Thermal Spraying
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Thermal spraying techniques are
coating A coating is a covering that is applied to the surface of an object, usually referred to as the Substrate (materials science), substrate. The purpose of applying the coating may be decorative, functional, or both. Coatings may be applied as liquid ...
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 microns to several mm, depending on the process and feedstock), over a large area at high deposition rate as compared to other coating processes such as
electroplating Electroplating, also known as electrochemical deposition or electrodeposition, is a process for producing a metal coating on a solid substrate through the reduction of cations of that metal by means of a direct electric current. The part to be ...
,
physical Physical may refer to: *Physical examination In a physical examination, medical examination, or clinical examination, a medical practitioner examines a patient for any possible medical signs or symptoms of a medical condition. It generally co ...
and
chemical vapor deposition Chemical vapor deposition (CVD) is a vacuum deposition method used to produce high quality, and high-performance, solid materials. The process is often used in the semiconductor industry to produce thin films. In typical CVD, the wafer (substra ...
. 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. The surface may not heat up significantly, allowing the coating of flammable substances. Coating quality is usually assessed by measuring its
porosity Porosity or void fraction is a measure of the void (i.e. "empty") spaces in a material, and is a fraction of the volume of voids over the total volume, between 0 and 1, or as a percentage between 0% and 100%. Strictly speaking, some tests measure ...
,
oxide An oxide () is a chemical compound that contains at least one oxygen atom and one other element in its chemical formula. "Oxide" itself is the dianion of oxygen, an O2– (molecular) ion. with oxygen in the oxidation state of −2. Most of the E ...
content, macro and micro-
hardness In materials science, hardness (antonym: softness) is a measure of the resistance to localized plastic deformation induced by either mechanical indentation or abrasion. In general, different materials differ in their hardness; for example hard ...
,
bond strength In chemistry, bond energy (''BE''), also called the mean bond enthalpy or average bond enthalpy is the measure of bond strength in a chemical bond. IUPAC defines bond energy as the average value of the gas-phase bond-dissociation energy (usually at ...
and surface roughness. Generally, the coating quality increases with increasing particle velocities.


Variations

Several variations of thermal spraying are distinguished: *Plasma spraying * Detonation spraying *Wire arc spraying *Flame spraying *High velocity oxy-fuel coating spraying (HVOF) *High velocity air fuel (HVAF) *Warm spraying *
Cold spraying Gas dynamic cold spraying or cold spraying (CS) is a coating deposition method. Solid powders (1 to 50 micrometers in diameter) are accelerated in a supersonic gas jet to velocities up to ca. 1200 m/s. During impact with the substrate, particle ...
*Spray and Fuse In classical (developed between 1910 and 1920) but still widely used processes such as flame spraying and wire arc spraying, the particle velocities are generally low (< 150 m/s), and raw materials must be molten to be deposited. Plasma spraying, developed in the 1970s, uses a high-temperature plasma jet generated by arc discharge with typical temperatures >15,000 K, which makes it possible to spray refractory materials such as oxides,
molybdenum Molybdenum is a chemical element with the symbol Mo and atomic number 42 which is located in period 5 and group 6. The name is from Neo-Latin ''molybdaenum'', which is based on Ancient Greek ', meaning lead, since its ores were confused with lea ...
, etc.


System overview

A typical thermal spray system consists of the following: *Spray torch (or spray gun) – the core device performing the melting and acceleration of the particles to be deposited *Feeder – for supplying the
powder A powder is a dry, bulk solid composed of many very fine particles that may flow freely when shaken or tilted. Powders are a special sub-class of granular materials, although the terms ''powder'' and ''granular'' are sometimes used to distin ...
,
wire Overhead power cabling. The conductor consists of seven strands of steel (centre, high tensile strength), surrounded by four outer layers of aluminium (high conductivity). Sample diameter 40 mm A wire is a flexible strand of metal. Wire is c ...
or
liquid A liquid is a nearly incompressible fluid that conforms to the shape of its container but retains a (nearly) constant volume independent of pressure. As such, it is one of the four fundamental states of matter (the others being solid, gas, a ...
to the torch through tubes. *Media supply –
gas Gas is one of the four fundamental states of matter (the others being solid, liquid, and plasma). A pure gas may be made up of individual atoms (e.g. a noble gas like neon), elemental molecules made from one type of atom (e.g. oxygen), or ...
es or
liquid A liquid is a nearly incompressible fluid that conforms to the shape of its container but retains a (nearly) constant volume independent of pressure. As such, it is one of the four fundamental states of matter (the others being solid, gas, a ...
s for the generation of the flame or plasma jet, gases for carrying the
powder A powder is a dry, bulk solid composed of many very fine particles that may flow freely when shaken or tilted. Powders are a special sub-class of granular materials, although the terms ''powder'' and ''granular'' are sometimes used to distin ...
, etc. *Robot/Labour – for manipulating the torch or the substrates to be coated *Power supply – often standalone for the torch *Control console(s) – either integrated or individual for all of the above


Detonation thermal spraying process

The detonation gun consists of a long water-cooled barrel with inlet valves for gases and powder. Oxygen and fuel (acetylene most common) are fed into the barrel along with a charge of powder. A spark is used to ignite the gas mixture, and the resulting detonation heats and accelerates the powder to supersonic velocity through the barrel. A pulse of nitrogen is used to purge the barrel after each detonation. This process is repeated many times a second. The high kinetic energy of the hot powder particles on impact with the substrate results in a buildup of a very dense and strong coating. The coating adheres through a mechanical bond resulting from the deformation of the base substrate wrapping around the sprayed particles after the high speed impact.


