What makes a spray nozzle wear resistant?
Wear resistance in a spray nozzle is the nozzle’s ability to withstand gradual erosion by particles and friction. It is very dependent on the material. The higher the wear resistance, the better it is at maintaining its original shape, flow rate, and spray pattern. And the better the wear resistance, the less often the spray nozzle needs replacement.
What causes a spray nozzle to wear out?
1: Abbrasive liquids
The more unpure liquid which is sprayed, the faster the spray nozzle can wear out. Abbrasive liquids containing grinding materials such as sand, minerals, or metal powders will wear the nozzle out faster depending on the strength of the material.
2: High operating pressure
High operating pressure is demanding for spray nozzles because it dramatically increases the speed at which liquid exits the nozzle. Higher liquid velocity means more energy is concentrated on the nozzle’s internal surfaces, accelerating wear and placing greater mechanical stress on the nozzle.
3: Long spraying cycles
The more frequent the spray nozzle is running, the faster it will wear. The continuous erosion and pressure will build up and wear down the nozzle. The weaker the material, the faster it will go.
4: Corrosive chemicals
Chemical spraying is the fastest way to wear down a spray nozzle. Especially if the material is not made to withstand the chemical which is used. Prolonged exposure to chemicals will slowly degrade the nozzle material. Even corrosion-resistant materials have limits, especially during continuous operation.
Which spray nozzle materials are the most wear resistant?
Material and wear resistance
The figure to the right shows the increase in flow for each nozzle due to worn orifices. The shaded area indicates the excess spray flow from a stainless steel nozzle relative to a spray nozzle made from ceramics. As can be seen on the graph, the ceramic spray nozzle has an outstanding wear-resistance, with a hardness of 7 on the Mohs scale. It can last 20–30 times longer than stainless steel nozzles and several hundred times longer than brass ones. Ceramic spray nozzles are recommended for applications requiring wear resistant nozzles, including high-pressure cleaning and for use with liquids containing slurry
Other factors which increase the lifespan of a spray nozzle
1: Heat resistance
The heat resistance of a spray nozzle can also help to increase the lifespan, if it is exposed to higher temperatures. The temperature a spray nozzle can withstand varies greatly depending on the environmental conditions and the properties of the spray liquid. The table below show the heat resistance of different spray nozzle materials in the right side of the table. As can be seen on the table, the materials Alumina ceramics, SiC and SiSiC have the highest temperature resistance of all the materials. For nozzles including adhesives it is important to also consider the heat resistance of the adhesive. The ceramic tips can crack if abruptly cooled down from high temperatures (200°C). Alumina ceramics will crack due to temperature changes of 100°C or more.
2: Chemical resistance
The chemical resistance of a spray nozzle can also have a great influence on the life-span if it sprays chemical fluids. When spraying chemicals or using spray nozzles in a corrosive environment, chemical-resistant materials must be used to avoid deterioration of nozzles. The table above shows the chemical resistance of different spray nozzle materials. As can be seen on the table, the materials Alumina ceramics, SiC and SiSiC have the broadest chemical resistance to most materials. However, plastic is also found to be highly chemical resistant to many materials. For nozzles including adhesives, also consider the chemical resistance of the adhesive.
3: Pressure resistance
The pressure resistance of a spray nozzle can also have a great influence on the lifespan if it is operating under high and fluctuating pressures. Each nozzle series is carefully designed to withstand specific pressures. Depending on the operating system, sudden pressure can be three to five times as much as the spray pressure. Consider measures to prevent these sudden pressure increases or surges in water pressure. For high pressure use, metal nozzles are recommended over plastic nozzles.
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