Thermal Spray - ASM International

TSSSM 

ASM Thermal Spray Society 

An Affiliate Society of ASM International ® 

Your Thermal Spray 

Information Partner 

February 2009 

Volume 4 • Issue 1 

I N T E R N A T I O N A L 

Thermal Spray & 

Surface Engineering 

TM 

THE OFFICIAL NEWSLETTER OF THE ASM THERMAL SPRAY SOCIETY 

Low Pressure 

Cold Spray 

of WC 

Research at 

Xi’an Jiaotong 

University 

Preview of 

ITSC ’09 

Symposia 

2008 TSS Achievements 

Industry News 

JTST Highlights 

tss.asminternational.org 

ss.asminternational.org

FEBRUARY 2009 • Volume 4 • Issue 1 

8 Low Pressure Cold Spraying of 

Tungsten Carbide Composite 

Coatings 

11 Application Note: Metal Sprayed 

Corrosion Protection for LPG Bottles 

12 Thermal Spray Research Activities 

at Xi’an Jiaotong University 

Departments 

2 Editorial 

4 Industry News 

6 ASM Thermal Spray Society News 

18 JTST Highlights 

Dense, hard tungsten 

carbide composite coatings 

were deposited by cold 

spraying carbide particles 

that had been coated with 

either aluminum or copper. 

A robust thermal spray 

research program resides 

at the Thermal Spray 

Laboratory in the State Key 

Laboratory for Mechanical 

Behavior of Materials at 

Xi’an Jiaotong University in 

China. 

Editor Christopher C. Berndt 

Associate Editors Robert Gansert 

William Jarosinski 

Managing Editor Eileen De Guire 

Art Director Barbara L. Brody 

Production Manager Joanne Miller 

Publisher Joe Zion 

National Account Manager 

Kelly Thomas, CEM.CMP 

Materials Park, Ohio 

tel: 440/338-1733 

e-mail: kelly.thomas@asminternational.org 

Thermal Spray Society 

Executive Committee 

Mitchell Dorfman, President 

Peter Hanneforth, Immediate Past President 

Charles Kay, Vice President 

William Lenling, Secretary/Treasurer 

Thomas S. Passek, Executive Director 

About the cover 

A Centerline SST low-pressure cold 

spray robotic gun mounted on a 

standard robot arm deposits aluminum 

on an aluminum A319 cast engine head. 

Picture is courtesy of CenterLine 

Windsor Ltd., Windsor, Ontario, Canada. 

International Thermal Spray & Surface Engineering 

1 

TM 

is published quarterly by ASM International ® , 

9639 Kinsman Road, Materials Park, OH 44073; 

tel: 440/338-5151; www.asminternational.org. 

Vol. 4, No. 1. Copyright© 2009 by ASM International ® . 

All rights reserved. 

The acceptance and publication of manuscripts in 

International Thermal Spray & Surface Engineering does 

not imply that the editors or ASM International ® accept, 

approve, or endorse the data, opinions, and conclusions 

of the authors. Although manuscripts 

published in International Thermal Spray & Surface 

Engineering are intended to have archival significance, 

author’s data and interpretations are frequently 

insufficient to be directly translatable to specific design, 

production, testing, or performance applications 

without independent examination and verification 

of their applicability and suitability by professionally 

qualified personnel. 

iTSSe 

ADVANCED MATERIALS & PROCESSES/FEBRUARY 2009 47 

TM

GUEST 

EDITORIAL 

TSS 2008 Achievements 

and Direction 

With the close of 2008, I want to thank all the dedicated volunteers and ASM staff that have worked very hard to 

make TSS a very strong and successful affiliate society of ASM. 

The year 2008 saw many positive accomplishments as we tried to move technology and awareness of thermal 

spray into new markets and regions in order to develop and grow new memberships that are sustainable. Below 

is a review of some of the TSS achievements, as well as what we need to work on in the upcoming year. 

iTSSe 

2 

Technology Transfer: 2008 saw TSS involved in three 

events! We supported the German Welding Society, 

DVS, with ITSC 2008 in Maastricht and developed two 

topical events. The goal of the topical events was to 

reach out to specific market and technology sectors. 

One event was the TSS Aerospace Symposium in Hartford, 

Connecticut; the other was the Reliability and Consistency 

Symposium in Montreal, Canada. See article 

on page 8 for a summary of the specific accomplishment 

of the TSS Aerospace Symposium. The ASM-TSS 

Best Practices Manual for Events was signed off by the 

ASM Events Manager and TSS Programming Committee, 

and approved by the TSS Board. 

Creation of a Certification Committee: In 2008, the TSS 

Board voted for the creation of a TSS Certification Committee 

that will be populated in 2009. Details will be 

worked on in 2009, but the idea is to have an accredited 

certification program for operators. The goal is to 

have this implemented by 2011, and to determine what 

other programs are already available in order to minimize 

the amount of effort required by certification members. 

Mr. Luc Pouliot of TECNAR Automation Ltd. has agreed 

to become chair of this committee. 

Student Board Member Program: In 2008, the TSS 

Board voted for the inclusion of a TSS Student Board 

Member to be added to the TSS Board in 2009. The 

Nominating Committee, chaired by Peter Hanneforth, is 

working on the implementation of this strategy. This follows 

the strategy implemented on the ASM level. 

iTSSe Newsletter: 2008 saw the creation of a new editorial 

team. This team is presently headed by Professor 

Chris Berndt and two new additions, Dr. Robert Gansert 

and Mr. William Jarosinski, with staff support from Eileen 

De Guire. The main focus of iTSSe will be on application 

success in TSS and commercial information from 

around the world. It was agreed to also transfer general 

news from JTST to iTTSe. 

Journal of Thermal Spray Technology (JTST): 2008 saw 

a new editorial chair for JTST from Prof. Chris Berndt to 

Dr. R. C. (Tuck) Tucker. Tuck will be working closely with 

Springer, Christian Moreau, and his team to continually 

improve and expand the market and distribution of JTST. 

Today, JTST sees 5 editions per year. The fifth edition 

has anywhere from 60-80 specially selected ITSC papers 

included. 

TSS Training Committee: P. Mohanty took over the chair 

of the TSS Training Committee. He is supported by Dr. 

Jeganathan (Karthi) Karthikeyan, as the TSS Board 

Mentor, and Pam Kleinman of ASM. Under his leadership, 

the Training Committee is looking at new educational 

and training courses to support the career development 

of young professionals. ITSC 2009 will see 

the creation of new classes on soft factors, such as team 

building, which is critical to the success of organizations 

and individuals. The Training Committee is also looking 

at updating older videos into DVDs. 

Environmental, Health & Safety Issues: Guidelines for 

the Use of Personnel Protection Equipment (PPE) in 

Thermal Spraying was developed by the Safety Committee 

and added to the TSS website in 2008. Other 

documents already seen on the website include 1) Safety 

Guidelines for Performing Risk Assessment, 2) OSHA 

Final Standard on Hexavelent Chromium, 3) Safety 

Guidelines for Handling and Use of Gases in Thermal 

Spraying, and 4) Thermal Spray Booth Design Guidelines. 