Plasma spraying

In
plasma Plasma or plasm may refer to: Science * Plasma (physics), one of the four fundamental states of matter * Plasma (mineral), a green translucent silica mineral * Quark–gluon plasma, a state of matter in quantum chromodynamics Biology * Blood pla ...
spraying process, the material to be deposited (feedstock) — typically as a
powder A powder is a dry, bulk solid composed of many very fine particles that may flow freely when shaken or tilted. Powders are a special sub-class of granular materials, although the terms ''powder'' and ''granular'' are sometimes used to distin ...
, sometimes as a
liquid A liquid is a nearly incompressible fluid that conforms to the shape of its container but retains a (nearly) constant volume independent of pressure. As such, it is one of the four fundamental states of matter (the others being solid, gas, a ...
,
suspension Suspension or suspended may refer to: Science and engineering * Suspension (topology), in mathematics * Suspension (dynamical systems), in mathematics * Suspension of a ring, in mathematics * Suspension (chemistry), small solid particles suspend ...
or wire — is introduced into the plasma jet, emanating from a
plasma torch A plasma torch (also known as a plasma arc, plasma gun, plasma cutter, or plasmatron) is a device for generating a directed flow of plasma. The plasma jet can be used for applications including plasma cutting, plasma arc welding, plasma spra ...
. In the jet, where the temperature is on the order of 10,000 K, the material is melted and propelled towards a substrate. There, the molten droplets flatten, rapidly solidify and form a deposit. Commonly, the deposits remain adherent to the substrate as coatings; free-standing parts can also be produced by removing the substrate. There are a large number of technological parameters that influence the interaction of the particles with the plasma jet and the substrate and therefore the deposit properties. These parameters include feedstock type, plasma gas composition and flow rate, energy input, torch offset distance, substrate cooling, etc.


Deposit properties

The deposits consist of a multitude of pancake-like 'splats' called
lamella Lamella (plural lamellae) means a small plate or flake in Latin, and in English may refer to: Biology * Lamella (mycology), a papery rib beneath a mushroom cap * Lamella (botany) * Lamella (surface anatomy), a plate-like structure in an animal ...
e, formed by flattening of the liquid droplets. As the feedstock powders typically have sizes from micrometers to above 100 micrometers, the lamellae have thickness in the micrometer range and lateral dimension from several to hundreds of micrometers. Between these lamellae, there are small voids, such as pores, cracks and regions of incomplete bonding. As a result of this unique structure, the deposits can have properties significantly different from bulk materials. These are generally mechanical properties, such as lower
strength Strength may refer to: Physical strength *Physical strength, as in people or animals * Hysterical strength, extreme strength occurring when people are in life-and-death situations *Superhuman strength, great physical strength far above human c ...
and modulus, higher
strain Strain may refer to: Science and technology * Strain (biology), variants of plants, viruses or bacteria; or an inbred animal used for experimental purposes * Strain (chemistry), a chemical stress of a molecule * Strain (injury), an injury to a mu ...
tolerance, and lower
thermal A thermal column (or thermal) is a rising mass of buoyant air, a convective current in the atmosphere, that transfers heat energy vertically. Thermals are created by the uneven heating of Earth's surface from solar radiation, and are an example ...
and
electrical conductivity Electrical resistivity (also called specific electrical resistance or volume resistivity) is a fundamental property of a material that measures how strongly it resists electric current. A low resistivity indicates a material that readily allow ...
. Also, due to the rapid solidification, metastable phases can be present in the deposits.


Applications

This technique is mostly used to produce coatings on structural materials. Such coatings provide protection against high temperatures (for example
thermal barrier coating Thermal barrier coatings (TBCs) are advanced materials systems usually applied to metallic surfaces operating at elevated temperatures, such as gas turbine or aero-engine parts, as a form of exhaust heat management. These 100 μm to 2 mm ...
s for exhaust heat management),
corrosion Corrosion is a natural process that converts a refined metal into a more chemically stable oxide. It is the gradual deterioration of materials (usually a metal) by chemical or electrochemical reaction with their environment. Corrosion engine ...
,
erosion Erosion is the action of surface processes (such as water flow or wind) that removes soil, rock, or dissolved material from one location on the Earth's crust, and then transports it to another location where it is deposited. Erosion is distin ...
,
wear Wear is the damaging, gradual removal or deformation of material at solid surfaces. Causes of wear can be mechanical (e.g., erosion) or chemical (e.g., corrosion). The study of wear and related processes is referred to as tribology. Wear in m ...
; they can also change the appearance, electrical or tribological properties of the surface, replace worn material, etc. When sprayed on substrates of various shapes and removed, free-standing parts in the form of plates, tubes, shells, etc. can be produced. It can also be used for powder processing (spheroidization, homogenization, modification of chemistry, etc.). In this case, the substrate for deposition is absent and the particles solidify during flight or in a controlled environment (e.g., water). This technique with variation may also be used to create porous structures, suitable for bone ingrowth, as a coating for medical implants. A polymer dispersion aerosol can be injected into the plasma discharge in order to create a grafting of this polymer on to a substrate surface. This application is mainly used to modify the surface chemistry of polymers.


