UNIQUECOAT TECHNOLOGIES, LLC

M2M™ Supersonic HVAF Spray Gun

The M2M™ supersonic HVAF single nozzle spray gun is designed specifically for cost-effective deposition of high quality cemented carbide, metal and metal alloy coatings. The M2M™ can apply all HVOF powders, as well as special HVAF cuts (-30+5 μm, -30+10 μm), and superfine cuts (-15+5 μm, -10+5 μm). Metals and metal alloys can also be effectively applied.

Powder	Cut	Velocity	D.E.	Spray Rate
WC-based powders	-30+5 μm	~ 935 m/s	46-55%	30 kg/h max
CrC-based powders	-25+5 μm	~ 1040 m/s	45-55%	18 kg/h max
Hardfacing Alloys	-45+15 μm	~ 850 m/s	65-85%	16 kg/h max

_{Data obtained on Propylene}

WC-based coatings with hardness of up to 1500 HV₃₀₀
Coating porosity typically below 0.2%
Compressive residual stresses in coatings
Negligible oxide content in coatings (1.5-2 times that of feed stock material)

HVAF tungsten carbide based coatings outperform HVOF counterparts by 3-6 fold in slurry erosion tests, and up to 15 fold in cavitation resistance tests. Due to very low W₂C content and high bond strength, M2M™ applied tungsten carbide coatings also exhibit higher fatigue and impact resistance.

The M2M™ spray gun operates on Propylene or Propane, but also fully supports the use of natural gas, offering flexibility and the option of substantial cost savings while retaining good deposition efficiency. Highly efficient 100% air cooling eliminates the need for a chilled water supply.

The cost of coating application with M2M™ is 2-4 times lower compared to HVOF process due to use of air instead of oxygen and high spray rates that reduce spraying time.

Grit Blasting

The M2M™ spray gun can also be used to grit blast parts immediately prior to coating application. By supplying grit to the gun and executing the normal spraying sequence on the robot a part can be grit blasted in place. Hot grit blasting may also be similarly perfomed, by supplying grit to a running gun. This high velocity grit blasting offers 20-50 fold reduction in grit consumption, and up to 15 fold reduction in blasting time. For example, a mandrel that normally takes 30 minutes to grit blast, can be hot grit blasted in just under 2 minutes. Hot grit blasting technology permits to substantially increase the bond strength of subsequently applied coatings. Grit options include Aluminum Oxide # 120, 150, 180 or 220, as well as Tungsten Carbide 8-14 µm, 14-26 µm, 26-32 µm.

M2M™ Spray Gun

Fuel Types	Air Consumption	Cooling
Propylene, Propane Natural Gas	200 SCFM @ 140 PSI	100% air cooled

Cost-effective spraying of cemented carbides, metals, metal alloys
Axial powder injection
100% Air Cooling (no water chillers)
Can spray continuously for hours without stopping
Low operating cost
Low consumption of spare parts
Fast start-up

M2M™ Tungsten Carbide Coating

Powder	Cut	Hardness	Porosity	Bond Strength
WC86-Co10-Cr4	-30+5 µm	1500 HV₃₀₀	< 0.1-0.3%	82+ MPa

UltraCoat™ Process Control System

All HVAF spray guns, including M3, M2, M2M, and ID series, are controlled by the UltraCoat HVAF process control system. The control system features an intuitive touch screen interface, that provides a single point of control for the entire spray operation.

The system integrates with the robot, lathe or turn tables, powder feeder, compressor, ventilation, vaporizer and all the safety switches. AutoSpray feature of the UltraCoat system permits a fully automated spray process, assuring the highest possible consistency of coating quality from batch to batch.

The touchscreen operator interface is intuitive and user-friendly, minimizing personnel training time.

System supports remote diagnostics by the factory, which can be done anywhere in the world where an internet connection is available.

Features

Intuitive Touch Screen Interface
Fast Start Up with Start Up Control
Complete Process Monitoring with Auto Shut-Off
Full-featured Data Logging
Unlimited Recipes
SprayView™ Live Video Feed (shown)
Integrated Control of Analog and Weight Loss Powder Feeders
Integrated Control of Robot, Compressor, Vaporizer, Ventilation, Turn Tables and other Equipment
AutoSpray features permits fully automated spraying
Remote Diagnostics and Monitoring
ATEX Compliance

HVAF: High Velocity Air Fuel

Uniquecoat Technologies' HVAF process, or High Velocity Air-Fuel, is a thermal spray process for deposition of high performance coatings from cemented carbide and metal powders for protection of parts against abrasion, erosion and corrosion.

HVAF coatings are similar to and are generally comparable to coatings produced by HVOF and Cold Spray. HVAF is a "warm spray" process that is cooler than HVOF, but hotter than Cold Spray. HVAF guns utilize axial powder injection into an air-fuel jet with a temperature of about 1900-1950°C. Therefore, the process is capable of effectively applying carbide-based materials, but since the air-fuel jet produces considerably less oxides than high temperature oxy-fuel jets, the HVAF process can also apply metals with almost zero oxidation, similar to Cold Spray. All common thermal spray powder materials may be applied with HVAF, except for ceramics.

High Velocity Air Fuel:

a derivative of conventional HVOF
uses compressed air instead of oxygen
higher spray rates and deposit efficiency
faster spraying and lower application cost
harder, better performing coatings due to the "warm spray" nature of the process
surface preparation is done with the spray gun

Features & Benefits

Features	Benefits
Drop in replacement for HVOF	Easy to implement with existing spray booth and hardware
Better quality coatings (higher density, better wear resistance, better bond strength)	Coatings perform better in service
Faster spray rate	Complete jobs in less time with less cost
Higher deposit efficiency	Use less powder to make coatings
Much lower spare parts consumption	Gun does not wear quickly, so combustion conditions are consistent which produces consistent coating quality with 0 defects
Robust materials of construction	Gun is not easily damaged by operator mistakes
Easily configurable to spray a broad range of materials and achieve various coating properties	An HVAF gun can spray practically any metal or cer-met by simply changing the hardware configuration
No need to maintain oxygen storage	Less real estate is required to set up an HVAF system
No chilled water requirement	Gun is easier to maintain, there is no mess when it is taken apart
Portable	Can be used in workshop or on-site
Fully automatic	Controller monitors inlet and outlet conditions to maintain set points
Built in data logging	Provides detailed record of spray history for documentation
Unlimited recipe storage	Store custom parameter sets with descriptive text for each coating material or part
Autospray function completely automates spray process	Saves time and labor, anyone can spray good coatings
Grit blast with the gun	Operators set parts one time, grit blasting and coating occur in one location. Greatly reduces preparation time and cost.
Remote login support	Factory assistance available at no charge, no need to wait for service technician to travel to customer site