What is thermal spray?

The demands for engineering coatings are becoming more and more stringent. Environmental concerns are also being considered as an integral part of the design process. For future economic competitiveness and a lower environmental impact we must therefore turn our attention to processes that use the minimum of resources. Thermal spraying is an attractive coating technique as it offers a wide choice of materials and processes that have a reduced impact on the environment when compared to conventional plating processes.

Thermal spray coating techniques such as HVOF, flame wire spraying, flame powder spraying, arc wire spraying, plasma spraying and cold gas spraying,allow many problems of wear, corrosion and thermal degradation to be resolved by engineering the surface with tailor-made coatings.

SPRAY TECH - Thermal Spray Technology

In the simplest terms possible, thermal spray coating involves heating a material in powder or wire form to a molten or semi-molten state. The material is propelled using a stream of gas or compressed air to deposit it, creating a surface structure on a given substrate. The coating material may consist of a single element, but is often an alloy or composite with unique physical properties that are only achievable through the thermal spray process.  ....
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Poster  "About Thermal Spray"


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Thermal Spray Process

About Thermal Spray

Cross Section of Coating

  1. Particle Impact
  2. Oxidized particle
  3. Porosity
  4. Unmelted particle
  5. Grit blast interface

 

 

Microscopic cross-sections

  1. HVOF Sprayed Carbide
  2. APS Sprayed Ceramic
  3. ARC Sprayed Metal

 

 

Bonding Mechanisms

Bonding Mechanisms

At the coating/substrate interface and between the particles

1 Mechanical keying
Interlocking / anchoring

2 Diffusion bonding
Metallurgical bonding

3 other adhesive
Chemical and physical bonding mechanisms -oxide films, Van de Waals forces, etc.

eGun HVOF spray

eGun HVOF spray

more info and systems

Typical coatings

  • Nickel & Cobalt based alloys,
  • Stellite, Triballoy, Inconel, 
  • Iron based alloys, AISI 316L, etc.
  • Carbides & Cermets 
  • MCrAlY 

Main applications

  • Wear resistance
  • Sliding,     Abrasive, Erosion, etc.
  • Chemical resistance
  • High Temperature applications
  • Dimensional restoration
Cold Spray

Cold Spray

more info and systems > 

Typical coatings

  • Ductile materials & alloys  Zn, Al, Ni, Ti, Cu, Ag, NiCr, CuAl, MCrAlY’s, etc.
  • High end materials: Nobium or Tantalum

Main applications

  • Electrical and thermal conductivity 
  • Pre-placement of solders
  • Corrosion protection
  • Dimensional restoration
HVOF Spray

HVOF Spray

(High Velocity Oxygen Fuel) 

more info and systems > 

 

 

 

Typical coatings

  • Nickel & Cobalt based alloys, Stellite, Triballoy, Inconel, 
  • Iron based alloys, AISI 316L, etc.
  • Carbides & Cermets 
  • MCrAlY

Main applications

  • Wear resistance Sliding, Abrasive, Erosion, etc.
  • Chemical resistance
  • High Temperature applications
  • Dimensional restoration
Plasma Spray

Plasma Spray

more info and systems > 

Typical coatings

  • Ceramics
  • Carbides & Cermets 
  • Iron, Nickel & Cobalt based alloys 
  • Abradables

Main applications

  • Wear resistance Sliding, Abrasive, Erosion, etc.
  • Corrosion resistance
  • Thermal barriers
  • Combinations
Arc Wire Spray

Arc Wire spray

more info and systems > 

Typical coatings

  • Iron based alloys 
  • Nickel based alloys 
  • Copper & Copper alloys
  • Aluminium, Zinc, Al/Zn alloys
  • Babbitt alloys

Main applications

  • Wear resistance
  • Corrosion protection
  • Dimensional restoration
  • Bond coat

Flame Powder spray

more info and systems 

Typical coatings

  • Self-fluxing alloys (fusing)
  • Iron based alloys 
  • Nickel based alloys 
  • Ceramics & Cermets
  • Abradables

Main applications

  • Wear resistance
  • Corrosion protection
  • Chemical resistance
  • Dimensional restoration

Flame Wire spray

more info and systems > 

Typical coatings

  • Iron based alloys 
  • Nickel based alloys 
  • Molybdenum
  • Copper & Copper alloys
  • Aluminium, Zinc, Al/Zn alloys

Main applications

  • Wear resistance 
  • Friction properties 
  • Corrosion protection
  • Dimensional restoration
  • Electromagnetic shielding
Sperator bottom

Bonding Mechanisms

At the coating/substrate interface and between the particles

1 Mechanical keying
Interlocking / anchoring

2 Diffusion bonding
Metallurgical bonding

3 other adhesive
Chemical and physical bonding mechanisms -oxide films, Van de Waals forces, etc.

Bonding Mechanisms

1 Mechanical keying

Interlocking / anchoring

2 Diffusion bonding
Metallurgical bonding

3 other adhesive
 

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