Variations

Plasma spraying systems can be categorized by several criteria. Plasma jet generation: *
direct current Direct current (DC) is one-directional flow of electric charge. An electrochemical cell is a prime example of DC power. Direct current may flow through a conductor such as a wire, but can also flow through semiconductors, insulators, or even ...
( DC plasma), where the energy is transferred to the plasma jet by a direct current, high-power electric arc * induction plasma or RF plasma, where the energy is transferred by induction from a coil around the plasma jet, through which an alternating, radio-frequency current passes Plasma-forming medium: *gas-stabilized plasma (GSP), where the plasma forms from a gas; typically
argon Argon is a chemical element with the symbol Ar and atomic number 18. It is in group 18 of the periodic table and is a noble gas. Argon is the third-most abundant gas in Earth's atmosphere, at 0.934% (9340 ppmv). It is more than twice as abu ...
,
hydrogen Hydrogen is the chemical element with the symbol H and atomic number 1. Hydrogen is the lightest element. At standard conditions hydrogen is a gas of diatomic molecules having the formula . It is colorless, odorless, tasteless, non-toxic, an ...
,
helium Helium (from el, ἥλιος, helios, lit=sun) is a chemical element with the symbol He and atomic number 2. It is a colorless, odorless, tasteless, non-toxic, inert, monatomic gas and the first in the noble gas group in the periodic table. ...
or their mixtures *water-stabilized plasma (WSP), where plasma forms from
water Water (chemical formula ) is an inorganic, transparent, tasteless, odorless, and nearly colorless chemical substance, which is the main constituent of Earth's hydrosphere and the fluids of all known living organisms (in which it acts as a ...
(through evaporation, dissociation and ionization) or other suitable liquid *hybrid plasma – with combined gas and liquid stabilization, typically argon and water Spraying environment: *atmospheric plasma spraying (APS), performed in ambient
air The atmosphere of Earth is the layer of gases, known collectively as air, retained by Earth's gravity that surrounds the planet and forms its planetary atmosphere. The atmosphere of Earth protects life on Earth by creating pressure allowing f ...
*controlled atmosphere plasma spraying (CAPS), usually performed in a closed chamber, either filled with
inert gas An inert gas is a gas that does not readily undergo chemical reactions with other chemical substances and therefore does not readily form chemical compounds. The noble gases often do not react with many substances and were historically referred to ...
or evacuated *variations of CAPS: high-pressure plasma spraying (HPPS), low-pressure plasma spraying (LPPS), the extreme case of which is
vacuum A vacuum is a space devoid of matter. The word is derived from the Latin adjective ''vacuus'' for "vacant" or "void". An approximation to such vacuum is a region with a gaseous pressure much less than atmospheric pressure. Physicists often dis ...
plasma spraying (VPS, see below) *underwater plasma spraying Another variation consists of having a liquid feedstock instead of a solid powder for melting, this technique is known as
Solution precursor plasma spray Solution precursor plasma spray (SPPS) is a thermal spray process where a feedstock solution is heated and then deposited onto a substrate. Basic properties of the process are fundamentally similar to other plasma spraying processes. However, ins ...


