Premium Sg100 -175 Pure Copper Plasma Thermal Spray Nozzle

Product Description

 

Product Description

Functions and Properties of the SG100 Thermal Plasma Spray Nozzle (Anode)and Electrode(Cathode)

1. Overview

The SG100 plasma spray system is widely used in thermal spraying applications to deposit coatings (e.g., ceramics, metals, or composites) onto surfaces for wear resistance, thermal insulation, or corrosion protection. The nozzle and electrode are critical components that directly influence plasma generation, stability, and coating quality.

 

2. Plasma Spray Nozzle

Functions:

• Plasma Arc Formation: The nozzle constricts and stabilizes the plasma arc generated between the cathode and anode, ensuring a high-temperature, high-velocity plasma jet.

• Gas Acceleration: It directs and accelerates plasma-forming gases (e.g., argon, hydrogen, or nitrogen) to create a supersonic jet (~Mach 2-3) for efficient particle heating and acceleration.

• Coating Deposition: The nozzle shape (e.g., convergent-divergent design) affects spray pattern, particle velocity, and melting efficiency, influencing coating density and adhesion.

Key Properties:

• Material: Typically made from high-purity copper (or copper alloys) for excellent thermal conductivity and resistance to thermal fatigue.

• Cooling Mechanism: Often water-cooled to prevent overheating and prolong service life.

• Geometry: Optimized internal contours (e.g., Laval nozzle design) to enhance gas dynamics and plasma stability.

 

3. Plasma Spray Electrode (Cathode/Anode)

Functions:

• Cathode (Negative Electrode): Emits electrons via thermionic emission, initiating and sustaining the plasma arc.

• Anode (Positive Electrode): Completes the electrical circuit, allowing current flow and plasma generation.

• Arc Stability: The electrode design affects arc root movement, minimizing fluctuations for consistent plasma performance.

Key Properties:

• Cathode Material: Usually thoriated tungsten (Th-W) or lanthanated tungsten (La-W) due to high electron emissivity and erosion resistance.

• Anode Material: Often oxygen-free copper (OFC) for high thermal/electrical conductivity and durability.

• Cooling System: Water-cooled to manage extreme heat (plasma temperatures can exceed 10,000°C).

• Wear Resistance: Electrodes degrade over time due to arc erosion; high-quality materials extend lifespan.

 

4. Combined Role in Plasma Spraying

• The nozzle-electrode assembly ensures:

  • Stable plasma generation for uniform particle heating.

  • Controlled particle acceleration for dense, well-bonded coatings.

  • Efficient heat management to prevent component failure.

Performance Factors:

• Gas Flow Rate: Affects plasma temperature and velocity.

• Current/Voltage Settings: Influence arc stability and coating quality.

• Nozzle Wear: Erosion can alter spray characteristics, requiring periodic replacement.

5. Applications

• Aerospace: Thermal barrier coatings (TBCs) for turbine blades.

• Automotive: Wear-resistant coatings for engine components.

• Industrial: Corrosion protection for pipelines and machinery.

Conclusion

The SG100 plasma spray nozzle and electrode are essential for generating a high-energy plasma jet, ensuring precise and efficient coating deposition. Their material properties, cooling mechanisms, and geometric design directly impact spraying performance, making them critical for industrial and advanced material applications.

Plasma thermal spray gun consumables
As we all know, the most critical components of plasma thermal spray guns such as F4, F1, 9MB, 7MB, 3M7, SG-100,SinplexPro,TriplexPro and so on are the nozzle and electrode . These two products are also consumable parts and are one of the most important consumables in plasma thermal spraying.
Our company is a manufacturer specializing in the production of plasma spray electrodes and nozzles (also known as plasma cathodes and anodes, tungsten copper cathodes, and tungsten copper anodes).

 

 

SG-100 plasma spray gun
    The SG100 plasma spray gun produced by Praxair is a very flexible spray gun that can be used in a variety of application scenarios. Its operating power is 80KW. If you have higher requirements for coatings, or require large-volume production, or small-volume testing, the SG100 spray gun can be used very well.
    This spray gun has two modes: internal powder feeding and external powder feeding. Different modes can provide multiple incident angles, obtain better spraying speed, or mix multiple spraying materials.
Different modes, matched with different hardware, can form different working modes. We can provide suitable nozzles (anode) and electrodes (cathode) for different modes.
What material is used for the anode?
As you can see, all copper materials are used on the market, but there are many types of copper materials, and the purity and composition of different copper materials are different. For specific industries that require special treatment of copper materials, we have been supplying copper anodes to different industries and are very clear about customers' material requirements in different industries.
Anode matching:
The product accessories provided by Praxair have high precision, and general processing manufacturers can provide similar shapes. However, there is a very big gap in the actual control of product size.
We have been providing anode and cathode accessories for various plasma spraying service providers, and we can control the size very accurately.


SG-100 plasma thermal spray anode and cathode models
 

Product model	Product name	Related product model
WLE-SG100-129	SG100 electrode	843083129
WLE-SG100-720	SG100 electrode	841083720
WLN-SG100-730	SG100 nozzle	02083-730
WLN-SG100-145	SG100 nozzle	03083-145
WLN-SG100-165	SG100 nozzle	03083-165
WLN-SG100-175	SG100 nozzle	03083-175

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

<0.2<><0.2<><0.2<>

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.