All five of these guidelines were placed on a CD 

and distributed to attendees at the two topical events 

held this fall and will be distributed at ITSC 2009. Practical 

Learning Series for Safety / Handling and Documentation 

are also seen on the TSS website. 

United Nations of Thermal Spray and Ambassadors: 

This list has been expanded to not only include formal 

organizations but individuals from around the world that 

can support our TSS mission to expand TSS markets 

and the dissemination of technology. This unofficial committee 

can support TSS marketing efforts for informing 

organizations from around the world on TSS products 

and services. 

Industrial Advisory Council (IAC): The TSS Board and 

IAC met at ITSC 2008. IAC’s concerns centered around 

48 ADVANCED MATERIALS & PROCESSES/FEBRUARY 2009

event programming. The feeling was that ITSC was too 

frequent and not beneficial for its members when run 

every year. The benefit to industry relative to cost spent 

was not satisfactory. Thom Passek responded, based 

on the opinion of the TSS Executive Board and that of 

our event partner, DVS, that an ITSC event is needed 

every year for the following reasons: 1) a change to a two 

year rotational format would result in ITSC being in one 

region every 6 years, and this would open up competition 

from other organizations in the event business; and 

2) financially, this would be a major problem for TSS and 

DVS. The TSS Executive Board, however, did understand 

IAC’s concerns. The TSS Executive Board, along 

with DVS, are working on new and creative ways to address 

the issues. One approach is the growth of market 

and technology programming. Topical events would 

provide greater market outreach and networking to industry 

and government. ITSC events will see new and 

creative programming ideas. 

TSS Strategy and Vision: TSS Board discussed Vision 

and Strategy at the October 2008 Board meeting. Committee 

chairs will receive a summary of the critical issues 

facing the TSS industry and how the various TSS committees 

can work together to help address these issues. 

Committees will see this summary early 2009. The goal 

of the committee chairs will be to review this information, 

and develop and implement an action plan on how 

to satisfy the vision and strategy of the TSS Board. 

TSS Board Requirements: The TSS Board reconfirmed 

the need for all TSS Board members to be able to attend 

all TSS Board meetings and conference calls. In addition, 

all TSS Board members need to be ASM as well as 

TSS members. The next TSS Board meeting will be a 

conference call on March 11, 2009. 

Future Needs and Directions ~ How Do We Get There? 

As TSS President, it is my expectation that the TSS Executive Board will work closely with the various committees 

and TSS Board members to: help recruit new committee members; work with the MM&O Committee to increase 

membership to a sustainable level of 1,500 members by the end of 2010; support 

the establishment of the Certification Committee, with targeted implementation by end of 

2010; support the Web Sub-Committee of MM&O to improve the TSS website; help establish 

improved global outreach through the United Nations of Thermal Spray (UNTS) and 

improve the marketing initiative with ASM; increase IAC to 7-8 members; and improve the 

budgeting process between TSS Committee volunteers and ASM staff. 

Sincerely, 

Mitchell R. Dorfman 

President, ASM Thermal Spray Society 

Thermal Spray Society 

now accepting 

board nominations 

The terms of four current members of the ASM 

Thermal Spray Society board will expire in October 

2009. The ASM TSS nominating committee is currently 

seeking nominations to fill these four positions. 

In accordance with the TSS Rules of Governance, the 

nominating committee is particularly seeking nominees 

for four directors from the academic, user, service, international, 

and government/research communities. 

Nominations, however, are welcome from all segments 

of the thermal spray community. 

Nominees must members of the ASM Thermal Spray 

Society and must be endorsed by five TSS members. 

Board members whose terms are expiring may be eligible 

for nomination and possible re-election on an 

equal basis with any other nominee. Nominations must 

be received no later than May 15, 2009. 

Instructions and nomination forms are available at 

http://tss.asminternational.org. Please address questions 

to Sarina Pastoric at 440/338-5151 ext. 5513 or 

email sarina.pastoric@asminternational.org. 


SM 

iTSSe 

3

INDUSTRY NEWS 

Cold Spray Military Standard Approved 

A new military standard for cold spray was approved by the Department of the Army 

in August 2008. Department of Defense Manufacturing Process Standard: Materials Deposition, 

Cold Spray (MIL-STD-3021), was developed by the Center for Cold Spray at 

the U.S. Army Research Laboratory at Aberdeen Proving Ground in Maryland. Mr. Richard 

Squillacioti of the ARL Specifications and Standards Office, received input for the document 

from dozens of experts representing private industry, academia, the DOD, and laboratories 

from all over the world. 

The purpose of the standard was to establish manufacturing process controls for cold 

spray. The term “cold spray” has been used to describe this process because both the temperature 

of the powder-laden gas jet and the temperature of the powder material are low 

enough to prevent a phase change in the deposit or substrate. The gas jet temperatures are 

well below the melting thresholds of most engineering materials. This allows the process 

to be used to apply deposits on a wide variety of substrates such as alloys, ceramics, and 

plastics. Moreover, the deleterious effects of oxidation, evaporation, and tensile residual 

stresses are avoided. 

The standard was required because the cold spray deposition process is significantly 

different from conventional thermal spray coating technologies such as high velocity oxyfuel 

(HVOF), detonation gun, plasma spray, flame spray, and arc spray. Some of these differences 

are the surface preparation requirement, application criteria, equipment, and operating 

parameters. 

The standard will allow applications of cold spray to be more easily adopted and implemented 

into the DOD and into the commercial sector. The distribution of this document 

is unlimited domestically and internationally. 

For more information: Contact Victor K. Champagne; e-mail: vchampag@arl.army.mil; 

or Dr. Matthew Trexler; e-mail: matthew.trexler @arl.army.mil; Web:www.arl.army.mil. 

Pre-Coated SOFC Interconnector by Sandvik 

Sandvik Surface Technology (Sandviken, Sweden) is launching new interconnector 

materials for use in solid oxide fuel cell (SOFC) technology, which combine 

excellent high temperature corrosion resistance with good surface 

conductivity. 

Carefully controlled chemical composition of the steel strip, 

with the addition of molybdenum and niobium, improves the material’s 

high temperature strength and oxidation resistance. A cobalt 

coating reduces the electrical resistance and minimizes chromium evap- 

oration, resulting in an extremely low degradation rate in fuel 

cell applications and, thus, extended operational life. Because 

the material is gas tight, thin plates within the fuel cell can 

be used. The interconnector is designed to closely mimic the 

expansion of ceramic materials used in SOFCs. Customized 

applications can be accommodated. 

Fabricated using normal industrial strip production routes 

and coated in a continuous process, the steel strip is fully 

recyclable. www.smt.sandvik.com/surftech. 

Sandvik Sanergy HT utilizes 

normal industrial strip 

production routes; the 

coating is applied by 

Sandvik Surface Technology 

in a continuous 

process for use in solid 

oxide fuel cell technology. 