Vacuum plasma spraying

Vacuum plasma spraying (VPS) is a technology for etching and surface modification to create
porous Porosity or void fraction is a measure of the void (i.e. "empty") spaces in a material, and is a fraction of the volume of voids over the total volume, between 0 and 1, or as a percentage between 0% and 100%. Strictly speaking, some tests measure ...
layers with high reproducibility and for cleaning and surface engineering of plastics, rubbers and natural fibers as well as for replacing CFCs for cleaning metal components. This surface engineering can improve properties such as frictional behavior,
heat resistance Thermal resistance is a heat property and a measurement of a temperature difference by which an object or material resists a heat flow. Thermal resistance is the reciprocal of thermal conductance. * (Absolute) thermal resistance ''R'' in kelvin ...
, surface
electrical conductivity Electrical resistivity (also called specific electrical resistance or volume resistivity) is a fundamental property of a material that measures how strongly it resists electric current. A low resistivity indicates a material that readily allow ...
,
lubricity Lubricity is the measure of the reduction in friction and/or wear by a lubricant. The study of lubrication and wear mechanisms is called tribology. Measurement of lubricity The lubricity of a substance is not a material property, and cannot be me ...
, cohesive strength of films, or
dielectric constant The relative permittivity (in older texts, dielectric constant) is the permittivity of a material expressed as a ratio with the electric permittivity of a vacuum. A dielectric is an insulating material, and the dielectric constant of an insulat ...
, or it can make materials
hydrophilic A hydrophile is a molecule or other molecular entity that is attracted to water molecules and tends to be dissolved by water.Liddell, H.G. & Scott, R. (1940). ''A Greek-English Lexicon'' Oxford: Clarendon Press. In contrast, hydrophobes are no ...
or
hydrophobic In chemistry, hydrophobicity is the physical property of a molecule that is seemingly repelled from a mass of water (known as a hydrophobe). In contrast, hydrophiles are attracted to water. Hydrophobic molecules tend to be nonpolar and, th ...
. The process typically operates at 39–120 °C to avoid thermal damage. It can induce non-thermally activated surface reactions, causing surface changes which cannot occur with molecular chemistries at atmospheric pressure.
Plasma processing Plasma processing is a plasma-based material processing technology that aims at modifying the chemical and physical properties of a surface. Plasma processing techniques include: *Plasma activation *Plasma ashing *Plasma cleaning *Plasma electro ...
is done in a controlled environment inside a sealed chamber at a medium vacuum, around 13–65 Pa. The
gas Gas is one of the four fundamental states of matter (the others being solid, liquid, and plasma). A pure gas may be made up of individual atoms (e.g. a noble gas like neon), elemental molecules made from one type of atom (e.g. oxygen), or ...
or mixture of gases is energized by an electrical field from DC to
microwave Microwave is a form of electromagnetic radiation with wavelengths ranging from about one meter to one millimeter corresponding to frequencies between 300 MHz and 300 GHz respectively. Different sources define different frequency ran ...
frequencies, typically 1–500 W at 50 V. The treated components are usually electrically isolated. The volatile plasma by-products are evacuated from the chamber by the
vacuum pump A vacuum pump is a device that draws gas molecules from a sealed volume in order to leave behind a partial vacuum. The job of a vacuum pump is to generate a relative vacuum within a capacity. The first vacuum pump was invented in 1650 by Otto v ...
, and if necessary can be neutralized in an exhaust
scrubber Scrubber systems (e.g. chemical scrubbers, gas scrubbers) are a diverse group of air pollution control devices that can be used to remove some particulates and/or gases from industrial exhaust streams. An early application of a carbon dioxide scr ...
. In contrast to molecular chemistry, plasmas employ: * Molecular, atomic, metastable and free radical species for chemical effects. * Positive ions and electrons for kinetic effects. Plasma also generates
electromagnetic radiation In physics, electromagnetic radiation (EMR) consists of waves of the electromagnetic field, electromagnetic (EM) field, which propagate through space and carry momentum and electromagnetic radiant energy. It includes radio waves, microwaves, inf ...
in the form of vacuum UV photons to penetrate bulk polymers to a depth of about 10 μm. This can cause chain scissions and cross-linking. Plasmas affect materials at an atomic level. Techniques like
X-ray photoelectron spectroscopy X-ray photoelectron spectroscopy (XPS) is a surface-sensitive quantitative spectroscopic technique based on the photoelectric effect that can identify the elements that exist within a material (elemental composition) or are covering its surface, ...
and scanning electron microscopy are used for surface analysis to identify the processes required and to judge their effects. As a simple indication of
surface energy In surface science, surface free energy (also interfacial free energy or surface energy) quantifies the disruption of intermolecular bonds that occurs when a surface is created. In solid-state physics, surfaces must be intrinsically less energe ...
, and hence
adhesion Adhesion is the tendency of dissimilar particles or surfaces to cling to one another ( cohesion refers to the tendency of similar or identical particles/surfaces to cling to one another). The forces that cause adhesion and cohesion can be ...
or wettability, often a water droplet contact angle test is used. The lower the contact angle, the higher the surface energy and more hydrophilic the material is.


Changing effects with plasma

At higher energies
ionization Ionization, or Ionisation is the process by which an atom or a molecule acquires a negative or positive charge by gaining or losing electrons, often in conjunction with other chemical changes. The resulting electrically charged atom or molecule i ...
tends to occur more than chemical dissociations. In a typical reactive gas, 1 in 100 molecules form
free radical A daughter category of ''Ageing'', this category deals only with the biological aspects of ageing. Ageing Ailments of unknown cause Biogerontology Biological processes Causes of death Cellular processes Gerontology Life extension Metabo ...
s whereas only 1 in 106 ionizes. The predominant effect here is the forming of free radicals. Ionic effects can predominate with selection of process parameters and if necessary the use of noble gases.


