The JP-8000 HP/HVOF® system is the "next generation" version of the renowned JP-5000®. The JP-8000 is our ultra-high performance HP/HVOF® process featuring advanced controls, exceptional throughput and unparalleled coating quality. Incorporating an array of desirable features, the JP- 8000 is even more user friendly than its predecessor. Improvements include a sophisticated PLC-based, closed-loop controlled Model 8100 gas/fuel management system that provides more precise control of the flame characteristics, resulting in increased up-time, more reproducible coatings, and an improvement in ultimate coating quality.

Model 8100 Console's Operator's Interface Terminal

"Features even simpler operation, closed-loop controls and modular drawer design"

The JP-8000 system revolutionizes the field of high quality HVOF coatings. As part of its commitment to excellence, Praxair Surface Technologies has engineered the JP-8000 console with two main objectives in mind: operator/system safety and ease of use. The JP-8000 incorporates separation of fuel, gas and electrical components, high/low flow controls and pressure switches to provide warnings and shutdown when operation is attempted outside specified limits. An intuitive Operator Interface Terminal (OIT) "touch-screen" permits easy parameter set-up and monitoring that ensures consistent spray coating characteristics every time. The OIT touch screen, as an option, can be mounted remotely from the cabinet containing the electronics and gas/fuel/water modular drawer unit.

The key benefits afforded by the JP-8000's high particle velocities include extremely high coating density and low oxide content. Density is achieved by particles packing tightly and uniformly to reduce porosity. Low oxide content results from reduced particle temperature and shorter dwell time in the flame. These two features are especially beneficial when applications require high hardnesses to combat wear and clean, dense coatings to resist corrosion.

System Benefits:
•  Safe Operation
•  Non-volatile Liquid Fuel
•  Simplicity / Ease of Use
•  Low Operating Costs
•  Exceptional Coating Quality
•  Reproducible Coating Quality
•  High Spray Rates
•  Maintenance Scheduling Built-in

The System

The JP-8000 system consists of the Model 8100 Control Console, Model 5220 Standard Gun, Model 1264 Powder Feeder, all necessary Gun and Supply Hoses, and Operating Manual.

Model 8100 Control Console
The Model 8100 is a closed-loop, fully automated control console with an easy to read and follow "touch-screen" Operator Interface Terminal (OIT). The operator merely selects the required recipe from memory and pushes the gun "RUN" symbol on the screen. A process engineer can easily develop and store new recipes via the "Control Panel" and "Recipe" screens.

The OIT "touch screen" makes the console extremely user friendly. To run the system the operator must first log on. Different levels of protection can be set to prevent unauthorized access to parameter adjustment and Recipe, Startup or Maintenance screens. Typically the Model 8100 contains a variety of screens, including:
•  SYSTEM SETUP menu screen that allows selection of a variety of items such as: Start and Idle flows for fuel and oxygen, English or Metric units, Powder Feeder Set-up, Carrier Gas chose and Heat Exchanger control.

•  MAINTENANCE SCHEDULING screens for scheduling maintenance of gun, console and powder feeder components.

Figure 2 RECIPE Screen

•  RECIPE screen for recalling stored parameters, adjusting stored parameters or high/low warnings or shutdown setpoints or entering new recipes. (see Figure 2)

Figure 3
Control Panel Screen

Figure 4
Control Panel Screen with Warning

•  CONTROL PANEL screen that displays all the data that an operator needs to monitor the process when spraying (see Figures 3+4). Parameter adjustment is password level protected. Bright color changes signify within setpoint or out-of-tolerance warning and alarm conditions of parameters.

Figure 5
Gun Components Maintenance Screen

•  COMBUSTION CHAMBER PRESSURE screen is an automated test of combustion chamber pressures to ensure HP/HVOF gun is operating within optimum conditions. (see Figure 5)

The Model 8100's modular circuits have been designed into individual drawers that slide out to make servicing and maintenance easy and hassle free. If needed, a drawer module could be disconnected and removed, then a new one can be slid into place in a short period of time to keep downtime to a minimum.The JP-8000 produces high quality, repeatable coatings due to accurate control of the gases, fuel and water flows. The oxygen flow is controlled by a Mass Flow Meter (MFM) and a pneumatic proportional valve circuit. The fuel flow is controlled by a turbine wheel and variable speed motor on the fuel pump. Both circuits are closed-loop controlled and produce maximum control of the spray process. The carrier gas circuit is Mass Flow Controlled (MFC) for accurate control and monitoring of the powder carrier gas. In addition, the built-in water booster pump module assures constant and consistent water flow and pressure through the gun. The end result is a control console that produces repeatable coatings that meet simple or critical application needs time after time.

