Axial III Core Technology

Axial III System

Mettech's Axial III Plasma Spray System is a high power, high efficiency deposition device with injection of feedstock materials directly into the centre of plasma plume – axial injection.  Axial III System has been field-proven both in deposition of conventional industrial coatings and high-performance applications such as graded coatings, reactive metal spraying, high temperature ceramics and spray forming.

The system is built around patented Axial III plasma spray torch and process. Axial III may be used in different spray technologies such as Atmospheric Plasma Spray (APS), Suspension Plasma Spray (SPS), or Vacuum Plasma Spray (VPS).

Axial III is fully computerized, which accounts for very high rate of consistency and reproducibility of sprayed coatings, safety of operators and equipment, and minimization of possibilities of human errors.

Control of Axial III deposition process is done by two computer based modules, one designed to control Axial III plasma process, the other to enable User Interface (UI).

The plasma process module includes all hardware control components and sensors required for safe operation of the system, as well as a dedicated computer that runs this module through Mettech’s proprietary control software.

PC based UI module is multifunctional. Its functions include storage and selection of process parameters, starting and stopping plasma, datalog of process variables, real-time trending, elements of Statistical Process Control (SPC), and graphical screens continuously displaying all parameters of plasma process.

This control architecture, where plasma process control is independent from UI, reduces risk of human error and allows for safe hands-free control of Axial III.

Both hardware and software components of Axial III control computers have been designed to allow easy interfacing with third party equipment commonly used within plasma spray infrastructure.  This feature provides for easy customizations, as well as facility of complete automation of the entire spray process from start to finish.

In-line Axial III In-line Axial III ID Axial III ID Axial III

Axial III Torch

Mettech's Axial III Torch is a high power, high velocity, and high efficiency plasma spray device.

Our patented, three cathode plasma torch supports axial injection of feedstock. Three plasma jets generated by three independent Direct Current (DC) arcs converge into one unified plasma plume inside the torch. The feedstock is injected into the centre of unified plasma jet along the axis of its flow.

Consequently, all of the feedstock remains fully entrapped inside the plasma and then uniformly heated before being projected onto the coated surface.

Due to elimination of feedstock losses during injection and increased efficiency of heating Deposition Efficiencies (DEs) of Axial III Torch are significantly higher than those of conventional torches.

Thanks to axial injection, three-plasma design, and outlet nozzle geometry, particle velocities can be tightly controlled in a very wide range.  The particle velocity range spans from lows comparable to conventional equipment to highs at HVOF levels. The high velocity feature allows Axial III to be used for deposition of coatings traditionally achievable only with HVOF systems but at much higher deposition rates and efficiencies. 

Axial III Spray Capabilities

  • spraying of all materials from plastics to ceramics
  • spraying of  fine powders <10 µm 
  • spraying of  nanopowders in suspensions
  • oblique angle spraying of cermets and ceramics
  • controlled plasma velocities from low to supersonic
  • spraying of  reactive materials
  • powder processing and manufacture

Applications of Axial III Sprayed Coatings

  • wear protection (abrasion, adhesion, fretting, erosion, cavitation)
  • thermal barriers
  • printing rollers
  • clearance control (abradable coatings)
  • restoration
  • corrosion /oxidation protection
  • electrical and electronic components

Benefits - Coating Quality

  • better reproducibility,
  • higher density
  • lower porosity
  • better homogeneity  
  • smoother surfaces
  • better control of sprayed areas

Benefits - Efficiency & Productivity

  • high deposition efficiencies
  • high deposition rates
  • high consistency
  • low overspray
  • low defect rate
  • long component lifetimes