Equipping Businesses with the Technology They Need to Leap Frog the Competition in Cold Spray Deposition, Powder Spheroidization, Laser Metal Deposition, Compressors, High Pressure Gas Mixing, Particle Analysis, & Reusable Masking

Helium Gas Mixer for Cold Spray Applications

30% cost savings Depositing

15-5PH Stainless Steel

with 63% He/N2

For the 15-5PH Stainless Steel powder, the least expensive coatings were found at 63% helium by volume. This Value resulted in a cost of 1.06N$ per gram of coating, compared to 1.53N$ for pure nitrogen and 1.49N$ for pure Helium. For this case it demonstrated that using this exact gas mixture results in a cost savings of approximately 30%

An Economical Approach to Cold Gas Dynamic Spraying using In-Line Nitrogen-Helium Blending

D. MacDonald, S. Rahmati, B. Jodoin
University of Ottawa Cold Spray Laboratory, Ottawa, ON Canada
Daniel.MacDonald@uottawa.ca
W. Birtch
Metal Tech & Mgmt Inc., Menomonee Falls, WI USA

Technical Specifications

Specially designed to reduce the use of helium in Cold Spray applications, Polycontrols offers two systems that can provide a helium gas mixture specific to Cold Spraying.


Fully automated system to blend air or nitrogen with helium


Equipment description

High pressure gas mixer using Mass Flow Meters with automatic control valves, piloted pressure regulators for high flow rates applications. Equipped with a user interface (HMI), the operator is able to select mixture ratios and pressure conditions. Mixture accuracy is maintained via a PLC based solution. Precise pressure regulation at the orifice is assured with specific pressure transducers.

Technical specifications:

  • Mixture maximum flow: up to 125 SCFM
  • Mixing ratio: 5% up to 100% He
  • Inlet Pressure: up to 2000 psi(g)
  • Outlet pressure: up to 1750 psi(g)
  • Flow turndown at least 20:1 for each line
  • Accuracy of each gas flow measurement: 1% of reading or better

Cost-effective gas mixer to blend air or nitrogen with helium


Equipment description.

High pressure gas mixer using rotameters with manual control valves and pressure regulators for high flow applications. Pressure is regulated by a free carrier gas (N2 or Air) and by a self priming Helium manual valve. Helium flow is measured with a rotameter and gas mixture is based on orifice calculations with multiple ratio charts based on gas, temperature and pressure.

Technical specifications:

  • Mixture maximum flow: 125 SCFM
  • Mixing ratio: 10% up to 90% He.
  • Inlet Pressure: up to 800 psi(g)
  • Outlet pressure: up to 500 psi(g)
  • Flow turndown: maximum 5:1 for each gas line
  • Accuracy of each gas flow measurement: 5% F.S.
  • Conversion chart provided for all pressures and temperatures

Efficient use of helium during warmup time

Both versions of the GMX-He make possible to warmup the system by using nitrogen gas and then seamlessly switches to helium mixture to minimize helium consumption.