Multi-shot power-supply using capacitors for an electromagnetic powder deposition (EPD) gun

The Department of Defense (DoD) and commercial entities are dependent on chemical plating and coating-processes to replace worn or eroded material on damaged parts. Air Force Logistics Centers have been forced to consider replacement methods for repair operations due to the tightening of government regulations on the use of toxic and hazardous materials. The electromagnetic coating process is an available alternative to existing build-up methods, and is based on proven "railgun" technology. Railguns have been under development for 15 years by the DoD and are high energy capacity electrical systems designed for rapid acceleration of an object. Railguns are effective in accelerating projectiles to very high, armor-piercing velocities exceeding 2 km/s. Current thermal spray technology limits coating velocities to the 1 km/s range. In the electromagnetic coating process, equipment similar to a railgun accelerates the coating material. The impressive acceleration capability of electromagnetic systems is expected to produce coatings with superior density and bond strength properties. In addition to potentially improving coating properties, the electromagnetic coating process may serve as a replacement for operations that generate hazardous chemical wastes, such as hard chrome plating. The purpose of the program is to identify, develop, and design a production system for high-quality coatings in industrial manufacturing and repair operations. This paper presents the design of a multi-shot power supply for EPD proof of principle testing.