Wire arc spray

Wire arc spray is a form of thermal spraying where two consumable metal wires are fed independently into the spray gun. These wires are then charged and an arc is generated between them. The heat from this arc melts the incoming wire, which is then entrained in an air jet from the gun. This entrained molten feedstock is then deposited onto a substrate with the help of compressed air. This process is commonly used for metallic, heavy coatings.


Plasma transferred wire arc

Plasma transferred wire arc (PTWA) is another form of wire arc spray which deposits a coating on the internal surface of a cylinder, or on the external surface of a part of any geometry. It is predominantly known for its use in coating the cylinder bores of an engine, enabling the use of Aluminum engine blocks without the need for heavy cast iron sleeves. A single conductive wire is used as "feedstock" for the system. A supersonic plasma jet melts the wire, atomizes it and propels it onto the substrate. The plasma jet is formed by a transferred arc between a non-consumable cathode and the type of a wire. After atomization, forced air transports the stream of molten droplets onto the bore wall. The particles flatten when they impinge on the surface of the substrate, due to the high kinetic energy. The particles rapidly solidify upon contact. The stacked particles make up a high wear resistant coating. The PTWA thermal spray process utilizes a single wire as the feedstock material. All conductive wires up to and including 0.0625" (1.6mm) can be used as feedstock material, including "cored" wires. PTWA can be used to apply a coating to the wear surface of engine or transmission components to replace a bushing or bearing. For example, using PTWA to coat the bearing surface of a connecting rod offers a number of benefits including reductions in weight, cost, friction potential, and stress in the connecting rod.


High velocity oxygen fuel spraying (HVOF)

During the 1980s, a class of thermal spray processes called high velocity oxy-fuel spraying was developed. A mixture of gaseous or liquid
fuel A fuel is any material that can be made to react with other substances so that it releases energy as thermal energy or to be used for work. The concept was originally applied solely to those materials capable of releasing chemical energy but ...
and
oxygen Oxygen is the chemical element with the symbol O and atomic number 8. It is a member of the chalcogen group in the periodic table, a highly reactive nonmetal, and an oxidizing agent that readily forms oxides with most elements as wel ...
is fed into a
combustion chamber A combustion chamber is part of an internal combustion engine in which the fuel/air mix is burned. For steam engines, the term has also been used for an extension of the firebox which is used to allow a more complete combustion process. Interna ...
, where they are ignited and combusted continuously. The resultant hot gas at a pressure close to 1 MPa emanates through a converging–diverging nozzle and travels through a straight section. The fuels can be gases (
hydrogen Hydrogen is the chemical element with the symbol H and atomic number 1. Hydrogen is the lightest element. At standard conditions hydrogen is a gas of diatomic molecules having the formula . It is colorless, odorless, tasteless, non-toxic, an ...
,
methane Methane ( , ) is a chemical compound with the chemical formula (one carbon atom bonded to four hydrogen atoms). It is a group-14 hydride, the simplest alkane, and the main constituent of natural gas. The relative abundance of methane on Eart ...
,
propane Propane () is a three-carbon alkane with the molecular formula . It is a gas at standard temperature and pressure, but compressible to a transportable liquid. A by-product of natural gas processing and petroleum refining, it is commonly used a ...
,
propylene Propylene, also known as propene, is an unsaturated organic compound with the chemical formula CH3CH=CH2. It has one double bond, and is the second simplest member of the alkene class of hydrocarbons. It is a colorless gas with a faint petrole ...
,
acetylene Acetylene (systematic name: ethyne) is the chemical compound with the formula and structure . It is a hydrocarbon and the simplest alkyne. This colorless gas is widely used as a fuel and a chemical building block. It is unstable in its pure ...
,
natural gas Natural gas (also called fossil gas or simply gas) is a naturally occurring mixture of gaseous hydrocarbons consisting primarily of methane in addition to various smaller amounts of other higher alkanes. Low levels of trace gases like carbo ...
, etc.) or liquids (
kerosene Kerosene, paraffin, or lamp oil is a combustible hydrocarbon liquid which is derived from petroleum. It is widely used as a fuel in aviation as well as households. Its name derives from el, κηρός (''keros'') meaning "wax", and was regi ...
, etc.). The jet velocity at the exit of the barrel (>1000 m/s) exceeds the
speed of sound The speed of sound is the distance travelled per unit of time by a sound wave as it propagates through an elastic medium. At , the speed of sound in air is about , or one kilometre in or one mile in . It depends strongly on temperature as w ...
. A powder feed stock is injected into the gas stream, which accelerates the powder up to 800 m/s. The stream of hot gas and powder is directed towards the surface to be coated. The powder partially melts in the stream, and deposits upon the substrate. The resulting coating has low
porosity Porosity or void fraction is a measure of the void (i.e. "empty") spaces in a material, and is a fraction of the volume of voids over the total volume, between 0 and 1, or as a percentage between 0% and 100%. Strictly speaking, some tests measure ...
and high
bond strength In chemistry, bond energy (''BE''), also called the mean bond enthalpy or average bond enthalpy is the measure of bond strength in a chemical bond. IUPAC defines bond energy as the average value of the gas-phase bond-dissociation energy (usually at ...
. HVOF coatings may be as thick as 12 mm (1/2"). It is typically used to deposit
wear Wear is the damaging, gradual removal or deformation of material at solid surfaces. Causes of wear can be mechanical (e.g., erosion) or chemical (e.g., corrosion). The study of wear and related processes is referred to as tribology. Wear in m ...
and
corrosion Corrosion is a natural process that converts a refined metal into a more chemically stable oxide. It is the gradual deterioration of materials (usually a metal) by chemical or electrochemical reaction with their environment. Corrosion engine ...
resistant coatings on materials, such as ceramic and metallic layers. Common powders include WC-Co,
chromium carbide Chromium(II) carbide is a ceramic compound that exists in several chemical compositions: Cr3C2, Cr7C3, and Cr23C6. At standard conditions it exists as a gray solid. It is extremely hard and corrosion resistant. It is also a refractory compound, ...
, MCrAlY, and alumina. The process has been most successful for depositing
cermet A cermet is a composite material composed of ceramic (cer) and metal (met) materials. A cermet can combine attractive properties of both a ceramic, such as high temperature resistance and hardness, and those of a metal, such as the ability to und ...
materials (WC–Co, etc.) and other corrosion-resistant alloys (
stainless steel Stainless steel is an alloy of iron that is resistant to rusting and corrosion. It contains at least 11% chromium and may contain elements such as carbon, other nonmetals and metals to obtain other desired properties. Stainless steel's corros ...
s, nickel-based alloys, aluminium,
hydroxyapatite Hydroxyapatite, also called hydroxylapatite (HA), is a naturally occurring mineral form of calcium apatite with the formula Ca5(PO4)3(OH), but it is usually written Ca10(PO4)6(OH)2 to denote that the crystal unit cell comprises two entities. ...
for medical implants, etc.).