Raymor Aerospace Gains AS 9100 Certification 

SE Techno Plus, a division of Raymor Aerospace, Raymor Industries Inc.(Boisbriand, 

Quebec, Canada), a developer and producer of single-walled carbon nanotubes, nanomaterials, 

and advanced materials, has received AS 9100 certification for its operations, which 

Nordson Opens 

Industrial 

Coating 

Customer Lab in 

China 

Nordson Corporation (Westlake, 

Ohio) has invested nearly half a 

million dollars in global upgrades 

to their industrial coating customer 

demonstration labs in 2008. The 

company recently inaugurated 

their new customer lab near 

Shanghai, China with events and 

training for industry partners and 

customers. In addition to the recent 

opening in China, Nordson’s 

Industrial Coating & Automotive 

Systems group has upgraded many 

of its laboratory and demonstration 

facilities worldwide. 

The Chinese facility operates as 

a Center of Excellence to demonstrate 

Nordson’s capabilities to 

customers in the appliance, automotive, 

container, nonwovens, 

electronics, furniture and wood assembly, 

life science, packaging, 

powder and liquid painting, 

product assembly, and semiconductor 

industries. In addition to 

investments in China, Nordson 

recently invested in upgrades 

to lab facilities in Germany, 

India, and Mexico. 

Nordson Corporation is a producer 

of precision dispensing 

equipment that applies adhesives, 

sealants, and coatings to a broad 

range of consumer and industrial 

products during manufacturing operations. 

The company also manufactures 

equipment used in the 

testing and inspection of electronic 

components as well as technologybased 

systems used for curing 

and surface treatment processes. 

www.nordson.com. 

consists of the manufacturing, repair, and precision grinding of aerospace and industrial components. The AS 9100 certification 

of the division’s quality system is another major milestone and a prerequisite in becoming an approved supplier to the major aerospace 

original equipment manufacturers (OEMs). With this certification, coupled with the AS 9100 and NADCAP certifications 

achieved by its Thermal Spray Coating division, Raymor Aerospace can supply thermal spray coating services to the aircraft 

landing gear industry in the aerospace sector. Raymor Aerospace intends to add more processes in order to provide the landing 

gear OEMs with a “one-stop shop” for coating, grinding, surface treatment, and testing. 

AS 9100 is an ISO 9001 based set of standards that addresses the stringent quality requirements of the aerospace industry, from 

commercial aviation to defense. Certification against AS 9100 standard requirements can be applied to virtually any area of the 

aerospace industry throughout the entire supply chain. It covers areas such as design and manufacture of equipment, aircraft ac- 

iTSSecessory 

supply, replacement parts, supply and maintenance, overhaul and repair services. www.raymor.com. 

4 


A Nearly Perfect Antireflection Coating for Silicon Solar Energy 

A Rensselaer Polytechnic Institute team led by physics professor, 

Dr. Shawn-Yu Lin, has developed a new antireflective 

coating that boosts the amount of sunlight captured by solar 

panels and enables absorption across the solar spectrum from 

nearly any angle. 

An untreated silicon solar cell only absorbs 67.4% of the incident 

sunlight; nearly one-third of the sunlight is reflected away 

and not harvestable. The unharvested light is wasted energy and 

a barrier to widespread adoption of solar power. A silicon surface 

treated with Lin’s new nanostructured antireflective coating 

absorbed 96.21% of the incident sunlight, thus, only 3.79% of 

the sunlight was reflected and unharvested. This huge gain in 

absorption was consistent across the entire spectrum of sunlight, 

from UV to visible light to infrared. 

The new coating stacks seven layers in such a way that each 

Nanostructured 

antireflection 

coating for solar 

cells. Credit: 

Rensselaer/ 

Shawn Lin 

layer enhances the antireflective properties of the layer below 

it. The layers also help “bend” the sunlight to an angle that augments 

the coating’s antireflective properties. Each layer not only 

transmits sunlight, it also helps to capture any light that otherwise 

may have been reflected off the layers below. 

The seven layers, each with a height of 50-100 nm, are made 

up of silicon dioxide and titanium dioxide nanorods positioned 

at an oblique angle. Each layer functions similar to a dense forest 

where sunlight is “captured” between the trees. The nanorods 

were attached to a silicon substrate via chemical vapor disposition. 

According to Prof. Lin, the new coating can be affixed to 

nearly any photovoltaic materials, including III-V multi-junction 

and cadmium telluride. www.rpi.edu 

PAS Technologies Facility 

Receives NADCAP Coatings 

Accreditation 

The North Kansas City facility of PAS Technologies Inc. 

(Kansas City, Mo.) has received accreditation by NADCAP in 

accordance with SAE Aerospace Standard AS7003 for its coating 

services. The facility’s quality management system is also certified 

to the ISO 9001:2000 and AS 9100 quality specifications. 

The NADCAP quality accreditation is in the specialty areas of 

coatings, chemical processing, heat treating, nondestructive 

testing, and surface enhancement including shot peening, peen 

forming, and glass bead peening. www.pas-technologies.com. 


INDUSTRY NEWS 

iTSSe 

5

TSS News 

Symposium Covers the Needs 

of Aerospace Thermal Spray Researchers and Practitioners 

More than 170 thermal spray engineers, scientists and pracings, as well as new equiptitioners 

from the U.S., Canada, Japan, Germany, Switzerland ment technologies that 

and Israel gathered last October to discuss new thermal spray have shown the ability to 

technologies for aerospace applications. 

add cost savings while re- 

Held on Oct. 15-16 in Hartford, Conn., the 2008 Aerospace ducing production times. 

Coatings Symposium was organized by the ASM Thermal Spray Among the topics dis- 

Society (TSS) to bring together decision makers throughout the cussed were: 

aerospace coatings supply chain. Materials and equipment sup- • The potential techpliers, 

coating applicators, system integrators, engine manufacnical benefits of nanosturers, 

airlines, and service providers were represented. tructured MCrAlY and en- 

“The aerospace thermal spray market is a € 2 billion per year gineered coatings for 

market with roughly three quarters of this business in coating TBC’s and ceramic abrad- 

services and finishing,” said Dr. Markus Heusser, Sulzer Metco ables, 

(US) Inc. 

• New materials tech- 

The symposium featured keynote presentations from across 

the specialty of aerospace coatings: 

Dr. William Brindley, Rolls-Royce Corporation, discussed 

the need for engine manufacturers to be proactive in the design 

of surface engineered coatings. This implies robust manufacnology 

in TBC’s with A large audience at one of five key- 

reduced thermal conducnote addresses. Keynote speakers 

were William Brindley, Rolls Royce; 

tivity and high tempera- 

Marc Froning, BASF Surface Techture 

ceramic abradables nologies; Markus Heusser, Sulzer 

without tip coatings, Metco; Christian Moreau, NRC 

turing, upfront engineered solutions to problems, accurate 

testing, and characterization. 

• Emerging technologies 

such as cold spray 

Canada; Andrew Bordick, Pratt & 

Whitney. 

Dr. Markus Heusser, Sulzer Metco, discussed the four mega- and precursor plasma spraying, 

trends of lower fuel consumption and emissions, just-in-time • CMAS and its effect on coating life (as temperature increases, 

production, cost of ownership, and the implications of proper new problems need to be addressed), 

behavior on the aerospace industry – and how thermal spray • EH&S issues, including the replacement of hard chrome 

technology can contribute and how to get more out of equip- plating with carbide containing materials, and the need for high 

ment and material suppliers. 

quality systems requirements. 

