Factory Supply Plasma Spray Gun F4 Nozzle

• Customization: Available
• Application: Plasma Spray
• Material: Copper Inlaid with Tungsten Electrode
• Model NO.: F4 nozzle
• Nozzle Size: 6mm
• Pressure Range: 150-200 PSI
• Spray Angle: 90 degrees
• Spray Pattern: Powder Spraying
• Apply in: Plasma Spray Coating Industry
• Making Method: Back-Casting
• Style: Standard
• Internal Diameter: 5mm, 6mm, 7mm, 8mm
• Certificate: ISO, RoHS
• Condition: New
• Name 1: F4 Nozzles
• Name 2: F4 Nozzle
• Name 3: F4 Spray Nozzle
• Name 4: F4 Thermal Spray Nozzle
• Transport Package: Carton
• Specification: 39*21*29cm
• Trademark: NA
• Origin: China
• HS Code: 8515900090
• Production Capacity: 20000PCS/Per Month
• Package Size: 10.00cm * 10.00cm * 10.00cm
• Package Gross Weight: 1.000kg
• Lead Time: 3 days (1 - 10 Pieces) ; To be negotiated ( > 10 Pieces)

Product Description

Product Description

F4 nozzle is a core component and key consumable within the F4 plasma spray gun assembly. Positioned downstream of the electrode, it plays a pivotal dual role: acting as the anode in the electrical circuit and shaping the plasma jet.

Key Functions and Characteristics:

1. Function: F4 Nozzle (Positive Terminal):

   • The F4 nozzle serves as the anode (positive terminal) in the plasma circuit.
   • The pilot arc and main plasma arc attach internally to the inner bore surface of the nozzle.
   • It completes the electrical circuit with the cathode (electrode), allowing high current to flow and sustaining the plasma arc.

2. Function: Plasma Gas Constriction and Acceleration:

   • The internal geometry of the F4 nozzle bore constricts the flowing plasma gas that has been ionized between the electrode and nozzle.
   • This constriction forces the hot, ionized gas through a narrow passage.
   • Simultaneously, the design accelerates the plasma gas to very high velocities (often supersonic).
   • The converging/diverging or straight cylindrical bore design dictates the final shape, velocity, temperature, and stability of the plasma jet exiting the gun.

3. Material: High-Conductivity Copper Alloys:

   • Primarily made from high-purity copper or, more commonly, precipitation-hardened copper alloys (e.g., copper-chromium-zirconium, CuCrZr).
   • Why Copper Alloys?
     • Exceptional Thermal Conductivity: Essential for rapidly conducting intense heat away from the arc attachment zone to the cooling water channels. Prevents melting.
     • High Electrical Conductivity: Minimizes resistive heating losses and ensures efficient current transfer at the anode.
     • Moderate Erosion Resistance: While eroded by the arc, these alloys offer a balance between conductivity and resistance to vaporization/sputtering. Hardened alloys (CuCrZr) significantly outperform pure copper in erosion resistance and high-temperature strength.
     • Good Machinability: Allows for precise manufacturing of complex internal geometries.

4. Structure and Design Features:

   • Internal Bore: The most critical feature. Shapes the plasma jet. Common bore types include:
     • Cylindrical: Simple design, common in standard F4 nozzles.
     • Convergent-Divergent (De Laval): Features a converging section followed by a narrow throat and then a diverging section. Used in variants like the F4MB-XL nozzle to achieve higher gas velocities and hypersonic particle speeds for denser coatings.
   • Bore Diameter (d): A key parameter (typically ranging from ~6mm to 9mm for F4 standard nozzles). Smaller diameters increase jet velocity and temperature but reduce powder throughput capacity and increase erosion. Larger diameters handle more powder but yield lower velocities.
   • Bore Length (L): Influences jet stability and dwell time (L/d ratio is important). Longer bores generally provide a more stable, laminar jet but increase pressure drop.
   • Chamfer/Inlet: The entrance to the bore is often chamfered or rounded internally to guide the plasma gas smoothly and influence the arc root attachment stability.
   • Cooling Channels: Intricate internal passages surrounding the bore carry high-velocity cooling water to extract immense heat generated at the anode (arc attachment point can exceed 10,000°C locally).
   • Mounting Flange/Threads: Designed for precise concentric alignment with the electrode and secure mounting within the gun front cap assembly.

5. Operation:

   • High-velocity plasma gas (e.g., Ar, N, H, He, or mixtures) flows around the electrode and through the gap between the electrode tip and the nozzle inlet.
   • The arc jumps across this gap and attaches to the inner bore surface of the nozzle.
   • The constricting bore forces the ionized gas into a narrow, dense, high-enthalpy stream.
   • As the gas exits the nozzle, it expands rapidly, forming the characteristic high-velocity, high-temperature plasma jet used to melt and propel coating powder particles.

6. Lifespan & Failure Modes:

   • A major consumable due to anode erosion caused by:
     • Intense Heat: Localized melting/vaporization at the arc root attachment point(s).
     • Ion Bombardment: Sputtering of nozzle material by high-energy ions.
     • Oxidation/Chemical Attack: Especially aggressive with oxygen-containing gases or moisture.
   • Erosion typically manifests as pitting, grooves (rifling), or enlargement/widening of the bore, especially near the inlet.
   • Catastrophic failure (e.g., melting, cracking, bore blow-out) can occur due to cooling failure, excessive power input, gas surges, or severe oxidation (e.g., using air plasma without a special nozzle).
   • Hydrogen (H) as a secondary gas is particularly erosive to the nozzle anode.

