Pressure-Controlled HVAF Systems

Pressure-Controlled HVAF Spray Systems

Built for reliability and long-term value, our pressure-controlled HVAF platforms—M2H™, M2™, M3™, and M4™ for OD spraying, and i5™ and i7™ for ID coating applications—have delivered proven performance over thousands of operating hours in demanding industrial environments. Paired with the ULTRACOAT-P pressure-based control console, these systems remain a trusted solution for a broad range of thermal spray applications.

Pressure-Controlled HVAF Systems

HVAF Spray Guns – Durable & Versatile

The M3 and M4 spray guns feature Uniquecoat’s proven combustor design, delivering consistent coating quality and long-term durability. In dual-stage combustion mode, these guns can spray both fine HVAF powders and standard HVOF-grade powders, producing dense, hard coatings with excellent wear resistance.

The M2 and M2H guns use a single-stage combustion configuration optimized for HVAF-grade powders and Flash Carbide coatings. Their simple, robust design provides exceptional durability and reliability in demanding industrial environments.

The i5 and i7 internal-diameter HVAF guns extend the same proven pressure-controlled technology to ID coating applications, enabling high-quality carbide and alloy coatings on internal surfaces where conventional OD spray guns cannot be used.

All M2, M2H, M3, M4, i5, and i7 spray guns are designed to operate with the ULTRACOAT-P pressure-based control console, providing reliable process control across a wide range of thermal spray applications.

ULTRACOAT-P Console – Reliable Pressure-Based Control

The ULTRACOAT-P control center uses pressure-regulated gas delivery to provide dependable ignition, stable operation, and consistent process control for standard HVAF applications. Its proven pressure-based architecture offers a simple, robust, and cost-effective solution for a wide range of industrial coating requirements.

GDU-P – Simplified Gas Management

The GDU-P provides reliable gas distribution in a compact, straightforward design. It features separate pressure-regulated fuel gas lines and an MFC-controlled carrier gas line, providing stable gas delivery and flexible operation across a wide range of HVAF spray applications.

Proven Pressure Control vs. Next-Generation Precision

ULTRACOAT-P provides proven, reliable pressure-based control, while the next-generation ULTRACOAT-M platform adds precision mass-flow regulation, fully independent dual-stage combustion control, and exceptional process repeatability.

→[Compare with the M5™ HVAF System]

System Components

Each component of the ULTRACOAT-P system is designed to work seamlessly together, ensuring stable operation, high deposition efficiency, and consistent coating performance.

Gas Distribution Unit GDU-P

Pressure-Controlled Gas Distribution Unit for HVAF Systems

🟢 Single Air Supply Line – pressure-regulated via I/P controller for stable air delivery

🟢 Dual Fuel Gas Circuits – two separate, independently metered fuel lines, each regulated by its own I/P controller

🟢 Dual Carrier Gas Lines – combined into a single supply line, controlled by a mass flow controller (MFC)

🟢 Isolated Enclosures – dedicated Air and Fuel compartments; the Fuel compartment is positively pressurized and continuously monitored by an integrated flammable-gas detector

🟢 Optional Oxygen Cabinet – MFC-controlled oxygen supply for HVOF applications

🟢 Optional Hydrogen Cabinet – MFC-controlled, positively pressurized enclosure equipped with a flammable-gas detector for enhanced operational safety

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M2™

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Choose Your HVAF Gun

The M2 is a reliable single-stage HVAF spray gun based on the same general combustion approach used across conventional HVAF systems. It is valued for its simplicity, durability, process stability, and ability to produce high-quality coatings across a wide range of applications.

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The M3 is the first dual-stage combustion supersonic HVAF gun, providing enhanced powder heating compared with conventional single-stage HVAF guns.

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The M4 is an enhanced version of the M3, featuring process-air preheating by recovering heat from the combustion chamber. This improves thermal efficiency, resulting in higher deposition efficiency (DE) and improved coating quality. The M4 provides excellent performance with HVAF-grade powders, delivering consistent and reliable coating results.

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The M2H was the first handheld single-stage HVAF spray gun. Its lightweight design and reduced thrust, achieved through a smaller-diameter nozzle, make it well suited for manual spraying of areas that are difficult or impractical to access with robotic equipment.

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The i7 internal-diameter spray gun delivers high-performance carbide, metal, and alloy coatings for internal surface applications. It is designed for coating internal diameters of 120 mm and larger.

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The i5 internal-diameter spray gun delivers high-performance carbide, metal, and alloy coatings for internal surface applications. It is designed for coating internal diameters of 70 mm and larger.

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M4™

ULTRACOAT-P HVAF Control Center

🟢 Unified System Control – Centralized management of I/P regulators, mass flow controllers (MFCs), powder feeders, robot, compressor, and all auxiliary equipment from a single, intuitive interface. Fully compatible with all Uniquecoat guns.

🟢 Intuitive Touchscreen HMI – Large, responsive touchscreen provides quick parameter adjustment, clear visualization, and real-time system status feedback.

🟢 Real-Time Monitoring & Auto-Shutdown – Continuously tracks all critical process parameters with automatic safety shutdown in case of out-of-spec conditions.

🟢 Unlimited Recipe Library – Create, save, recall, and share coating profiles instantly for consistent, repeatable, high-quality results.

🟢 AutoSpray Automation Suite – One-button job startup, full process sequencing, and automatic end-of-cycle logging for streamlined operation.

🟢 Secure Remote Access – Internet-enabled connectivity for remote diagnostics, firmware updates, and real-time technical support.

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M2™

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Add a Powder Feeder

Add a Gravimetric or Volumetric Powder Feeder to your HVAF System

The gallery below includes Uniquecoat powder feeders recommended for use with the ULTRACOAT-P HVAF system.

If you do not plan to perform hot grit blasting, we recommend the G4™ gravimetric feeder or its economical volumetric counterpart, the V4™ — both provide stable and reliable powder delivery.

For users intending to perform hot grit blasting, we recommend adding the V1™ model, specifically designed to handle abrasive grit over extended periods without part replacement.

The V1 Powder Feeder is engineered for use with both standard thermal spray powders and abrasive media such as grit, which is occasionally used for surface preparation in hot grit blasting with an HVAF gun. Designed without wearing seals or consumable spare parts, the V1 offers long-term reliability with minimal maintenance. Its volumetric feed principle provides direct control of powder flow via metering wheel speed. Easy loading, unloading, and cleaning ensure simple operation and reduced downtime.

The V4 is a heavy-duty volumetric powder feeder featuring a patented powder-feeding mechanism that ensures consistent, pulseless delivery of thermal spray powders, while eliminating powder after-flow through the spray torch upon shutdown.

A versatile gravimetric powder feeder engineered for excellence in thermal spray processes such as HVOF, HVAF, Plasma, Cold Spray, Laser Cladding, and a broad spectrum of industrial applications. The G4 automatically maintains the feed rate, adjustable in standard or customary units. Its patented, seal-free feeding mechanism ensures smooth, pulseless powder flow that remains consistent over time.

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Pressure-Controlled HVAF Spray Systems