About Thermal Spray

Thermal Spray Process Cross Section of Coating Bonding Mechanisms Positioning

Microscopic
Positioning
cross-sections At the coating/substrate interface
and between the particles

1 Mechanical keying

C)
Interlocking / anchoring

Temperature (C)
3000
3000 W
W

(
2 Diffusion bonding

Spraying
Layer Ta
Ta
Metallurgical bonding

Particle Temperature
Spray Melting Molten Particle Impact

Spraying
Spraying
Coating
Material Spray Material Accelaration Particle/Substrate Substrate
3 other adhesive

Spraying
Spraying
Particle Impact Cr22O
Cr O33
Chemical and physical bonding

HVOF(Acetylene)
HVOF Sprayed Carbide

Vacuum Plasma
ArcSpraying
Mo, AlAl22O
O3

Top Gun
mechanisms -oxide films, Mo,
2000

VacuumPlasma
Van de Waals forces, etc. 2000

Plasma
Plasma
Oxidized particle

Spraying
Thermal Spray Processes

Generation
Cr33C
C22-NiCr

3th3ndGeneration
Cr -NiCr

Flame Spraying

Generation
ElectricArc

1th 1&th2&nd2nd
Generation
WC-Co
WC-Co

Particle

HVOF
1

Electric

HVOF
HVOF
Porosity Layer
steel, Ni-alloys
steel, Ni-alloys

Flame
Unmelted particle Substrate 1000
1000
HVAF
HVAF
Flame Electrical Kinetic APS Sprayed Ceramic 2 Cu
Cu
Grit blast interface 2
Cold spray Al
Al
Cold spray
plastics, paints
plastics, paints
Detonation HVOF Spray HVAF Spray Plasma Arc Wire Cold Gas
Flame Spray
Spray (High Velocity Oxygen Fuel) (High Velocity Air Fuel) Spray Spray Spray
Layer 2 00 100
100 300
300 400
400 500
500 600
600 700
700 800
800 900
900
2
Flame Wire Flame Powder Atmospheric Low-Pressure High Pressure Low Pressure Substrate 3 Particle Velocity
Particle Velocity (m/s)
(m/s)
ARC Sprayed Metal
Spray Spray Plasma Spray Plasma Spray Cold Gas Cold Gas

UHP HVOF eGun

Velocity

Spray powder supply

Pre-Combustion chamber
Combustion chamber
Workpiece
eGun Process Cost Temperature
Powder injection
Particles Melting and Acceleration Typical coatings Main applications
Nickel & Cobalt based alloys, Wear resistance
Stellite, Triballoy, Inconel, Sliding, Abrasive, Erosion, etc.
Ignition
Iron based alloys, AISI 316L, etc. Chemical resistance Technology Porosity
Level
Coating Carbides & Cermets High Temperature applications
Ethanol Oxygen Cooling water
Particles/Substrate Impact
MCrAlY Dimensional restoration
Oxide Level Bonding

Cold Gas

Velocity

Heated High-Pressure Chamber

Workpiece Cold Spray Process Cost Temperature
Power & Powder Heating
Supply element
Powder Powder Particles Typical coatings Main applications
injection Acceleration
Ductile materials & alloys Electrical and thermal
Zn, Al, Ni, Ti, Cu, Ag, conductivity
Cold Spray
NiCr, CuAl, MCrAlYs, etc. Pre-placement of solders Technology Porosity
Level
Pre-Heated High-Pressure
atomize Gas
Particles/Substrate Impact
High end materials: Corrosion protection
Nobium or Tantalum Dimensional restoration
Coating

Oxide Level Bonding

HVOF spraying

Velocity

Spray powder supply

Combustion chamber
Workpiece
HVOF Spray (High Velocity Oxygen Fuel)
Process Cost Temperature
Powder injection
Particles Melting and Acceleration Typical coatings Main applications
Nickel & Cobalt based alloys, Wear resistance
Stellite, Triballoy, Inconel, Sliding, Abrasive, Erosion, etc.
Iron based alloys, AISI 316L, etc. Chemical resistance
HVOF Spray
Technology Porosity
Level
Particles/Substrate Impact Carbides & Cermets High Temperature applications
Coating
Ignition
Oxygen Cooling water
MCrAlY Dimensional restoration
Kerosene Oxide Level Bonding

APS

Velocity

Powder supply
Cooling water Powder injection

Particles/Substrate
Impact Workpiece
Plasma Spray Process Cost Temperature
Cooling &
Power cables
Molten Particles
Acceleration Typical coatings Main applications
Ceramics Wear resistance
Carbides & Cermets Sliding, Abrasive, Erosion, etc.
Plasma Spray

Powder Particles Melting

Iron, Nickel & Cobalt based alloys Corrosion resistance Technology Porosity
Level
Plasma gas
ARC plasma flame Abradables Thermal barriers
Coating
Combinations
Anode
Cathode
Oxide Level Bonding

Arc Wire

Velocity

Arc Wire Spray

Particles/Substrate Impact Workpiece

- electrode Molten Particles Process Cost Temperature

Acceleration

Typical coatings Main applications

Wire & power supply
ARC Wire Spray Iron based alloys Wear resistance
Nickel based alloys Corrosion protection
Compressed air
+ electrode Wire Melting (ARC) Copper & Copper alloys Dimensional restoration Technology Porosity
Level
Aluminium, Zinc, Al/Zn alloys Bond coat
Control power cable
Atomize air Coating

Babbitt alloys
Oxide Level Bonding

Flame Powder

Velocity

Flame Powder Spray

Powder feed stock

Process Cost Temperature

Workpiece
Typical coatings Main applications
Particles/Substrate Impact Self-fluxing alloys (fusing) Wear resistance
Molten Particles Acceleration
Acetylene
Iron based alloys Corrosion protection
Flame Powder Spray Nickel based alloys Chemical resistance Technology Porosity
Level
Oxygen Ceramics & Cermets Dimensional restoration
Compressed air Coating
Powder Particles Melting Abradables
Oxide Level Bonding

Flame Wire
Workpiece
Velocity

Flame Wire Spray

Particles/Substrate Impact

Molten Particles Acceleration Process Cost Temperature

i re S
eW
m p Typical coatings Main applications
ra
Fla

Spray wire
Iron based alloys Wear resistance
y

Wire Melting
Nickel based alloys Friction properties
Coating
Molybdenum Corrosion protection Technology Porosity
Level
Copper & Copper alloys Dimensional restoration
Wire feed motor Acetylene - Compressed air - Oxygen Aluminium, Zinc, Al/Zn alloys Electromagnetic shielding
Oxide Level Bonding
Wire feed control cable

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