Marc Froning, BASF Surface Technologies, discussed the re- The second technical track was designed primarily to reach 

quirements imposed by OEMs and government on quality stan- thermal spray practitioners such as operators, technicians, and 

dards, and EH&S issues today compared to past years. process engineers. The session’s highlights included EH&S 

Andrew Bordick, Pratt and Whitney ACE, provided his per- topics; the ASM International lifelong learning and education 

spective on the need to understand human behavior in the work program focused on operator certification for the thermal spray 

place in order to improve job performance and quality. industry. 

Dr. Christian Moreau, NRC Canada, discussed how sensors Presenters discussed every aspect of the thermal spray process, 

and controls can result in more reliable coatings. “Output spray including part cleaning, masking, coating, mechanical and met- 

process parameters are critical and more important in underallurgical inspection, and process control. 

standing coating reliability than input spray parameters,” he The final part of the technical program featured a Technology 

said. The control of substrate temperature as well as techniques 

for coating characterization and NDE were also 

discussed. 

The symposium’s technical program, comprised 

of more than 35 presentations, was 

uniquely structured to provide a technical focus 

for scientists and engineers in one track, and for 

applications-related personnel in another. 

The track for scientists and engineers gave attendees 

an overview of key materials, equipment, 

and process technologies being investigated for 

the aerospace industry. Key designers voiced 

their views on critical issues that they would like 

to see addressed in the years ahead. 

Trends panel discussion, where attendees heard industry leaders 

Participants indicated their high interest in After a networking reception in the exhibitor area, attendees enjoyed dinner and 

iTSSeprocess 

control and reliability of aerospace coat- 

6 

conversation. 


present their visions of future thermal spray equipment 

developments. Following the panel, 35 participants 

attended a plant tour of BASF Catalysts 

LLC-Surface Technology’s East Windsor plant. 

The tour included BASF’s R&D spray booth, heat 

treating capabilities, metallography lab, and robotic 

production coating cells. 

A total of 17 tabletop exhibits provided additional 

opportunities for symposium participants 

to learn more about the latest advances in thermal 

spray technology. Participants viewed the latest 

available products and services for nearly the complete 

thermal spray coating process, from masking 

through testing. Exhibitors included suppliers of 

gases, masking materials, job shops, equipment 

and material suppliers and industry consultants. 

A tabletop display manned by the host ASM Hartford Chapter 

was also on display. 

To complete the learning experience, a specially designed 

seminar on Materials and Processes for High Temperature Gas 

Turbine Components was led by instructor Dr. Donald Boone 

of BWD Turbines Limited. The seminar focused on surface 

modification processes that are critical to the aerospace industry, 

and provided an effective complement to the technical program, 

A lively panel discussion on technology trends facing the industry. Panelists from 

the left are Paul Zajchowski, Pratt & Whitney; Daniel Godin, Sermatech Intl.; Dave 

Somerville, Southwest Aeroservice; Ray Sinatra, Rolls-Royce. 

panel discussions and exhibits provided by the symposium. 

“The success of the Aerospace Coatings Symposium reflects 

our commitment to improving programming quality that addresses 

the needs of industry, government and academia,” 

Dorfman said. “As the world’s thermal spray information resource, 

the ASM Thermal Spray Society looks forward to continuing 

to provide symposia and technical events that will benefit 

the global thermal spray industry.” 

Solicitations for Student Members to the TSS Board 

Following the model of the ASM Board of Trustees Student Member Program, the ASM Thermal Spray Society is initiating 

a Student Board Member program to add two new positions to the board. Nominations for candidates are now being 

solicited and are due by March 1, 2009. 

Young people are the future of the Society. TSS values the input and participation of these young people at all levels of 

activity. Participation already exists at the technical program level and the TSS Board wants to hear more of what you have 

to say and contribute. 

Eligibility 

Students must be a registered undergraduate or graduate during the 2009-2010 academic year, studying or involved in 

research in an area closely related to the field of thermal spray technology. 

To apply, submit an application package consisting of: 

• Current resume/CV 

• Two-page essay (typed and double-spaced in English) addressing your interest in participating in the program 

including: 

• What experiences led to your interest in the program? 

• What qualities, characteristics and skills do you possess that will make you a strong candidate to serve as a Student 

Representative on the TSS Board? 

• What do you hope to learn/gain from this program? 

Students also must submit two letters of recommendation from faculty. 

Applications will be reviewed by the TSS Nominating Committee, which will forward recommendations to the TSS Board 

for approval. Selected participants will be notified by May 1, 2009, and they will begin their non-renewable and non-voting, 

one-year term as Student Representatives on the TSS Board of Directors at its spring 2009 meeting in Las Vegas, Nevada. 

The Student Representatives must attend one regularly scheduled TSS Board meeting held in the U.S. each year, with expenses 

for travel, hotels, and meals paid for by ASM-TSS, and must participate in two interim TSS Board teleconferences. 

Student Representatives will receive a one-year complementary membership (worth $25) in Material Advantage, the program 

that provides student membership of ASM, TMS, AcerS, and AIST. 

This is a tremendous opportunity for leadership training. It also is a unique, first-hand way to experience how a Board of 

Directors functions and makes decisions. 

Please send your application package by mail to ASM International, Attn: Megan Herrmann, 9639 Kinsman Rd., 

Materials Park , OH 44073-0002 or via email at megan.herrmann@asminternational.org. iTSSe 

7 

ADVANCED MATERIALS & PROCESSES/FEBRUARY 2009 53

Low Pressure Cold Spraying 

of Tungsten Carbide 

Composite Coatings 

J. Wang, J. Villafuerte 

CenterLine (Windsor) Ltd., Windsor, ON, Canada 

are used 

extensively for wear 

WC-Cocoatings 

resistance applications. 

The hard WC phase provides wear resistance while 

the cobalt binder increases toughness. The recent implementation 

of regulations, such as the EU’s Regulation of 

Hazardous Substances (RoHS), to eliminate the environmental 

impact of hexavalent chromium during traditional 

chromium plating processes has opened new applications 

Figure 1 — Low-pressure cold spray system. 

for WC-Co coatings. Currently, WC-Co hard coatings replacing low pressure cold spray system is illustrated in Figure 1. 

electrolytic hard chrome (EHC) coatings are sprayed by high One characteristic of low pressure cold spray is the mixing 

velocity oxyfuel (HVOF). Cold spray processes can mitigate of a percentage of ceramic particles into the metal powder to in- 

the possibility of WC-Co coating imperfections like cracks, crease the bond strength and density of the metallic deposits. 

