THERMAL SPRAY
POWDER FEEDERS.
Metaflux Spray Solutions manufactures twin-disc thermal spray powder feeders in Pimpri-Chinchwad, Pune, India, for delivering metallic and ceramic powders at a controlled, pulse-free rate to HVOF, plasma spray and powder flame spray guns.
Twin Disc Powder Feeder
A rotating disc picks a fixed volume of powder from the hopper and a carrier gas stream sweeps it to the gun. Feed rate is set by disc speed rather than by gas pressure, so the deposition rate stays constant as the hopper empties — the single biggest variable in repeatable HVOF and plasma coating thickness.
TYPICAL
SPECIFICATIONS.
Typical operating data for twin-disc thermal spray powder feeders across the 1.5, 5 and 10 litre hopper sizes. Exact specifications vary by configuration — request a datasheet for the model you are evaluating.
| Parameter | Typical Range |
|---|---|
| Metering Principle | Twin rotating disc with carrier gas pick-up |
| Hopper Capacity | 1.5 / 5 / 10 litre |
| Powder Feed Rate | 5 – 150 g/min |
| Feed Rate Repeatability | Within approx. ±2% |
| Powder Size Range | 5 – 150 microns |
| Disc Speed | 0.5 – 12 rpm, digitally set |
| Carrier Gas | Nitrogen or Argon |
| Carrier Gas Flow | 2 – 15 SLPM |
| Hopper Pressurisation | Up to 10 bar for HVOF duty |
| Control | Closed-loop RPM control with local digital display |
| Power Supply | 230 V AC, 50 Hz, single phase |
| Compatible Processes | HVOF, Plasma Spray, Powder Flame Spray |
| Unit Weight | 40 – 70 kg, depending on hopper size |
FREQUENTLY ASKED
QUESTIONS.
The questions coating shops ask most often about thermal spray powder feeders and repeatable powder metering.
What does a thermal spray powder feeder do?
A thermal spray powder feeder meters powder out of a hopper at a controlled rate and delivers it to the spray gun in a carrier gas stream. On a Metaflux feeder a rotating disc picks up a fixed volume of powder per revolution, so the feed rate is set by disc speed rather than by gas pressure and stays constant as the hopper empties. Powder feed rate is the single biggest variable in repeatable coating thickness.
Which spray processes can a Metaflux powder feeder supply?
A Metaflux twin-disc powder feeder supplies HVOF, plasma spray and powder flame spray guns. The hopper can be pressurised to 10 bar so it can still push powder into an HVOF combustion chamber running at 6 to 10 bar, and the same unit handles plasma ceramics and self-fluxing flame spray alloys by changing the disc speed and carrier gas flow.
What powder feed rate range does a twin-disc feeder cover?
A Metaflux twin-disc powder feeder covers roughly 5 to 150 g/min, set by a disc speed of 0.5 to 12 rpm under closed-loop digital control, with repeatability within about ±2%. Hopper sizes are 1.5, 5 and 10 litres and the unit accepts powders from 5 to 150 microns.
Which carrier gas should a powder feeder use?
Nitrogen or argon are used as the carrier gas, typically at 2 to 15 SLPM. Nitrogen is the usual economical choice for carbides and self-fluxing alloys; argon is preferred where the powder is oxidation sensitive or where argon is already the plasma gas. Too much carrier gas disturbs the flame or plasma jet, so the flow is set as low as will still move the powder cleanly.
Why does the coating thickness drift during a long spray run?
On pressure-fed powder hoppers the delivery rate falls as the powder column drops, so coatings get thinner towards the end of a run. Volumetric disc metering removes that effect because each revolution carries the same powder volume regardless of hopper level. Powder that has absorbed moisture or been screened outside its size range will still cause drift, whatever the feeder.
How much does a thermal spray powder feeder cost in India?
Metaflux Spray Solutions quotes powder feeder prices on request, because the price depends on hopper size, whether the hopper is pressurised for HVOF duty, and the control and carrier gas package supplied. Send the spray process, powder chemistry and required feed rate through the enquiry form on this page for a written quotation from Pune.
Powder Feeder Applications
and Process Compatibility.
HVOF Carbides
WC-Co and Cr₃C₂-NiCr powders against back pressure of up to 10 bar.
Plasma Ceramics
YSZ, alumina and chrome oxide at low, stable feed rates.
Flame Spray Alloys
Self-fluxing Ni-Cr-B-Si and bronze for hardfacing work.