Design improvements for spraying device-gun EM-17

In this case study an improved design of the spray-gun electric arc metallizer has been analyzed. To analyze the factors affecting the process of spraying a computer simulation with SolidWorks Flow Simulation to analyze gas-dynamic of spraying process of the electric arc metallizer EM-17 has been conducted. After analysis of identified weaknesses for industrial electrometallization device (large spray angle, low speed and flow instabilities) several construction design changes were offered. We proposed an upgrade design of spray device which is used as a nozzle with a cocurrent, compressing the main stream of the air stream. To confirm the theoretical research an experimental model of a spray device with improved design was made. During the tests it has been found that the spray angle dropped from 45°-60° to 15°-20°, efflux was more stable and uniform. Comparative analysis of the performance of the deposition showed that when using the advanced-gun, it increased by an average of 25 %. Comparative experimental study on deposition of different materials has been conducted. Metallographic studies sprayed samples showed that the coatings provide improved metallizer are more uniform and have less porosity. The microhardness of the coating has a higher value. Increased strength of adhesion of the coating to the substrate is 30 %, and corrosion resistance increased by 15 %. Decreased porosity of the coating is 20-30 %. The utilization of materials increased from 0.6 to 0.85.