The Model 8100 is designed to operate with safe and economical liquid fuel, such as kerosene. Liquid fuel is easier to handle safely when compared with volatile gases such as hydrogen, propane/propylene or natural gas. Kerosene is also less expensive than most other HVOF fuel gases.

"Safety is not optional"

Praxair Surface Technologies takes thermal spray safety very seriously. The Model 8100 is engineered and built for productive and safe operation. Integrated safety features protect both the operator and the equipment. Safety features include:

•  Separation of electrical components from the oxygen, fuel and water modules by either solid metal panels, adequate space/ventilation or both.
•  Interlocked alarm circuits to monitor fuel, oxygen and water supplies and flows to prevent conditions that could be hazardous to the operator or equipment.
•  Kerosene is (a) prevented from entering the gun until combustion sequence is activated; and (b) shut-off immediately if combustion does not occur.
•  Combustion pressure is monitored and if combustion stops the system shuts down.
•  The console is designed for stability, employing large castors, a low center of gravity, and even weight distribution.
•  Electrical safety is enhanced through the use of intrinsically safe components and separation of electrical voltages into discrete wire-ways.
•  European equipment code approved (CE).

Model 8100 options include:
•  3 choices for Remote OIT mounting
•  Data Logging
•  Ethernet capability for "real-time" troubleshooting

Model 5220 Gun

The JP-8000 HP/HVOF® guns develop combustion chamber pressures up to 120 psi (8.2 bar) compared to other HVOF systems, which are limited to 30 to 80 psi (2.0 - 5.4 bar). This pressure is translated into higher velocities, higher coating hardnesses and better overall coating quality and integrity.

Fuel and oxygen mix and are atomized after passing through orifices into the combustion chamber, thereby creating stable, clean and uniform combustion. Importantly, the combustion chamber pressure is monitored to assure the proper combustion mode and constant pressure (Note: particle velocity is directly proportional to chamber pressure). Chamber pressure monitoring also provides a crosscheck on flow rates and is one of the most important factors influencing coating quality. The exit nozzle of the combustion chamber is configured to create a supersonic over-expanded jet and to maintain a low-pressure region where the powder is introduced. The powder is uniformly mixed with the gas and accelerated to the substrate.

Figure 8
Model 5220 Standard Gun

Unlike other HVOF designs, which require closely controlled water temperatures to reproduce coating quality, the Model 5220 gun is not as sensitive to water temperature. This unique design permits the use of incoming water temperature of up to 80oF (27oC).

Model 1264 Powder Feeder

The Model 1264 Powder Feeder (see Figure 10) is an open-loop, pressurized unit specifically designed for HVOF and other thermal spray applications. The 1264 feeder is economic, easy to operate and requires very low maintenance. Its proven design has become the standard for powder feeding, offering unparalleled precision and repeatability of powder delivery. Recent design improvements further enhance the 1264 feeder's consistency and compatibility with the JP-8000.

The 1264 feeder works on a volumetric principle that directly controls the powder feed rate by the speed of a pick-up wheel. When the powder feeder is in operation, holes in the variable-speed wheel fill with powder. Gravity, carrier gas, and the rotation of the wheel work in concert to deliver powder to the gun. One advantage of the 1264 powder feeder is that it is not sensitive to gun back-pressure. The 1264 includes a heating blanket that keeps the powder in the canister warm and free of moisture for more consistent powder feeding.

Model 1264 options include:

•  Several powder wheel choices for different powder sizes and densities. •  Stackable canisters to increase the amount of powder the feeder can hold. •  Feedrate Controller which enables more accurate control of powder dispensing through the use of a sophisticated loss-inweight platform.

Figure 9
Model 1264 Powder Feeder in operation