quality and efficiency are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of plasma spray guns, in particular to a high-power hypersonic plasma spray gun. Background Art

[0002] Thermal spraying is a process in which a coating material (powder or wire) is melted by a heat source (arc, flame, plasma, etc.) and then sprayed onto the surface of a substrate using a high-speed airflow to form a coating. Thermal spray coatings not only exhibit excellent properties such as wear resistance, corrosion resistance, high temperature resistance, and thermal insulation, but also can repair part size reduction caused by wear, corrosion, or machining tolerances. They are widely used in the military, aerospace, printing, textile, machinery manufacturing, petrochemical, and other fields. With the advancement of modern industrial technology, the demand for high-strength, high-performance coatings on the surfaces of mechanical components is becoming increasingly urgent.

[0003] Currently, the performance requirements for plasma spray guns are becoming increasingly stringent. Conventional plasma spray guns, when spraying high-melting-point materials, suffer from issues such as difficulty melting the powder and poor spraying results. Furthermore, under high-power operation, the guns also suffer from numerous deficiencies in cooling, gas distribution, and powder transport, making them unable to meet the demands of modern industry for high-quality, high-efficiency spraying. Therefore, we have developed a high-power hypersonic plasma spray gun to address these issues. Summary of the Invention

[0004] The purpose of the present invention is to solve the shortcomings of the prior art and to propose a high-power hypersonic plasma spray gun.

[0005] In order to achieve the above object, the present invention adopts the following technical solutions: A high-power hypersonic plasma spray gun includes an anode, a cathode rod insulator is installed in the anode, and one end of the cathode rod insulator extends to the left side of the anode, a water channel head is installed on the outside of the cathode rod insulator, a distribution ring is installed between the water channel head and the cathode rod insulator, and an anode cap is installed between the water channel head and the anode; A nozzle is installed in the water channel head, and the nozzle and one end of the water channel head are covered with the same nozzle cap. A powder feeding rack is installed on the outside of the nozzle cap through a detachable structure, and two powder feeding nozzles adapted to the nozzle are installed on the powder feeding rack; An electrode head adapted to the nozzle is installed in the cathode rod insulator, a cathode rod is installed at the right end of the electrode head, and the right end of the cathode rod extends to the right side of the anode, and an electrode head cooling duct is provided between the cathode rod and the electrode head; The cathode rod is provided with a cathode rod front insulator, which is installed in the anode and sealed with the cathode rod insulator. The cathode rod middle insulator is installed on the rear side of the cathode rod front insulator, and the cathode rod rear insulator is installed on the rear side of the cathode rod middle insulator. The cathode rod rear insulator is connected to the anode through the cathode rod cap.

[0006] Preferably, a water cable adapter is installed on the top of the anode, and a gas adapter is provided on one side of the anode.

[0007] Preferably, a gas channel is provided in the cathode rod insulator, the gas adapter is connected to the gas channel, and the gas is adapted to the distribution ring.

[0008] Preferably, the water channel head is provided with a plurality of water channels, and the water cable adapter is connected to the water channels.

[0009] Preferably, a water return hole is provided on the cathode rod, and the water return hole is connected to the electrode head cooling conduit.

[0010] Preferably, a sealing ring 1 is provided at the connection between the nozzle and the water head, the sealing ring 1 is located inside the nozzle cap, and the sealing ring 1 contacts the inner wall of the nozzle cap.

[0011] Preferably, a plurality of sealing grooves 1 are opened on the outer side of the cathode rod insulator, and sealing rings 2 are sleeved in the sealing grooves. The sealing ring 2 on the left is sealed connected to the water channel head, and the sealing ring 2 on the right is sealed connected to the anode.

[0012] Preferably, a plurality of sealing grooves 2 are opened on the outside of the cathode rod, and sealing rings 3 are installed in the sealing grooves 2. The sealing ring 3 on the left is sealed connected to the cathode rod insulator, and the sealing ring 3 on the right is sealed connected to the cathode rod front insulator.

[0013] Preferably, a spray gun handle is installed at the bottom of the anode, and the spray gun handle is fixedly connected to the anode by screws.

[0014] Beneficial effects of the present invention: 1. The high-power hypersonic plasma spray gun, through its unique structural design, can generate high-temperature plasma flame flow, making various powders easier to melt. It is especially suitable for spraying materials such as high-melting-point ceramics, improving the spraying quality and efficiency.