blisters, and/or delaminations associated with HVOF process Although a portion of hard particles is left dispersed in the metal 

effects such as oxidation, decarburization, thermal expansion matrix, the mechanical properties of the resulting deposit are 

mismatch, and undesirable metallurgical transformations. not enough to provide adequate abrasion resistance. Spraying 

mixtures that are primarily ceramic, such as WC-Co, using low 

Cold spraying 

pressure cold spray technology has proven particularly chal- 

Low pressure cold gas-dynamic spraying (low pressure cold lenging. Evidence suggests that the presence of a minimum 

spray) is a unique low temperature spraying process in which volume percent of ductile species is necessary for kinetic bonding 

the spray materials are not melted in the spray gun; instead they to occur. Attempts to spray hard materials by mixing them with 

are kinetically deposited on the substrate at low temperatures. ductile species (such as aluminum, zinc, and copper) have met 

Adhesion of the deposit is achieved through solid state bonding with limited success. 

as particles are accelerated towards the substrate at supersonic An alternative to mixing powders is to modify the surface 

speeds. As the first particles impact the substrate, they shatter chemistry of the powders. Chemical vapor deposition (CVD), 

the surface oxides and eject them from the bonding surface. Par- electroplating, and electroless plating are techniques that can 

ticle velocity control is critical for successful adhesion. When be used to modify the surface chemistry of metallic and non- 

the right critical velocity for a substrate/particle combination is metallic powders. Ductile metals such as copper and aluminum 

reached, there is a momentary high interfacial pressure at the can be deposited on the surfaces of individual non-metallic par- 

impact site that allows the atomic structures to come into intiticles, such as tungsten carbide. A ductile layer on the tungsten 

mate contact. Subsequent particle collisions at the critical ve- carbide particles may improve the ability to cold spray these 

locity cause the new particles to plastically deform, compact the materials while increasing the volume fraction of the hard phase 

already attached particles, and bond to the previously formed in the as-sprayed deposit. Incorporating a higher volume frac- 

layer. When particle velocity is too low, the particles simply tion of hard phase in the deposit could improve wear and abra- 

bounce off the substrate. If the particle velocity is too high, sion resistance of the deposits. 

the particles pulverize on impact. 

At Centerline, a study was undertaken to evaluate the feasi- 

Key advantages of low pressure cold spray include portability of cold spraying surface modified tungsten carbide powbility 

and low operating cost. Unlike traditional thermal ders. The microstructure and mechanical properties of the com- 

spraying processes there are no thermal effects such as oxidaposite coatings resulting from surface particles were compared 

tion, distortion, residual stresses, and/or metallurgical trans- with similar coatings produced by mixing of the precursor powformations. 

The process performs the functions of grit blast, 

spray coating, and shot peening in a single operation so a finders 

using traditional powder blending techniques. 

ished surfacing coating can be applied quickly and consistently. Feedstock powders 

Also, the deposits are fully dense and exhibit exceptional A number of commercially pure powdered materials were 

bonding strength. Mechanical and/or metallurgical bonding is used in this study, including aluminum (-325 mesh, Atlantic 

possible due to extensive and localized plastic deformation re- Equipment Engineers, USA), copper (-325 mesh, Acupowder 

iTSSesulting 

from high velocity particle impact. A schematic of a 

8 

International LLC, USA), and tungsten carbide (14-25 um, Buf- 


(a) 

Figure 2 — Microstructure of cold sprayed (a) aluminum-coated WC and (b) coppercoated 

WC. 

(a) 

Figure 3 — Microstructure of composite coatings produced from mixtures of (a) 

WC-30wt % pure aluminum powder and (b) WC-30wt % pure copper powder. 

(b) 

(b) 

Figure 4a — The macro-hardness of the coatings 

from aluminum-coated WC powder and Al-WC 

blends. 

Figure 4b — The macro-hardness of the coatings 

from copper-coated WC powder and Cu-WC 

blends. 

falo Tungsten Inc, USA). The feedstock particles and compotion and particle surface morphologies resulting from the CVD 

sitions used in the study are listed in Table 1. The Al-WC and process were not significantly better than was achievable through 

Cu-WC blends were produced by mechanical mixing of metallic mechanical mixing of the powders. Therefore, electroplating 

and ceramic powders. 

was selected as the preferred method to deposit copper on tungsten 

carbide particles. After electroplating, the carbide particles 

Table 1— Cold spray feedstocks and hard phase contents showed round edges indicating a uniform coating. Microstruc- 

Feedstock 

Cu-coated WC 

WC composition (wt%) 

80 

tural observations of cross-sections of selected copper-coated 

particles confirmed the presence of a uniform and continuous 

layer of copper around these particles. 

Cu-WC blend-1 20 

Cu-WC blend-2 

Al-coated WC 

Al-WC blend-1 

40 

70 

20 

Composite coatings 

A Centerline SST portable low pressure cold spray system 

was employed to produce the composite coatings. A convergent-divergent 

(de Laval) round-section nozzle was used with 

Al-WC blend-2 40 

an expansion ratio of 6.4 and divergent section length of 

Al-WC blend-3 70 

120mm. The substrate materials were 1018 carbon steel and 

6061 aluminum; they were grit blasted with 80-grit alumina 

Tungsten carbide particles were coated with aluminum via a prior to spraying. Table 2 summarizes the cold spraying process 

proprietary chemical vapor deposition (CVD) process. Wet parameters. 

coating methods are not feasible because of the high activity of 

aluminum. SEM inspection revealed that the aluminum did not Table 2 — Cold spray process parameters 

deposit homogeneously over the surfaces of the WC particles. Carrier gas Compressed air 

Rather, sub-micron and micron sized aggregated clusters of aluminum 

spheres were observed on the carbide particles. EDX 

analysis on the spheroids confirmed that the clusters were aluminum. 

The presence of aluminum as sub-micron spheres was 

expected to decrease the amount of aluminum available on the 

Carrier gas temperature, 

carbide surfaces, even though the overall aluminum content may 

have conformed to the nominal composition. 

The proprietary CVD technique also was used to deposit 

copper on WC particles. However, the copper phase distribu- 

9 


o C ( o F) 

Carrier gas pressure, MPa (psi) 

Standoff distance, mm (in.) 

375-540 (705-1005) 

0.5-0.6 (80-90) 

15 (0.6) 

Al-coated and Cu-coated WC feedstock powders were successfully 

cold sprayed, and typical microstructures of the composite 

coatings are shown in Figure 2. The addition of a layer of 

soft metal around the carbide particles appeared to provide suf-iTSSe

iTSSe 

ficient surface with the necessary ductility to stimulate solid 

state particle-to-substrate and particle-to-particle bonding. The 

powders behaved similar to a regular soft metal powder on cold 

spraying. The volume percentage of dispersed carbide in the deposit 

was estimated at 55% for both Al-coated and Cu-coated 

powders. The coating resulting from the Al-coated WC feedstock 

appeared to have the carbide phase well dispersed within 

a pure aluminum matrix. 

For comparison, Al-WC and Cu-WC blends with three different 

weight fractions of WC powder (20wt%, 40wt% and 

70wt%) were cold sprayed using the same spraying system 

and process parameters (Table 2). The microstructures of 

deposits resulting from Al-WC and Cu-WC powder blends 

are shown in Figure 3. The volume fraction of carbide phase 

retained in the metal matrix reached a plateau that could be 

well below the amount of carbide present in the original metal- 

WC blend. For example, the maximum amount of carbide 

phase retained in the Al-70 wt% WC feedstock deposit was 

about 30 vol%. For Cu-70 wt% WC feedstock, the maximum 

amount of carbide retained was higher, about 65 vol%. In both 

cases, the carbide was not homogeneously dispersed in the 

matrix. 

