Tecnalia

Konbus+ Thermal spray system

UNITE. Thermal spraying system

We introduce our new thermal spray system, a combination of two advanced innovative spray processes in a single highly-flexible production unit.

These advanced processes are integrated into Konbus+, our new thermal spray system.

We offer the most suitable technology for the best coating solution in each application.

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Konbus+ brochure

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Konbus+ System

The Konbus+ System consists of the following elements:

  • Spray guns (HVOAF and HFPDneo).
  • Gas module for controlled supply of gas to the guns.
  • Electronic control module to control and monitor the processes and facilitate an user interface for the entire system.
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These core elements integrate standard, commercially available, primary components such as:

  • Powder feeder
  • Gas supply system
  • Water cooler
UNITE System architecture

UNITE System architecture

Furthermore, any auxiliary equipment required in the thermal spray cell (handling equipment, spray chamber, gas exhaust system, safety sensors, etc.) can easily be integrated into the Konbus+ system.

Konbus-system-control-desk

Konbus+ System control desk


Our offer

Our experience in surface engineering and thermal spraying technologies along with the unique characteristics of the Konbus+ system provide our clients with high added-value quality coatings and efficient cost-effective thermal spray processes.

We offer the following range of services

1

Analysis of coating solutions and application requirements.

2

Development of customised coatings and spraying procedures based on the Konbus+ system.

3

Coating characterisation and testing.

4

Industrial production plans based on the Konbus+ system.

5

Konbus+ system supply and commissioning.

Technology
Konbus+ spray processes: High Velocity Oxy Air Fuel (HVOAF)

The HVOAF gun embodies the state-of-the-art in advanced supersonic spray systems based on oxygen/air fuel combustion. The system is designed to operate with natural gas (methane) as fuel and process powder feedstocks within a wide spectrum of thermal conditions and velocity regimes. From solid state deposition conditions to supersonic spraying of molten/semi-molten particles, the system is capable of producing customized coating solutions with common characteristics of high density, compactness, bond strength and fine surfaces, with values even outperforming their HVOF counterparts.

High quality coatings can be produced to provide wear resistance, corrosion protection, additive repair as well as other applications using light alloys, metals and cermet materials. The system is equipped with different barrel lengths to achieve the most optimal feedstock powder treatment for each case.

HVOAF spraying advantages

  • Dense, compact, high-resistance, hard, low roughness and cold-formed micro-structures.
  • Improved functional properties for wear, corrosion and conductivity applications.
  • Thermo-sensitive powder material spray deposition.
  • Reduced oxidation and support interaction.
  • Small-size particle spraying.
  • Reduced pretreatment requirements for substrates (grit-blasting).
  • Reduced risk of nozzle clogging.
  • Reduced residual stresses by balanced impact / thermal effects.

Why natural gas (methane)?

  • Reduced combustion temperature
  • Safe and clean gas
  • Available as pressurized gas
  • Affordable and network distributed

Why natural gas + oxygen / air mixtures?

  • Tailored flame temperatures.
  • High gas flows to keep supersonic speeds and high pressures.
Konbus+ spray processes: High Frequency Pulse Detonation (HFPDneo)

Advantages of HFPDneo spraying

  • One of the leaders in the spray coating market.
  • Reduced thermal impact (minor residual stresses and improved fatigue properties).
  • Adjustable detonation frequency process.
  • Cermet and ceramic oxide coatings.
  • High productivity, low gas consumption, and highly reliable industrial process.

konbus+ coatings

The Konbus+ spraying system produces top quality and performance coatings in a wide range of materials, from low melting point Al- and Cu- base alloys to cermets and ceramic materials.

Cermets

Cermet coatings produced using HVOAF system. Micrographs and hardness values.

Metals and alloys

Solid state deposition from light alloys to Ni/Co alloys by HVOAF. Micrograph.

Ceramic materials

High-density ceramic coatings by HFPDneo, produced by the Konbus+ system.

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