MP 3000 Atmospheric Plasma Spray System

Process Control Center

The Process Control Center coordinates system functions through a digital control architecture and HMI. It stores process programs, provides access control, monitors connected equipment, records operating parameters, and supports remote diagnostics.

GST MCoat™ is the process-control environment used to operate and supervise the MP 3000 platform. It combines equipment control, monitoring, diagnostics, data acquisition, and program management within one interface.

The software architecture is intended to improve coating repeatability, traceability, equipment availability, and ease of operation while giving process engineers controlled access to recipes and operating parameters.

Main software functions

• Graphical operator interface with process-parameter visualization.
• Spray-gun library with predefined operating limits and parameter sets.
• Remote diagnostics via secure connection.
• Saving and recalling process programs.
• Monitoring and control of external modules such as robots, filtration units, and refrigeration systems.
• Multi-level user access for operator, process engineer, and service functions.
• Real-time monitoring and recording of process parameters.
• Maintenance planning and resource-consumption monitoring.

Gas Management Center

The gas module supplies, mixes, regulates, and monitors plasma-forming and carrier gases. Depending on the configuration, the system can operate with argon, hydrogen, nitrogen, and helium. High-precision mass-flow controllers, pressure regulators, transmitters, filters, stainless-steel tubing, and gas-safety monitoring are integrated into the gas management architecture.

Plasma guns

The MP 3000 can operate with one or several plasma guns. The control system stores approved operating parameters for each supported gun, helping protect the torch from operation outside predefined limits and improving process repeatability.

F4MBXL / F4MBXL-90

The F4MBXL is a versatile, general-purpose plasma gun designed for a wide range of thermal spray applications. It is suitable for applying various functional and protective coatings, including wear-resistant, corrosion-resistant, hardfacing, thermal-resistant and other engineered coating systems.

The F4MBXL series can be used for coating both external and internal surfaces of components. Depending on the selected configuration, the plasma jet can be directed at different angles relative to the workpiece surface, providing flexibility for components with complex geometries and varying accessibility requirements.

SG-100

The GST SG-100 is a high-power plasma spray gun with a maximum power rating of up to 80 kW.

It is designed for applications requiring high productivity, stable plasma generation and reliable coating performance. The SG-100 is suitable for both high-volume industrial production and flexible manufacturing environments where a wide operating range and adaptability to different coating processes are required.

F1-45° / F1-90°

The F1 plasma gun is specifically designed for coating internal surfaces and other difficult-to-access areas. It is suitable for components with an internal diameter of 75 mm or greater and can be used for coating internal surfaces at depths of up to 495 mm. The gun body is manufactured from specially selected materials to minimize the influence of electrical fields on the plasma spraying process and to ensure stable operation during internal-diameter coating applications.

Depending on the configuration, the F1 plasma gun is available with a plasma jet angle of 45° or 90° relative to the longitudinal axis of the gun, allowing effective coating of different internal geometries.

Plasma Power Source

The MP 3000 uses an inverter-type power source developed for plasma spray operation. The standard platform is typically configured around a 100 kW power source, with optional capacity up to 200 kW. The inverter design provides low current ripple, stable plasma power, high electrical efficiency, and a 100% duty cycle.

Powder Feeder

The powder feeder transports coating powder to the plasma gun using carrier gas. Standard architecture supports up to four independent powder feed lines with 1.5 L or 5 L hoppers. Volumetric feeding is standard, while gravimetric feed control is available as an option.

Refrigeration Unit

Continuous forced-water cooling is required because plasma guns operate under high thermal loads. The refrigeration unit is selected to maintain stable cooling conditions for the installed plasma gun and associated system components.

Manipulators and Positioners

Industrial robots, gun manipulators, and workpiece positioners control relative motion between the plasma gun and the part. Proper selection of axes, payload, speed, and motion range helps maintain spray distance, angle, velocity, and trajectory.

Peripheral Equipment

The complete cell can include a soundproof spray booth and an exhaust/filtration unit. Plasma spraying generates heat, dust, overspray, and high noise levels, so these modules are important for workplace safety and process containment.