High Velocity Air Fuel (HVAF)

HVAF coating technology is the combustion of
propane Propane () is a three-carbon alkane with the molecular formula . It is a gas at standard temperature and pressure, but compressible to a transportable liquid. A by-product of natural gas processing and petroleum refining, it is commonly used a ...
in a compressed air stream. Like HVOF, this produces a uniform high velocity jet. HVAF differs by including a heat baffle to further stabilize the thermal spray mechanisms. Material is injected into the air-fuel stream and coating particles are propelled toward the part. HVAF has a maximum flame temperature of 3,560° to 3,650 °F and an average particle velocity of 3,300 ft/sec. Since the maximum flame temperature is relatively close to the melting point of most spray materials, HVAF results in a more uniform, ductile coating. This also allows for a typical coating thickness of 0.002-0.050". HVAF coatings also have a mechanical bond strength of greater that 12,000 psi. Common HVAF coating materials include, but are not limited to;
tungsten carbide Tungsten carbide (chemical formula: WC) is a chemical compound (specifically, a carbide) containing equal parts of tungsten and carbon atoms. In its most basic form, tungsten carbide is a fine gray powder, but it can be pressed and formed into ...
, chrome carbide,
stainless steel Stainless steel is an alloy of iron that is resistant to rusting and corrosion. It contains at least 11% chromium and may contain elements such as carbon, other nonmetals and metals to obtain other desired properties. Stainless steel's corros ...
,
hastelloy Haynes International, Inc., headquartered in Kokomo, Indiana, is one of the largest producers of corrosion-resistant and high-temperature alloys. In addition to Kokomo, Haynes has manufacturing facilities in Arcadia, Louisiana, and Mountain Home, ...
, and
inconel Inconel is a registered trademark of Special Metals Corporation for a family of austenitic nickel-chromium-based superalloys. Inconel alloys are oxidation-corrosion-resistant materials well suited for service in extreme environments subjected t ...
. Due to its
ductile Ductility is a mechanical property commonly described as a material's amenability to drawing (e.g. into wire). In materials science, ductility is defined by the degree to which a material can sustain plastic deformation under tensile stres ...
nature hvaf coatings can help resist
cavitation Cavitation is a phenomenon in which the static pressure of a liquid reduces to below the liquid's vapour pressure, leading to the formation of small vapor-filled cavities in the liquid. When subjected to higher pressure, these cavities, cal ...
damage.


Spray and Fuse

Spray and fuse uses high heat to increase the bond between the thermal spray coating and the substrate of the part. Unlike other types of thermal spray, spray and fuse creates a metallurgical bond between the coating and the surface. This means that instead of relying on friction for coating adhesion, it melds the surface and coating material into one material. Spray and fuse comes down to the difference between adhesion and cohesion. This process usually involves spraying a powdered material onto the component then following with an acetylene torch. The torch melts the coating material and the top layer of the component material; fusing them together. Due to the high heat of spray and fuse, some heat distortion may occur, and care must be taken to determine if a component is a good candidate. These high temperatures are akin to those used in welding. This metallurgical bond creates an extremely wear and abrasion resistant coating. Spray and fuse delivers the benefits of hardface welding with the ease of thermal spray.


