For those of us hackers who have gone down a machining rabbit hole, we all know how annoying it can be to over-machine a part. Thermal spraying, while sounding sci-fi, is a method where you can just spray that metal back on your workpiece. If you don’t care about machining, how about a gun that shoots a shower of sparks just to coat your enemies in a layer of metal? Welcome to the world of thermal spraying, led by the one and only [Alec Steele].
There are three main techniques shown that can be used to coat using metal spools. The first, termed flame spraying, uses a propane flame and compressed air to blast fine drops of molten metal onto your surface. A fuel-heavy mixture allows the metal to remain unoxidized and protect any surface beneath. Perhaps one of the most fun to use is the arc method of thermal spray. Two wires feed together to short a high current circuit; all it takes from there is a little pressured air to create a shower of molten metal. This leaves the last method similar to the first, but uses a powder material rather than the wires used in flame spraying.
As with much crazy tech, the main uses of thermal spraying are somewhat mundane. Coating is applied to prevent oxidation, add material to be re-machined, or improve the mechanical resistance of a part. As expensive as this tech is, we would love to see someone attempt an open-source version to allow all of us at Hackaday to play with. Can’t call it too crazy when we have people making their own X-ray machines.
Username checks out.
Cutting Edge Engineering has a great video of unboxing and using an innovative metal arc spray system.
https://www.youtube.com/watch?v=VuMdyStDmPI
Side note: this guy is rebuilding a crane. By himself. Actually deserves the term “amazing”.
A spray coating video that comes without those clickbait title pic and video sequences. Enjoyed watching a craftsman handling this technology.
CEE is amazing. Dude repairs tons of heavy duty equipment for mining companies etc. So much fun to watch. He loves his job and isn’t a showman.
“Tons” is accurate, both literally and figuratively.
He can’t weld cast iron though which is pretty lame.
Waiting for your video showing you doing it perfectly. Not gonna hold my breath though.
Anyone know why hydrocarbon fuels are typically used? How is hydrogen embrittlement avoided?
I would think oxy-acetlylene would be the obvious choice to avoid this but it seems that hydrocarbons are the norm for this process.
I don’t know the answer, but acetylene is a hydrocarbon as well
Acetylene and copper may build copper acetylide which is a highly sensitive explosive.
A BAD idea for metal spraying. Might appear as GOOD idea with other applications, idk.
When the layer being deposited is so thin and non-structural, I don’t see a reason for that to be addressed.
Does it need to be avoided? It normally occurs when metal is in contact with high pressure hydrogen gas for extended periods of time. Neither variable is significant here.
I used to work on site with a robotic plasma spray system used for building up CF6 turbine rings before re-machining them. One of the bigger spray heads was fondly referred to as the rocket – powered through a palletised rack of hydrogen cylinders in less than a day when in use. The whole building shook when it was running. Super rad to watch the process through the thick viewing window.
Adam Booth [Abom79] has a playlist on this very subject:
https://www.youtube.com/playlist?list=PLaNH2qXIMRq-qadZkkPkSpLfVLIZHwz9C
It appears to contain 19 videos so a few good examples no doubt.
does anyone know the cost on the propane system, I mean, I probably can’t afford it but it is behind a “quote” system…. I hate it when sites won’t tell you an amount…..
Surprise butt-sex face on video thumbnail trend continues.
As defined, the most common ‘metal sprayer’ is a MIG welder.