Hardness measurements indicated higher hardness values for 

cold spray deposits produced from metal coated carbide feedstock 

compared to cold spray deposits produced from metalcarbide 

powder blends (Figure 4a, 4b). This was attributed to 

better dispersion of the carbide phase in the aluminum or copper 

matrix produced from metal-coated carbide feedstock as well 

as possibly less porosity. 

This study demonstrated that metal coating of tungsten 

carbide feedstock is an effective means to cold spray otherwise 

unsprayable materials, such as pure tungsten carbide. 

Chemical vapor deposition of aluminum produced discontinuous 

clusters of sub-micron metal spheres on the carbide 

surfaces, however, the feedstock was still cold sprayable 

and produced enhanced coatings. Electroplating is more effective 

than CVD for coating WC particles suitable for cold 

spraying. 

The deposits fabricated from coated particles were characterized 

by a high percentage of well dispersed, retained carbide 

phase, and low porosity. These characteristics yielded hardness 

values higher than equivalent deposits produced from traditional 

metal-ceramic blends. 

This work was partly funded by National Research Council 

of Canada. The metal coating of WC powder was supported and 

conducted by Federal Technology Group and Advanced Powder 

Solution Inc. Metallographic inspection was conducted at the 

Physics Department of the University of Windsor. 

For more information contact Julio Villafuerte, Julio.Villafuerte@cntrline.com, 

www.supersonicspray.com. iTSSe 

This work was presented at MS&T 2008 in Pittsburgh, Pa. 

This summary is adapted from an article submitted for publication in 

Ceramic Transactions by the American Ceramic Society. 

Powders 

you can trust. MIM 

www.cartech.com For more information email jhunter@cartech.com 

HIP 

PTA 

Braze 

Laser 

Rapid Prototyping 

Thermal Spray 

PM Millforms 

10 


Metal Sprayed Corrosion 

Protection for LPG Bottles 

APPLICATION 

NOTE 

Vitkovice Milmet S.A., Sosnowiec, 

Poland (www.vitkovicemilmet.pl), 

the only manufacturer of 

LPG (liquefied petroleum gas) bottles in Poland, recently purchased 

three Arcspray 528E production metal spraying systems 

from Metallisation Ltd. (Dudley, West Midlands, UK). EMS 

Surface Technology Ltd. (Reading, UK) is the main contractor 

and supplier of the automation. The steel cylinders, used mainly 

for propane and butane gas, are produced at the company’s 

site in Sosnowiec and, as with all steel items, are susceptible 

to long term damage by corrosion. 

The LPG cylinder industry has been demanding more superior 

and reliable corrosion resistance. Metal spraying technology 

protects or extends the life of a wide variety of products in the 

most hostile environments. To provide the level of corrosion 

protection required, each bottle needs to be metal sprayed prior 

to powder coating or wet painting. Metal sprayed bottles are 

serviceable for 10 to 15 years before routine inspection is 

required. 

Vitkovice Milmet chose the Metallisation Arc528E System 

as it provides a consistently high quality zinc coating and can 

spray zinc at a rate of up to 46 kg per hour. The Arc528E pistols 

used to spray the base of the bottles are connected to two 

S250, 250 A energisers. The pistol spraying the sides of the bottles 

is connected to an S450, 450 A energiser, as this needs to 

spray at a higher spray rate than for the base and neck. Metallisation 

supplies the zinc in 250 g fiber drum production packs. 

Process Characteristics 

Initially, Vitkovice Milmet planned to metal spray the cylinders 

in a vertical orientation. This, unfortunately, can create a 

range of technical problems that can increase the cost of automation 

as well as produce an uneven coating. Metallisation and 

EMS demonstrated the benefits of spraying the bottles in a horizontal 

position, a manufacturing practice that Vitkovice Milmet 

has adopted. 

Vitkovice Milmet’s target production is to spray 2,100 of the 

11.3 kg bottles per day across three shifts. The adaptable automation 

in conjunction with the Metallisation Arc528E systems 

can spray bottle sizes weighing 3 to 33 kg with lengths of 

320 to 1330 mm and diameters of 215 o 375 mm. 

The bottles are fabricated by pressing the parts, welding them 

together with the fixtures, and pressure testing them prior to applying 

a surface coating. The surfaces are prepared by grit 

blasting the bottles in an automatic blasting machine, which produces 

a blast cleanliness of SA 2.5, to create an adequate profile 

for metal spray adhesion. The bottles are fed automatically 

into the metal spray machine, which aligns the pistols and rotates 

each bottle. One metal spray pistol moves across the base 

and sprays the bottom of the bottle; a second, fixed pistol, sprays 

the bottle neck and shroud, and a third pistol traverses along the 

length of the bottle to coat the sides. The machine is also sup- 

Grit blasted steel LPG cylinder in position for application of zinc sprayed 

coating. 

Completed 

LPG cylinders 

with 

protective 

coatings 

under their 

finish coats. 

plied with dust extraction and dry filtration equipment, to ensure 

there is no contamination of the coating and to provide a 

safe working environment. 

Each bottle is coated with an average of 60 µm of zinc. The 

base of the bottles is coated with a slightly thicker coating to 

provide greater protection in an area normally subjected to greater 

wear and tear. Once all the bottles have been metal sprayed, 

Vitkovice Milmet powder coats the bottles to meet its customer’s 

color requirements. Bottles are fitted with valves, pressure tested, 

certified and stamped, and, finally, screen-printed with the customer’s 

branding. 

Robert Kos’cielny, production manager at Vitkovice Milmet, 

says “We are looking forward to ramping up production over 

the coming months and seeing our new equipment in full action. 

It’s a very exciting time for us. Now that we have the ability 

to coat our bottles, it will allow us to expand our customer base 

into markets where zinc coatings are a prerequisite from certain 

gas suppliers such as Shell and Primagaz.” iTSSe 

11 


iTSSe

News from Research and Technology Institutes Worldwide 

Thermal Spray Research 

Activities at Xi’an Jiaotong 

University 

Chang-Jiu Li 

splashing occurs when a molten droplet impacts a substrate 

State Key Laboratory for Mechanical Behavior of Materials resulting in splats with different complicated morphologies. 

School of Materials Science and Engineering 

Thermal reactions of droplets with the underlying substrate may 

Xi’an Jiaotong University 

cause the desorption of surface adsorbates, local melting of sub- 

Xi’an, Shaanxi, P. R. China 

strate surface regions and chemical bonding between splats. The 

studies have lead to the understanding that the existence of evap- 

The Thermal Spray Laboratory in the State Key Laboratory 

for Mechanical Behavior of Materials is located 

in the School of Materials Science and Engineering, 

Xi’an Jiaotong University (XJTU) in Xi’an, 

which is famous as an ancient capital of China and a historical 

city known world wide by the Terracotta Warriors and Horses. 