[0015] 2. The optimized gas distribution structure and powder feeding structure ensure the uniform distribution of gas and the stable delivery of powder, further improving the spraying effect.

[0016] 3. The perfect water-cooling system effectively solves the heat dissipation problem of the spray gun under high-power working state, ensuring long-term stable operation of the spray gun.

[0017] 4. The two modes of use, machine installation and manual operation, increase the flexibility of the spray gun and meet the needs of different working scenarios. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a schematic diagram of the main structure of the high-power hypersonic plasma spray gun proposed by the present invention; Figure 2 This is a side structural schematic diagram of the high-power hypersonic plasma spray gun proposed by the present invention; Figure 3 This is a schematic diagram of the three-dimensional structure of the high-power hypersonic plasma spray gun proposed by the present invention; Figure 4 This is a rear perspective structural diagram of the high-power hypersonic plasma spray gun proposed by the present invention; Figure 5 This is a schematic cross-sectional view of the high-power hypersonic plasma spray gun proposed by the present invention; Figure 6 This is an exploded view of the high-power hypersonic plasma spray gun proposed by the present invention.

[0019] In the figure: 1. Powder feed nozzle; 2. Powder feed rack; 3. Nozzle; 4. Nozzle cap; 5. Water channel head; 6. Distribution ring; 7. Electrode head; 8. Cathode rod insulator; 9. Anode cap; 10. Electrode head cooling duct; 11. Cathode rod; 12. Anode; 13. Cathode rod front insulator; 14. Gas adapter; 15. Water cable adapter; 16. Cathode rod middle insulator; 17. Cathode rod rear insulator; 18. Cathode rod cap; 19. Spray gun handle. DETAILED DESCRIPTION

[0020] The technical solutions of the present invention will be described clearly and completely below with reference to specific embodiments. Obviously, the embodiments described are only some of the embodiments of the present invention, not all of them. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without inventive effort are also within the scope of protection of the present invention.

[0021] When a component is referred to as being "disposed on" another component, it can be directly on the other component or there can be an intervening component. "Disposed" indicates a way of existence, which can be a connection method such as connection, installation, fixed connection, active connection, etc. When a component is considered to be "connected" to another component, it can be directly connected to the other component or there can be an intervening component at the same time.

[0022] Reference Figure 1-6, a high-power hypersonic plasma spray gun, including an anode 12, a cathode rod insulator 8 is installed in the anode 12, and one end of the cathode rod insulator 8 extends to the left side of the anode 12, a water channel head 5 is sleeved on the outside of the cathode rod insulator 8, and a distribution ring 6 is installed between the water channel head 5 and the cathode rod insulator 8, an anode parallel cap 9 is installed between the water channel head 5 and the anode 12, a nozzle 3 is installed in the water channel head 5, and the nozzle 3 and one end of the water channel head 5 are sleeved with the same nozzle parallel cap 4, and a powder feeding rack 2 is installed on the outside of the nozzle parallel cap 4 through a detachable structure, and two powder feeding nozzles 1 compatible with the nozzle 3 are installed on the powder feeding rack 2; An electrode head 7 that is compatible with the nozzle 3 is installed in the cathode rod insulator 8, a cathode rod 11 is installed at the right end of the electrode head 7, and the right end of the cathode rod 11 extends to the right side of the anode 12, an electrode head cooling duct 10 is provided between the cathode rod 11 and the electrode head 7, a cathode rod front insulator 13 is mounted on the cathode rod 11, the cathode rod front insulator 13 is installed in the anode 12 and is sealed with the cathode rod insulator 8, a cathode rod middle insulator 16 is installed on the rear side of the cathode rod front insulator 13, a cathode rod rear insulator 17 is installed on the rear side of the cathode rod middle insulator 16, and the cathode rod rear insulator 17 is connected to the anode 12 through the cathode rod parallel cap 18. This layered insulation and connection structure design ensures the stable operation of the cathode system, while effectively preventing current leakage, improving the safety and reliability of the spray gun operation, and ensuring that the electrode head 7 and the cathode rod 11 can work normally under high voltage and high current environments.