7. Factors Affecting Life:

   • Current Level: Higher currents dramatically increase anode heat load and erosion.
   • Plasma Gas Composition: H and He are more erosive than Ar or N. Oxygen is extremely damaging unless using specialized nozzles.
   • Gas Flow Rates & Ratios: Affects arc stability and cooling efficiency.
   • Powder Injection Location: Internal injection causes more bore wear than external.
   • Cooling Water Flow Rate, Temperature, and Quality: Critical for heat extraction. Scaling or blockages reduce life.
   • Operating Voltage: Influenced by gas type, flow, L/d ratio, and electrode wear - affects arc attachment behavior.
   • Number of Arc Starts.

8. Variants: The F4 platform utilizes different nozzle geometries optimized for specific applications:

   • Standard F4 Nozzle (e.g., 6mm, 8mm bore): General purpose.
   • F4MB-XL Nozzle: Convergent-divergent bore for very high particle velocities (HVOF-like coatings).
   • F4NX Nozzle: Optimized for stable spraying with Ar/He mixtures.

In Summary:

The F4 plasma spray gun nozzle is a consumable copper alloy component performing two vital functions: acting as the anode for the plasma arc and constricting/accelerating the ionized gas into a focused, high-energy jet. Its precise internal bore geometry directly controls jet characteristics (velocity, temperature, stability), making nozzle selection and condition paramount for achieving desired coating properties. Subject to significant thermal and erosive stresses, regular inspection and replacement of the nozzle are essential for consistent, high-quality plasma spraying operations.

The corresponding list of the nozzle electrode model of our company's F4 and the model of other brand products
 

Product model	Product name	Related product model
WLE-F4	F4 electrode	1072006
WLN-F4-5	F4 nozzle	1088066
WLN-F4-6	F4 nozzle	1072007
WLN-F4-7	F4 nozzle	1088062
WLN-F4-8	F4 nozzle	1088057

There are many F4 electrode manufacturers on the market, but many of them can only make similar sizes, but there are many differences in service life and performance. As a professional manufacturer, we not only know how to produce, but also how to improve and understand customer's use, so we can provide more professional online services.

If you have any needs, users are welcome to come for consultation. Our company has a group of experienced technical and sales teams who will serve you wholeheartedly.

 

Certifications

Packaging & Shipping

You can choose cartons or plywood case:(Our packing)


All goods will be shipped by DHL or UPS or Fedex or SF as well as air freight agent company,you can choose any one only you like.



 

Company Profile

         Zhuzhou Weilai New Materials Technology Co., Ltd (Weilai) is located in China Power Valley in Zhuzhou City of Hunan province. Weilai devotes to research and develop high performance  heterogeneous refractory metal composites, including high-performance X-ray tube anode material, plasma spray nozzle as well as the electrodes and the resistance welding electrodes, etc. It is mainly used in medical equipment, plasma spray and automobile electrical equipment industries. Weilai provides the customized solutions for customers, it is a high-tech company integrating research and development, production, sales and service.

    Adhering to "Keep improving products and creating value for customers", the company focuses on the subdivided fields of refractory metal materials industry, continuously optimizes the technological adaptability of products, develops more supporting products in the industry, and provides users with more reasonable and comprehensive solutions. Weilai makes constant efforts to "become an excellent company in the field of new materials".

Our Advantages

Advantages of plasma spray nozzles and electrodes produced by our company:
1. Our company has been engaged in the production of pure tungsten and tungsten alloy materials for many years, and has an in-depth understanding of the structure and properties of materials. For the tungsten electrode used in plasma spraying electrodes, based on our full understanding of the application, we have made more improvements and treatments to the material structure to meet the material requirements of plasma spraying. By densifying the tungsten electrode, a finer, more uniform grain structure is formed. The modified tungsten alloy has relatively high hardness and density, fast arc starting, excellent resistance to arc burning loss, and long life.

2. Our company's plasma spraying electrodes and nozzles use unique back-casting technology to achieve seamless bonding between tungsten and copper. The bonding strength can be as high as 127MPa, while the traditional bonding strength is less than 100MPa. Compared with traditional brazing, joints made by back-casting have higher bonding strength between tungsten and copper, larger contact area, more uniform resistance, and stronger heat dissipation ability, making the nozzle and electrode more stable and more durable as well as long service life.

3. We produce tungsten electrodes of different materials (good arc starting performance and ablation resistance). Based on customer usage conditions, we can provide more suitable materials for customers to choose.
 

Material	Impurity content (%)	Electron work function (eV)
Lanthanum tungsten	<0.2	2.8-3.2
Cerium tungsten	<0.2	2.7-2.8
Thorium tungsten	<0.2	2.0-3.9

4. Based on the research and analysis of plasma spray guns, the electrodes and nozzles produced by our company can perfectly adapt to the original spray guns, and no additional adjustment of spraying parameters is required during replacement. We have a complete product series, and the plasma spray electrodes and nozzles we produce can be widely used in F4, 9M, SG-100 and other spray guns of Metco, GTV, FST, AMT AG, Praxair and other companies.
5. We have rich experience in producing various cathodes and anodes, which can be customized and processed according to customer samples or drawings. We can also provide semi-finished products with seamless combination of tungsten and copper.

After Sales Service

 

We can ensure our all products which are seamless bonding,no gas foam generating,and assure concentricity,if any defect has been found which are due to our cause,we can replace them for free and send you along with shipment for next time.