The main facilities of the laboratory 

include plasma spray, 

HVOF and cold spray. A controlled 

atmosphere plasma spray 

system will be installed in the 

next year, which can be operated 

at different atmospheres and 

under a wide span of chamber 

pressures. Thermal spray researches 

at XJTU focus on the 

understanding of thermal spray 

coating formation mechanisms 

involving splat formation 

through spray particles in different 

states, quantitative characterization 

of lamellar structure 

of plasma spray coatings, establishment 

of the relationships between 

coating microstructure 

and properties, and development of high performance thermal 

barrier coatings, wear-resistant super-hard cermet coatings and 

functional coatings applicable to solid oxide fuel cells and dyesensitized 

solar cells. 

orative adsorbates on substrate surfaces and their intensive evaporation 

caused by rapid heating from high temperature droplets 

are the dominant factors that cause splashing during impact 

on a flat surface where there is negligible melting of substrate. 

The transition of splat morphology from complicated irregular 

shape to a regular disc shape can be reasonably explained 

by the proposed models. When droplet impact induces substrate 

melting, splashing occurs despite removal of the adsorbates 

through substrate preheating. All types of splashing are associated 

with free jet formation due to detachment of flowing fluid 

from the substrate surface. The factors influencing the contact 

of spreading fluid with the underlying substrate are emphasized 

with the investigation of splashing even when surface roughness 

is involved. The interface bond formation is investigated 

through splat formation at high substrate pre-heat temperature, 

e.g., up to 1100 

Understanding of thermal spray deposition mechanisms 

through splat formation 

While considering the diverse states of sprayed particles prior 

to impact on the substrate and based on the recent advances of 

thermal spray processes, splat formation has been studied through 

three typical particle states in terms of heating and melting, i.e., 

completely molten droplets involved in plasma spraying, solidliquid 

two-phase droplets which are required for deposition of 

cermet coatings involved in HVOF and complete solid-state 

particles in cold spraying. 

Many factors influence splat formation in plasma spraying 

including droplet and substrate properties. Two basic issues are 

closely correlated with splat morphology and bond formation 

iTSSebetween 

splats. One essential issue is related to why and how 

12 

58 ADVANCED MATERIALS & PROCESSES/FEBRUARY 2009 

°C (2010 °F) 

This column, which formerly 

appeared in JTST, informs 

readers of activities in research 

and technology institutes 

active in the field of 

thermal spray technology. 

Knowledge of institutional expertise 

is important for getting 

to know the research interests 

and professional experience 

of thermal spray colleagues, 

developing complimentary 

partnering relationships, and 

increasing the quality and 

breadth of practical applications. 

To submit an article for 

this column, please contact 

Chris Berndt, iTSSe Editor, at 

CBerndt@groupwise.swin.edu. 

au. 

for YSZ. 

On the other hand, due to the requirement of retaining carbide 

particles from the cermet powder in subsequent coatings 

to achieve the optimized cermet coating performance, it is necessary 

to use a flame jet only to melt the binder phase within 

cermet powder particles while hard carbide particles should 

be kept in a solid state during spraying, requiring solid-liquid 

two-phase droplets. The limited ability of the HVOF flame to 

heat spray particles benefits the formation of such droplets. The 

investigation into splat formation of the cermet droplet revealed 

that carbide particle size significantly influences the flattening 

behavior of a two-phase droplet. When carbide particle size becomes 

large, carbides will emerge out of the liquid binder phase 

during spreading. Large carbides tend to rebound off at high velocity 

impact, which leads to changes in the coating chemistry 

with respect to the starting powder. Therefore, deposition behavior, 

coating composition and microstructure, properties and 

performance are all associated with the size of carbide particles 

in cermet powder, i.e., solid particles in the two-phase droplet. 

Based on the understanding of deposition behavior, desirable 

cermet coatings can be expected through properly designing 

cermet powder and employing certain spray process conditions. 

Quantitative characterization of lamellar structure 

and development of lamellar bonding 

The bonding at the interfaces between lamellae is important 

because it dominates thermal sprayed coating properties and 

performances. Understanding how much interface area between 

lamellae in the coating is bonded together and what parameters

dominate bond formation has been a long lasting project. The 

visualization of the lamellar bonding state was realized for 

plasma-sprayed alumina coatings through infiltration of copper 

by an electroplating technique. Quantitative characterization of 

lamellar structures was systematically carried out through introducing 

microstructural parameters including the mean bonding 

ratio between lamellae and the mean lamellae thickness. Recently, 

a more general visualization approach applicable to different 

plasma-sprayed ceramic coatings was developed in which 

the tracer of the nonbonded interface is infiltrated through using 

an aqueous solution and the visualization is realized by analyzing 

the distribution of the tracer. Through systematic characterization, 

it was quantitatively revealed that the mean bonding 

ratio of thermal sprayed ceramic coatings conventionally ranges 

from about 10% to about 32%. Moreover, increasing particle 

velocity is inversely related to the mean bonding ratio. The measurement 

yielded a mean bonding ratio of about 10% for a detonation 

gun alumina coating. We recently reached the conclusion 

that particle temperature controls the bonding formation. 

With this conclusion, it is possible not only to explain why the 

maximum bonding ratio is limited but also to develop an alternative 

approach to extend the bonding to a higher value. 

Although our studies suggested that particle temperature is a 

key factor controlling the interface bonding formation in the ceramic 

coating, the intrinsic negative correlation between particle 

heating and accelerating makes it difficult to significantly 

increase particle temperature through process optimization. 

Therefore, increasing the temperature of the coating surface 

over which the splats are overlapped was proposed as an alternative 

approach. The experiments using YSZ proved that compared 

to the typical lamellar structure of the YSZ coating deposited 

following the conventional routine, the YSZ coating 

deposited at a high substrate temperature of 880 °C (1615 °F) exhibited 

a continuously grown columnar structure across lamellae 

interfaces (Fig.1) which indicates clearly the formation of the 

well bonded interface. The measurement illustrates that the ionic 

conductivity of the YSZ coating can be improved by a factor of 

greater than 3 resulting from the increased interface bonding. 

The significant improvement makes it possible to extend the 

bonding ratio from approximately 10% to approximately 100%. 

A broader possible range of bonding will make plasma sprayed 

coatings more flexible to meet the requirements of different applications 

which require different microstructures. For example, 

YSZ coatings with less bonded lamella interfaces are suitable 

for thermal barrier coatings while YSZ coatings with fully bonded 

interfaces are suitable for use as electrolytes for solid oxide fuel 

cells requiring high ionic conductivity. 

method to measure the critical velocity was proposed based 

on the theoretical modeling of deposition efficiency as a function 

of particle size, velocity and spray angle. Our results showed 

that the surface conditions of metal powders such as oxidation 

state significantly influence the critical velocity and subsequently 

the deposition behavior. With the increase of oxide content in 

copper powder from 0.02 wt% to 0.35 wt%, the critical velocity 

increased from 315 to 610 m/s. The deposition behavior in cold 

spraying was further investigated through modeling of single 

solid particle impact considering the influence of spray materials, 

particle temperature and particle surface state which all 

affect the critical velocity. 

