Gun 6/11 AH EvoCSII Axial Cold Spray Gun

General Introduction

The Gun 6/11 AH EvoCSII axial cold‑spray gun incorporates axial powder‑injection technology and can be optionally equipped with a cooling injector and a cooled pre‑combustion chamber, ensuring seamless compatibility with the system. From its structural design to its functional configuration, this spray gun has undergone a complete overhaul, addressing the technical limitations of conventional cold‑spray guns in areas such as powder delivery, temperature control, and thermal management.

Compared with conventional center‑jet cold‑spray guns, the 6/11 AH EvoCSII axial cold‑spray gun features an optimized axial powder‑injection design that reconfigures the mixing of powder and process gas, significantly enhancing spray accuracy and material compatibility. The gun incorporates a high‑power 40 kW heating module capable of delivering process gases up to 1,100°C, and can be optionally equipped with a water‑cooled injector, a water‑cooled pre‑combustion chamber, and an advanced nozzle‑cooling system, enabling constant‑temperature control at the gun tip. This addresses key industry challenges in high‑temperature spraying, such as powder adhesion and excessive gun overheating. The gun is suitable for the full range of cold‑gas spraying processes, handling ultrafine, temperature‑sensitive metal powders like copper, aluminum, and silver, while also accommodating conventional metal and composite powders. It is currently employed in high‑end coating applications across aerospace, precision manufacturing, automotive, and other sectors. With its distinctive structural design and robust performance, it has become a benchmark for high‑precision cold‑spray operations. Its performance remains consistent with that of the 6/11 EvoCSII series, and it is compatible with the standard nozzles used on this model, thereby reducing inventory requirements and lowering operating costs for users.

Working principle

The Gun 6/11 AH EvoCSII axial cold-spray gun is based on the core principle of solid-state deposition in cold spraying and features a structural innovation in the mixing and injection of process gas and powder. At its heart, it achieves precise, uniform blending of powder with a supersonic gas stream through axial powder injection, while an optimized thermal-management design enables temperature control throughout the spraying process. The gun’s operational sequence comprises five key steps: receiving and heating the process gas, axially injecting the powder, accelerating the gas flow, and performing mixed‑phase spraying. First, the gun draws high‑pressure process gas (nitrogen or helium) from the EvoCSII system’s gas‑management unit. The gas then enters the gun’s integrated heating module, which delivers up to 40 kW of power and can heat the gas across a range from ambient temperature to 1100°C, thereby meeting the specific temperature requirements of various materials.

The heated, high-pressure gas enters the pre‑combustion chamber and the Laval nozzle section of the spray gun, where it begins to expand and accelerate. Unlike conventional spray guns, the 6/11 AH EvoCSII features an axially positioned powder injection port, delivering powder precisely into the process‑gas pre‑combustion zone rather than through a side‑entry design. This ensures central positioning and uniform mixing of the powder within the process gas, preventing deflection of the powder jet and enabling more even acceleration of the powder particles with the gas flow. For models equipped with a water‑cooled injector and a water‑cooled pre‑combustion chamber, cooling water circulates through dedicated channels at the gun’s front end. Working in tandem with the nozzle’s optimized water‑cooling system, this configuration maintains constant temperature control across critical components—including the pre‑combustion chamber, injector, and nozzle—thereby preventing localized overheating that could cause powder adhesion inside the gun.

The supersonic gas stream mixed with powder achieves final acceleration within the Laval nozzle, propelling the powder particles to impact the substrate surface at high velocity and enabling solid‑state deposition. The gun’s heating element is arranged at an angular orientation relative to the nozzle, allowing flexible adjustment of its position according to the spraying direction—horizontal, downward, and so on—thereby optimizing thermal management during the coating process and ensuring both heating efficiency and stable gas temperatures. When operating under varying pressure and temperature conditions, the gun can stably switch between 60 bar/1000°C and 50 bar/1100°C modes, while remaining compatible with standard nozzles used on the 6/11 EvoCSII guns, eliminating the need for dedicated nozzle changes and thus maintaining the continuity and flexibility of the coating process.

Advantages and Key Features

The Gun 6/11 AH EvoCSII axial cold‑spray gun’s core advantages lie in its precision powder delivery, material compatibility, thermal management, and process flexibility. Its structural design and functional configuration have been optimized to address real‑world challenges in industrial cold spraying, enhancing both the tool’s practicality and operational stability. In terms of powder delivery, the gun employs an axial powder‑injection technology that precisely directs the powder into the central region of the process‑gas pre‑combustion chamber, enabling centrally positioned spray. This eliminates the deflection issues associated with side‑injection in conventional guns, resulting in more uniform mixing between powder particles and the process gas, higher powder utilization, and a significant reduction in the risk of powder adhesion within the pre‑combustion chamber and nozzle. This makes the system particularly well suited for ultrafine metal powders, effectively resolving industry‑wide challenges such as nozzle clogging and uneven mixing during fine‑powder spraying.

