Boeing B777 Pin Hybrid HVAF Coating

Boeing B777 Pin being sprayed with our AH-06 Hybrid torch

Chrome Plating vs Hybrid HVAF Coating

Transitioning Away from Chrome Plating

As the Aerospace industry is looking to move away from traditional chrome plating on their components what are the alternatives?  One of the questions that we frequently get asked is “Can Hybrid HVAF effectively process the hundreds of thousands of parts that are currently chrome plated”.  The answer is a resounding YES, Hybrid HVAF can achieve very high spray rates.  Higher spray rates equate to a high amount of coating material being applied in a relatively short period.

Reduced Processing Time = Increased Productivity

With faster coating application, production throughput is increased. This is particularly advantageous in the aerospace industry to process large quantities of components within an expected timeframe.

The efficiency gained from high spray rates translate into time and cost savings. Less time spent on coating processes means lower labor costs and reduced energy consumption. Additionally, the overall cost per coated unit will decrease as a result of these time efficiencies.

Numbers Tell the True Story

Our video https://youtu.be/hbRQ6ZS3KrU demonstrates a Boeing B777 Pin coated with our AH-06 Hybrid torch depositing a WC-10Co4Cr coating at a spray rate of 62 lbs/hr (28kg/hr).  As demonstrated the total coating time to apply a 0.0065” (165µm) thickness was 2.28 minutes.  By comparison, traditional chrome plating processing time would be approximately 600 minutes.  Consequently, our AH-06 torch can easily spray 175-200 B777 pins in the time that it takes to chrome plate a typical batch size of 4 pins.

 

Benefits of High Spray Rate HVAF Coating

The benefits of high spray rates in HVAF include:

  • Increased Productivity: High spray rates allow for faster coating deposition, leading to increased productivity in the coating process. This is particularly beneficial in industrial applications where efficiency and throughput are critical.
  • Improved Coating Quality: Higher spray rates can contribute to improved coating quality by ensuring better coverage and uniformity. This can result in coatings with enhanced mechanical and thermal properties, providing improved performance and longevity.
  • Reduced Heat Transfer to Substrate: The high velocity of the HVAF process can help minimize heat transfer to the substrate. This is important for coating delicate or heat-sensitive materials, as it reduces the risk of substrate damage or distortion.
  • Enhanced Particle Kinetics: High spray rates contribute to increased particle kinetic energy, allowing for better adhesion to the substrate. This can lead to coatings with improved bond strength and durability.
  • Optimized Powder Efficiency: High spray rates can contribute to better powder utilization efficiency. This is important for cost savings, as it ensures that a higher percentage of the sprayed material is deposited onto the substrate, minimizing waste.
  • Increased Coating Thickness: The ability to achieve high spray rates provides flexibility in adjusting coating thickness. This is valuable in applications where varying coating thicknesses are required for different parts or components.
  • Cost Efficiency: Higher spray rates provide increased productivity and efficiency, that contributes to long-term cost savings, especially in large-scale or high-volume production environments.

Summary

Hybrid HVAF high spray rates contribute to increased productivity by enabling rapid and efficient coating application, reducing processing times, enhancing production throughput, and minimizing downtime. These benefits make Hybrid HVAF extremely valuable when coating performance and efficiency are critical.

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