Cold spraying

Cold spraying Gas dynamic cold spraying or cold spraying (CS) is a coating deposition method. Solid powders (1 to 50 micrometers in diameter) are accelerated in a supersonic gas jet to velocities up to ca. 1200 m/s. During impact with the substrate, particle ...
(or gas dynamic cold spraying) was introduced to the market in the 1990s. The method was originally developed in the Soviet Union – while experimenting with the erosion of the target, which was exposed to a two-phase high-velocity flow of fine powder in a wind tunnel, scientists observed accidental rapid formation of coatings. In cold spraying, particles are accelerated to very high speeds by the carrier gas forced through a converging–diverging de Laval type nozzle. Upon impact, solid particles with sufficient kinetic energy deform plastically and bond mechanically to the substrate to form a coating. The critical velocity needed to form bonding depends on the material's properties, powder size and temperature.
Metal A metal (from Greek μέταλλον ''métallon'', "mine, quarry, metal") is a material that, when freshly prepared, polished, or fractured, shows a lustrous appearance, and conducts electricity and heat relatively well. Metals are typicall ...
s,
polymer A polymer (; Greek '' poly-'', "many" + ''-mer'', "part") is a substance or material consisting of very large molecules called macromolecules, composed of many repeating subunits. Due to their broad spectrum of properties, both synthetic a ...
s,
ceramic A ceramic is any of the various hard, brittle, heat-resistant and corrosion-resistant materials made by shaping and then firing an inorganic, nonmetallic material, such as clay, at a high temperature. Common examples are earthenware, porcelain ...
s,
composite material A composite material (also called a composition material or shortened to composite, which is the common name) is a material which is produced from two or more constituent materials. These constituent materials have notably dissimilar chemical or ...
s and
nanocrystalline A nanocrystalline (NC) material is a polycrystalline material with a crystallite size of only a few nanometers. These materials fill the gap between amorphous materials without any long range order and conventional coarse-grained materials. De ...
powders can be deposited using cold spraying. Soft metals such as Cu and Al are best suited for cold spraying, but coating of other materials (W, Ta, Ti, MCrAlY, WC–Co, etc.) by cold spraying has been reported. The deposition efficiency is typically low for alloy powders, and the window of process parameters and suitable powder sizes is narrow. To accelerate powders to higher velocity, finer powders (<20 micrometers) are used. It is possible to accelerate powder particles to much higher velocity using a processing gas having high
speed of sound The speed of sound is the distance travelled per unit of time by a sound wave as it propagates through an elastic medium. At , the speed of sound in air is about , or one kilometre in or one mile in . It depends strongly on temperature as w ...
(helium instead of nitrogen). However, helium is costly and its flow rate, and thus consumption, is higher. To improve acceleration capability, nitrogen gas is heated up to about 900 °C. As a result, deposition efficiency and tensile strength of deposits increase.


Warm spraying

Warm spraying is a novel modification of high velocity oxy-fuel spraying, in which the temperature of combustion gas is lowered by mixing nitrogen with the combustion gas, thus bringing the process closer to the cold spraying. The resulting gas contains much water vapor, unreacted hydrocarbons and oxygen, and thus is dirtier than the cold spraying. However, the coating efficiency is higher. On the other hand, lower temperatures of warm spraying reduce melting and chemical reactions of the feed powder, as compared to HVOF. These advantages are especially important for such coating materials as Ti, plastics, and metallic glasses, which rapidly oxidize or deteriorate at high temperatures.


Applications

*
Crankshaft A crankshaft is a mechanical component used in a piston engine to convert the reciprocating motion into rotational motion. The crankshaft is a rotating shaft containing one or more crankpins, that are driven by the pistons via the connecting ...
reconditioning or conditioning *
Corrosion Corrosion is a natural process that converts a refined metal into a more chemically stable oxide. It is the gradual deterioration of materials (usually a metal) by chemical or electrochemical reaction with their environment. Corrosion engine ...
protection *
Fouling Fouling is the accumulation of unwanted material on solid surfaces. The fouling materials can consist of either living organisms (biofouling) or a non-living substance (inorganic or organic). Fouling is usually distinguished from other surf ...
protection *Altering
thermal conductivity The thermal conductivity of a material is a measure of its ability to conduct heat. It is commonly denoted by k, \lambda, or \kappa. Heat transfer occurs at a lower rate in materials of low thermal conductivity than in materials of high thermal ...
or
electrical conductivity Electrical resistivity (also called specific electrical resistance or volume resistivity) is a fundamental property of a material that measures how strongly it resists electric current. A low resistivity indicates a material that readily allow ...
*Wear control: either
hardfacing Hardfacing is a metalworking process where harder or tougher material is applied to a base metal. It is welded to the base material, and generally takes the form of specialized electrodes for arc welding or filler rod for oxyacetylene and gas tungst ...
(wear-resistant) or
abradable coating An abradable coating is a coating made of an abradable material – meaning if it rubs against a more abrasive material in motion, the former will be worn whereas the latter will face no wear. Abradable coatings provide a .1 to .2% performance im ...
*Repairing damaged surfaces *Temperature/oxidation protection (thermal barrier coatings) *Medical implants coatings (by using
polymer derived ceramics Polymer derived ceramics (PDCs) are ceramic materials formed by the pyrolysis of preceramic polymers, usually under inert atmosphere. The compositions of PDCs most commonly include silicon carbide (SiC), silicon oxycarbide (SiOxCy), silicon nitride ...
) *Production of
functionally graded material In materials science Functionally Graded Materials (FGMs) may be characterized by the variation in composition and structure gradually over volume, resulting in corresponding changes in the properties of the material. The materials can be desig ...
s (for any of the above applications)


