THERMAL SPRAY COATING

Thermal spraying techniques are coating processes in which melted (or heated) materials are sprayed onto a surface. The "feedstock" (coating precursor) is heated by electrical (plasma or arc) or chemical means (combustion flame).

Thermal spraying can provide thick coatings (approx. thickness range is 20 micrometers to several mm, depending on the process and feedstock), over a large area at high deposition rate . Coating materials available for thermal spraying include metals, alloys, ceramics, plastics and composites. They are fed in powder or wire form, heated to a molten or semimolten state and accelerated towards substrates in the form of micrometer-size particles. Combustion or electrical arc discharge is usually used as the source of energy for thermal spraying. Resulting coatings are made by the accumulation of numerous sprayed particles

Coating quality is usually assessed by measuring its porosity, oxide content, macro and micro-hardness, bond strength and surface roughness. Generally, the coating quality increases with increasing particle velocities.

Several variations of thermal spraying are distinguished:

  • Plasma spraying
  • Wire arc spraying
  • Flame spraying
  • High velocity oxy-fuel coating spraying (HVOF)
  • High velocity air fuel (HVAF)
  • Cold spraying