[0023] In this embodiment, a water cable adapter 15 is installed on the top of the anode 12, and a gas adapter 14 is provided on one side of the anode 12. The reasonable layout of the water cable adapter 15 and the gas adapter 14 facilitates the access of cooling water and working gas, so that the cooling system and the gas supply system can operate efficiently, ensuring the temperature control of the spray gun during operation and the stable generation of plasma flame flow.

[0024] In this embodiment, a gas channel is provided in the cathode rod insulator 8, the gas adapter 14 is connected to the gas channel, and the gas is adapted to the distribution ring 6. The cooperation between the gas channel and the distribution ring 6 ensures that the working gas can be evenly and stably transported to the inside of the spray gun, providing a guarantee for generating a stable and high-quality plasma flame flow, which is beneficial to improving the uniformity and quality of spraying.

[0025] In this embodiment, multiple water channels are provided on the water channel head 5, and the water cable adapter 15 is connected to the water channels. The design of multiple water channels increases the circulation area of ​​cooling water and improves the cooling efficiency. It is connected to the water cable adapter 15, so that deionized water can circulate efficiently, effectively taking away a large amount of heat generated when the spray gun is working, ensuring that the spray gun operates stably for a long time and extending the service life of the spray gun.

[0026] In this embodiment, a return water hole is opened on the cathode rod 11, and the return water hole is connected to the electrode head cooling duct 10. The return water hole is connected to the electrode head cooling duct 10, forming a complete cooling circulation loop, which can take away the heat generated by the electrode head 7 in time, prevent the electrode head 7 from being damaged due to overheating, ensure the normal operation of the electrode head 7 in a high temperature environment, and thus ensure the stable performance of the spray gun.

[0027] In this embodiment, a sealing ring 1 is provided at the connection between the nozzle 3 and the water head 5. The sealing ring 1 is located inside the nozzle cap 4 and contacts the inner wall of the nozzle cap 4. The setting of the sealing ring 1 effectively prevents the leakage of working gas and cooling water, ensures the pressure stability inside the spray gun, improves the sealing and reliability of the spray gun, and thus ensures the stability and continuity of the spraying process.

[0028] In this embodiment, a plurality of sealing grooves 1 are provided on the outer side of the cathode rod insulator 8, and a sealing ring 2 is provided in the sealing groove. The sealing ring 2 on the left side is sealed with the water channel head 5, and the sealing ring 2 on the right side is sealed with the anode 12. The sealing connection of the sealing ring 2 in the sealing groove 1 further enhances the sealing between the cathode rod insulator 8 and the water channel head 5 and the anode 12, prevents the leakage of gas and liquid, ensures the normal operation of various systems inside the spray gun, and improves the overall working performance of the spray gun.

[0029] In this embodiment, a plurality of sealing grooves 2 are provided on the outer side of the cathode rod 11, and a sealing ring 3 is installed in the sealing groove 2. The sealing ring 3 on the left side is sealed with the cathode rod insulator 8, and the sealing ring 3 on the right side is sealed with the cathode rod front insulator 13. The sealing effect of the sealing ring 3 in the sealing groove 2 effectively prevents current leakage and liquid leakage, ensures the electrical insulation and sealing performance between the cathode rod 11 and the surrounding components, and improves the stability and reliability of the spray gun in a complex working environment.

[0030] In this embodiment, a spray gun handle 19 is installed at the bottom of the anode 12, and the spray gun handle 19 is fixedly connected to the anode 12 by screws. The installation of the spray gun handle 19 enables the spray gun to have the function of handheld operation, which is convenient for the operator to use flexibly in different work scenarios, increases the flexibility of the spray gun, and meets diverse spraying needs.

[0031] The high-power hypersonic plasma spray guns of the present invention are available in two types: machine-mounted and manual. The gun can be handheld with a handle installed, or mounted on a robotic arm by removing the screw holes for mechanized spraying. The gun uses argon (or nitrogen) as the primary gas and hydrogen (or helium) as the secondary gas. Gas pipes are installed through a gas adapter 14. Gas enters the anode 12 and then enters the cathode rod insulator 8 through the air holes. The gas is evenly distributed by a distribution ring 6. A certain voltage and current are applied between the cathode and anode 12, generating a plasma flame. Powder passes through the powder feed nozzle 1 and reaches the front end of the nozzle 3, where it is heated and sprayed, completing the spraying process. The high plasma arc temperature makes various powders more easily meltable, highlighting its excellent performance when spraying high-melting-point ceramics. Due to the high temperature during the spraying process, water cooling is required. Deionized water is introduced through the anode 12, circulated through holes in the gun, and finally discharged from the cathode rod 11, achieving a cooling effect.

