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2nd Canadian Cold Spray Conference (CCSC), June 2010
Industrial Materials Institute of the National Research Council (NRC-IMI), Canada
Sylvain Desaulniers, Eng, MBA - Day 1 workshop
Helium Recovery System designed for Cold Spraying
PRESENTATION AGENDA
About Polycontrols
Benefits to use He on Coatings
Particles velocity
Microstructure
HRS System description
System evaluation
Performance
Efficiency
Cost/benefits analysis
Acknowledgements
HRS : Helium recovery System
• Flow focused company
• The largest flow calibration laboratory in Canada.
• Gasses, liquids
• ISO/IEC 17025 certified
• Main industry serviced : Aerospace, Fuel Cell
ABOUT POLYCONTROLS …
Flow lab - Primary standard Flow lab – Liquids & Fuel shop Flow lab – Gas lab
• Flow system – Manufacturer of systems for specialty gases.
• Hydrogen, Oxygen, Corrosives, Acids & Super Acids
• Main industry deserved: Automotive, Metallurgy, Reacherch
ABOUT POLYCONTROLS …
CO2 & Cryogenic H2 / Argon3M – Specialty fluids
BENEFITS TO USE HELIUM ON COATINGS
Highest Particules Velocity
Cp Ti plasma atomized (spherical)
Sources: NRC-CNRC, Using system Kinetiks 4000 (40 bar), Measured using DPV 2000
0 200 400 600 800 1000 1200 1400 16000
200
400
600
800
1000
1200
1400
Freq
uenc
y
Particle Velocity (m/s)
0
200
400
600
800
1000
1200
1400
B
Freq
uenc
y
AN2MOC24 800 oC805 m/s
He ASB VH70 nozzle350 oC1173 m/s
BENEFITS TO USE HELIUM ON COATINGS
Microstructure: No porosity
Inert gas: No risk of oxidation and/or nitridationCp Ti
N2
MOC24 800 oC
He ASB VH70350 oC
Efficiency: 100%Porosity: 2%
Efficiency: 100%Porosity: 0%
Sources: NRC-CNRC, Substrate mild steel
HRS SYSTEM DESCRIPTION …
HRS SYSTEM DESCRIPTION …
Spray room & He storage tanks
Helium High pressure booster Filtration & gas separation unit
Recovery rate in steady state operation (at full capacity)
SYSTEM EVALUATION
0
20
40
60
80
100
120
140
160
180
0 10 20 30 40 50
He
Flo
w R
ate
(NCM
H)
He
Reco
very
Rat
e (%
)
Time (min)
Helium Flow Rate at gun
Helium Recovery Rate
Global efficiency : Includes all losses from the HRS, dust collector, spray chambers, loading and unloading operation.
Steady state : All data excluding the initial start-up and stabilization phases
Efficiency: Global 88%HRS 95+%
Recovery rate while varing the gun demand
SYSTEM EVALUATION
Global Efficiency = Recycled Helium / Helium to the gunEnergy consumption: 1/2Kw per normal cubic meter (nm3)
Efficiency: Global 88%HRS 95+%
0
50
100
150
200
250
0 10 20 30 40 50 60 70 80
He
Flow
Rat
e (N
CMH
)H
e Re
cove
ry R
ate
(%)
He flow rate at the gun He Recovery Rate
COST/BENEFITS ANALYSYS
Considering that the Helium costs is 10 times more expensive than the N2 and the HRS efficiency is 90%: the cost of spraying using Helium is comparative to the cost of spraying using N2. However, capital investment needs to be assess on a case by case basis.
Spraying using He enables coating with better properties (lower porosity).
Spraying using He is less sensitive to charge effect (velocity is maintained with particle feed rate up to 3 time that of nitrogen)
By using the proper nozzle materials, it would be possible to spray using Helium at higher temperatures reducing the flow rate
Sources: NRC-CNRC, Using system Kinetiks 4000 (40 bar), Measured using DPV 2000
ACKNOWLEDMENTS
The helium recovery system and the cold spray equipment were provided by CFI project number 8246, awarded to McGill University.
Technical and support staff from NRC/IMI and McGill University
CONTACT
Sylvain Desaulniers, Eng, MBA3650, blvd. Matte (Unit A-1)Brossard (Quebec) J4Y 2Z2Canada
[email protected] 450 444-3600
www.polycontrols.com