In terms of material compatibility, axial spraying combined with optimized thermal management enables the spray gun to handle temperature‑sensitive materials such as copper, aluminum, and silver with exceptional precision. These materials are prone to oxidation and melting in conventional high‑temperature spraying processes; by contrast, this spray gun employs precise powder mixing and constant‑temperature control, maintaining optimal airflow while preventing high‑temperature degradation of the powder, thereby delivering high‑quality coatings on temperature‑sensitive substrates. Compared with traditional center‑jet spray guns, this model accommodates a broader range of operating temperatures—up to 1,100°C—offering an expanded thermal envelope that meets the processing requirements of various metallic and composite powders.

In terms of thermal management, the spray gun’s heating element is arranged at an angular orientation relative to the nozzle, allowing for adjustable angle settings. This configuration enables flexible positioning of the heating element according to the spraying direction—whether horizontal, downward, or otherwise—thereby optimizing heating efficiency while enhancing operational versatility and accommodating various workpiece‑specific spray angles. The gun can be optionally equipped with a water‑cooled injector and a water‑cooled pre‑combustion chamber, complemented by an optimized nozzle‑water‑cooling system. Together, these components ensure constant temperature control at the gun’s tip, maintaining stable core‑temperature during spraying, preventing localized overheating that could lead to equipment degradation and powder adhesion, and ultimately extending the gun’s service life and improving its operational stability.

In addition, this spray gun is compatible with the EvoCSII cold‑spraying system and can use the standard nozzles designed for the 6/11 EvoCSII models, eliminating the need to procure and stock dedicated nozzles for each gun and thereby reducing users’ accessory‑procurement and inventory costs. The gun’s structural design balances ease of operation with maintenance‑friendliness; components such as the cooling system and the injector can be quickly disassembled and serviced, enhancing equipment uptime. At the same time, its performance remains consistent with that of other 6/11 EvoCSII guns in the same series, delivering identical coating results under identical process parameters, allowing users to switch between guns flexibly according to their application needs and ensuring uninterrupted production.

Application Areas and Use Cases

The Gun 6/11 AH EvoCSII axial cold-spray gun, as a high-precision cold-spraying system, leverages its axial‑jet technology, broad temperature compatibility, and capability to process temperature‑sensitive materials. It has been deployed in aerospace, precision electronics, high-end automotive manufacturing, mold machining, and other sectors, primarily for the deposition of high‑precision, high‑performance coatings and for spraying temperature‑sensitive materials and ultrafine powder materials. As such, it serves as a critical component in the high‑end manufacturing field for surface strengthening and coating fabrication.

In the aerospace sector, this spray gun is employed for preparing surface coatings on aeroengine blades and precision rocket components. Leveraging the precision of axial spraying, it enables the deposition of uniform wear‑resistant and corrosion‑protective coatings on titanium‑alloy and high‑temperature alloy substrates. It can also process lightweight alloy powders such as aluminum and copper, providing surface strengthening for lightweight aerospace parts. In the field of precision electronics, this spray gun is suitable for fabricating conductive coatings on electronic components, handling ultrafine conductive powders like silver and copper to produce uniform, dense conductive layers on ceramic and nonmetallic substrates. The resulting coatings exhibit excellent electrical conductivity and adhesion, meeting the stringent process requirements of precision electronic devices.

In the high-end automotive manufacturing sector, coating processes are employed for brake systems and precision chassis components, treating alloy powders such as aluminum and titanium to enhance wear resistance and corrosion protection. Leveraging the advantages of cold-spray solid-state deposition, this approach prevents thermal deformation of parts, ensuring machining accuracy. In mold‑making, the spray gun is suitable for surface repair and reinforcement of precision molds, processing ultrafine metal powders to apply high‑precision repair coatings on worn mold surfaces. This restores dimensional accuracy and surface properties, extending mold service life; the technology has already been adopted by numerous precision mold manufacturers.

In addition, this spray gun can be employed in the manufacturing of medical devices to process biocompatible metal powders such as titanium alloys, enabling the deposition of biocompatible coatings on the surfaces of medical‑device components and meeting both process‑related and performance requirements. Thanks to its high‑precision spraying capabilities, it has become a critical piece of equipment for the advanced production of medical devices.