Limitations

Thermal spraying is a line of sight process and the bond mechanism is primarily mechanical. Thermal spray application is not compatible with the substrate if the area to which it is applied is complex or blocked by other bodies.


Safety

Thermal spraying need not be a dangerous process if the equipment is treated with care and correct spraying practices are followed. As with any industrial process, there are a number of hazards of which the operator should be aware and against which specific precautions should be taken. Ideally, equipment should be operated automatically in enclosures specially designed to extract fumes, reduce noise levels, and prevent direct viewing of the spraying head. Such techniques will also produce coatings that are more consistent. There are occasions when the type of components being treated, or their low production levels, require manual equipment operation. Under these conditions, a number of hazards peculiar to thermal spraying are experienced in addition to those commonly encountered in production or processing industries.


Noise

Metal spraying equipment uses compressed gases which create noise. Sound levels vary with the type of spraying equipment, the material being sprayed, and the operating parameters. Typical sound pressure levels are measured at 1 meter behind the arc.


UV light

Combustion spraying equipment produces an intense flame, which may have a peak temperature more than 3,100 °C and is very bright. Electric arc spraying produces ultra-violet light which may damage delicate body tissues. Plasma also generates quite a lot of UV radiation, easily burning exposed skin and can also cause "flash burn" to the eyes. Spray booths and enclosures should be fitted with ultra-violet absorbent dark glass. Where this is not possible, operators, and others in the vicinity should wear protective goggles containing BS grade 6 green glass. Opaque screens should be placed around spraying areas. The nozzle of an arc pistol should never be viewed directly unless it is certain that no power is available to the equipment.


Dust and fumes

The atomization of molten materials produces a large amount of dust and fumes made up of very fine particles (ca. 80–95% of the particles by number <100 nm). Proper extraction facilities are vital not only for personal safety, but to minimize entrapment of re-frozen particles in the sprayed coatings. The use of respirators fitted with suitable filters is strongly recommended where equipment cannot be isolated. Certain materials offer specific known hazards: #Finely divided metal particles are potentially
pyrophoric A substance is pyrophoric (from grc-gre, πυροφόρος, , 'fire-bearing') if it ignites spontaneously in air at or below (for gases) or within 5 minutes after coming into contact with air (for liquids and solids). Examples are organolith ...
and harmful when accumulated in the body. #Certain materials e.g. aluminum, zinc and other base metals may react with water to evolve hydrogen. This is potentially explosive and special precautions are necessary in fume extraction equipment. #Fumes of certain materials, notably zinc and copper alloys, have a disagreeable odour and may cause a fever-type reaction in certain individuals (known as
metal fume fever Metal fume fever, also known as brass founders' ague, brass shakes, zinc shakes, galvie flu, galvo poisoning, metal dust fever, welding shivers, or Monday morning fever, is an illness primarily caused by exposure to chemicals such as zinc oxide (Zn ...
). This may occur some time after spraying and usually subsides rapidly. If it does not, medical advice must be sought. #Fumes of reactive compounds can dissociate and create harmful gasses. Respirators should be worn in these areas and gas meters should be used to monitor the air before respirators are removed.


Heat

Combustion spraying guns use oxygen and fuel gases. The fuel gases are potentially explosive. In particular, acetylene may only be used under approved conditions. Oxygen, while not explosive, will sustain combustion and many materials will spontaneously ignite if excessive oxygen levels are present. Care must be taken to avoid leakage and to isolate oxygen and fuel gas supplies when not in use.


Shock hazards

Electric arc guns operate at low voltages (below 45 V dc), but at relatively high currents. They may be safely hand-held. The power supply units are connected to 440 V AC sources, and must be treated with caution.


See also

*
List of coating techniques A coating is a covering that is applied to the surface of an object, usually referred to as the substrate. The purpose of applying the coating may be decorative, functional, or both. Coatings may be applied as liquids, gases or solids e.g. Powde ...
*
Thin film A thin film is a layer of material ranging from fractions of a nanometer (monolayer) to several micrometers in thickness. The controlled synthesis of materials as thin films (a process referred to as deposition) is a fundamental step in many ap ...


References

{{DEFAULTSORT:Thermal Spraying Coatings Materials science Chemical processes Thin film deposition Metallurgical processes