[0032] The high-power hypersonic plasma spray gun provided by the present invention has been introduced in detail above. The principles and implementation methods of the present invention are described herein using specific embodiments. The description of the above embodiments is intended only to facilitate understanding of the method and core concept of the present invention. It should be noted that those skilled in the art may make various improvements and modifications to the present invention without departing from the principles of the present invention, and such improvements and modifications also fall within the scope of protection of the claims of the present invention.

Claims

1. High-power hypersonic plasma spray gun, characterized by: The invention comprises an anode (12), a cathode rod insulator (8) is installed in the anode (12), and one end of the cathode rod insulator (8) extends to the left side of the anode (12), a water channel head (5) is sleeved on the outside of the cathode rod insulator (8), a distribution ring (6) is installed between the water channel head (5) and the cathode rod insulator (8), and an anode cap (9) is installed between the water channel head (5) and the anode (12); A nozzle (3) is installed in the water channel head (5), and the nozzle (3) and one end of the water channel head (5) are sleeved with the same nozzle cap (4), and a powder feeding frame (2) is installed on the outer side of the nozzle cap (4) through a detachable structure, and two powder feeding nozzles (1) adapted to the nozzle (3) are installed on the powder feeding frame (2); An electrode head (7) adapted to the nozzle (3) is installed in the cathode rod insulator (8), a cathode rod (11) is installed at the right end of the electrode head (7), and the right end of the cathode rod (11) extends to the right side of the anode (12), and an electrode head cooling conduit (10) is provided between the cathode rod (11) and the electrode head (7); The cathode rod (11) is provided with a cathode rod front insulator (13), which is installed in the anode (12) and sealed with the cathode rod insulator (8). A cathode rod middle insulator (16) is installed on the rear side of the cathode rod front insulator (13), and a cathode rod rear insulator (17) is installed on the rear side of the cathode rod middle insulator (16). The cathode rod rear insulator (17) is connected to the anode (12) through a cathode rod cap (18).

2. The high-power hypersonic plasma spray gun according to claim 1, characterized in that: A water cable adapter (15) is installed on the top of the anode (12), and a gas adapter (14) is provided on one side of the anode (12).

3. The high-power hypersonic plasma spray gun according to claim 1, characterized in that: A gas channel is provided in the cathode rod insulator (8), the gas adapter (14) is connected to the gas channel, and the gas is adapted to the distribution ring (6).

4. The high-power hypersonic plasma spray gun according to claim 1, characterized in that: The water channel head (5) is provided with a plurality of water channels, and the water cable adapter (15) is connected to the water channels.

5. The high-power hypersonic plasma spray gun according to claim 1, characterized in that: A water return hole is provided on the cathode rod (11), and the water return hole is connected to the electrode head cooling conduit (10).

6. The high-power hypersonic plasma spray gun according to claim 1, characterized in that: A sealing ring 1 is sleeved at the connection between the nozzle (3) and the waterway head (5), the sealing ring 1 is located inside the nozzle cap (4), and the sealing ring 1 contacts the inner wall of the nozzle cap (4).

7. The high-power hypersonic plasma spray gun according to claim 1, characterized in that: The cathode rod insulator (8) is provided with a plurality of sealing grooves 1 on the outside, and sealing rings 2 are sleeved in the sealing grooves. The sealing rings 2 on the left are sealedly connected to the water channel head (5), and the sealing rings 2 on the right are sealedly connected to the anode (12).

8. The high-power hypersonic plasma spray gun according to claim 1, characterized in that: The cathode rod (11) is provided with a plurality of sealing grooves 2 on the outside thereof, and sealing rings 3 are installed in the sealing grooves 2. The sealing rings 3 on the left side are sealedly connected to the cathode rod insulator (8), and the sealing rings 3 on the right side are sealedly connected to the cathode rod front insulator (13).

9. The high-power hypersonic plasma spray gun according to claim 1, characterized in that: A spray gun handle (19) is installed at the bottom of the anode (12), and the spray gun handle (19) is fixedly connected to the anode (12) by screws.

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