The incomplete deformation of surface layers forms a porous 

top layer on the coating surface as found typically in Ti coatings. 

The tamping effect from successive particle impacts increases 

the deformation of the previously deposited top porous 

layer and leads to the densification of the deposited layer. 

Coating development by cold spraying 

It is evident that limited contact between deposited parti- 

A home-made cold spray system was installed in 2001 at cles exists in cold sprayed coatings as in thermal sprayed coat- 

XJTU. Different types of coatings including pure metals such ings. As indicated by the electrical conductivity of cold-sprayed 

as Ti, Cu, Al, Zn, alloys such as Al-Si alloy, nanostructured Fe- copper coatings, the limited contact dominates coating proper- 

Si alloy and MCrAlY alloys, super-hard cermets such as ties and performance. A study was directed toward the develop- 

nanoWC-Co, cBN-NiCrAl, and diamond-NiCrAl have been dement of particle interface bonding through post-spray treatments. 

posited by cold spray for different applications. Studies are The investigation into the microstructure of cold sprayed metallic 

focused on the deposition mechanisms, coating microstructure coatings revealed that the intensive plastic deformation results 

development, intermetallics and superhard cermet coating de- in the evolution of fine grain structures with grain size in the 

velopments. 

sub-micrometer or nanometer range which is thermally 

Critical velocity is an essential parameter in cold spray. A metastable and active. Such features can be effectively utilized iTSSe 

13 


(a) 

(b) 

2 µm 

2 µm 

Fig.1 — Typical fractured cross-section microstructures of YSZ 

coatings deposited at (a) room temperature and (b) 880°C (1615 

°F).

to modify the coating microstructure and properties by improving 

the interface bonding through post-spray annealing. 

Development of super-hard cermet 

and intermetallic matrix composites 

Based on research results for microstructure, properties and 

wear performance of HVOF sprayed WC-Co cermets, the hardness 

and wear resistance of cermet coatings may be significantly 

increased by decreasing carbide particle size. Therefore, nanostructured 

cermet is expected to exhibit higher hardness and 

better wear performance. 

Cold spray has been successfully used to deposit super-hard 

nano-structured WC-Co coatings without any decarburization. 

Cold-sprayed nano-structured WC-12Co with WC particles of 

sizes from 50 nm to 300 nm exhibited a hardness of 1820 HV, 

which is comparable to that of the sintered counterpart. However, 

the limited toughness of nano-structured WC-Co may limit 

its wear performance. To achieve both toughening and strengthening 

effects, a nano-structured WC-Co based cermet concept 

has been proposed, using carbides with bimodal particle sizes, 

i.e., carbides in both micrometer and nanometer sizes. In this 

novel design, nano-structured WC-Co acts as the matrix in which 

carbide particles of the micrometer size are dispersed as the hard 

phase. The experiment proved that such bimodal WC-12Co 

cermet deposited by cold spraying exhibits a high hardness comparable 

to nano-structured WC-12Co and a high toughness comparable 

to conventional microstructured WC-12Co. Other studies 

focused on the optimization of nano-structured WC-Co matrix 

cermet and development of high performance cermets with superhard 

phases such as cubic boron nitride and artificial diamond 

to further increase hardness and wear resistance. Moreover, particle 

interface bonding in cold-sprayed super-hard cermets is 

emphasized because the erosion and abrasion at severe conditions 

for the WC-Co and Cr3C2-NiCr cermet coatings are dominated 

by splat spalling. 

Intermetallic compound materials are promising coating materials 

due to their excellent oxidation and corrosion resistance, 

high temperature strength and cavitation and erosion resistance. 

It is difficult to directly deposit such materials by cold spraying 

due to their intrinsic low temperature brittleness. A novel approach 

including deposition of mechanically alloyed powder 

and post annealing have being developed to form in-situ the intermetallic 

compound coatings. The process has been applied 

to intermetallics such as FeAl, NiAl, and TiAl, and NiTi. Due 

to the flexibility of producing alloy powders by mechanical 

alloying, the intermetallics-based composite coating can be 

easily produced. The microstructure development and relationship 

between processing parameters, microstructure, properties 

and performance are under investigation. 

LSM Cathode 

ScSZ Electrolyte 

Ni-ZrO2 Anode 

Ni-Al2O3Support 

Moreover, NiAl based bond coats are being developed using a 

novel approach with cold spray and post-spray heat treatment. 

In addition, hybrid structure ceramic top coats with lower thermal 

conductivity and higher fracture toughness are being developed 

by controlled plasma spraying. 

Development of solid oxide fuel cells 

through thermal spray processes 

Solid-oxide fuel cells (SOFCs) combine the benefits of environmentally 

benign power generation with fuel flexibility. A 

novel tubular configuration design has been developed in our 

group using a cermet supporting tube (Fig. 2a). The study is oriented 

to coating development for all functional layers in SOFCs 

including the Ni-YSZ anode, the ZrO2-based electrolyte, the 

perovskite ceramic cathode, the interconnector and insulating 

layer and the coatings interface structure development for manufacturing 

of high performance SOFCs by thermal spray 

processes. 

The first topic is aimed at thin ZrO2-based electrolyte development 

with sufficient gas tightness and high ionic conductivity 

for achieving high performance with limited ohmic 

polarization from the electrolyte. The second topic is on plasma 

Development of advanced thermal barrier coatings spray deposition of YSZ-NiO as the anode involving the opti- 

The life time of TBCs is determined by the microstructures mization of the compositions and microstructure for sufficient 

of the bond coat and the ceramic top coat and the nature of the gas permeability, high electronic conductivity and possible ex- 

interface between the bond coat and the top coat. The depositension of the triple phase boundaries into the anode region near 

tion of MCrAlY bond coat by cold spray has been studied to ex- the interface. The third topic is the development of plasma spray 

amine the feasibility of using cold spray as an alternative to low deposition of a chemically active cathode layer with high elec- 

pressure plasma spraying (LPPS) in terms of technological tronic conductivity and sufficient gas permeability. The fourth 

merits. It has been demonstrated by preliminary thermal shock topic is the creation of effective interfaces of the electrolyte- 

tests that the lifetime of TBCs with cold sprayed MCrAlY bond anode and electrolyte-cathode to increase the triple phase bound- 

iTSSecoats 

is potentially longer than TBCs with LPPS bond coats. aries through controlling splat formation. The typical cell con- 

14 

60 ADVANCED MATERIALS & PROCESSES/FEBRUARY 2009 

(a) 

Voltage, V 

(b) 

1.2 

1.0 

0.8 

0.6 

0.4 

100 µm 

0.0 0.3 0.6 0.9 1.2 1.5 1.8 

Current density, A/cm2 1.0 

1030 

1000 

0.8 

950 

W/cm2 

0.6 

0.4 

density, 

0.2 

900 

0.0Power Fig.2 — Cross-sectional microstructure of Ni-Al2O3 cermet supported 

tubular SOFC cell (a) and output performance at different 

temperatures (b).

sists of a free standing Ni-Al2O3 tube prepared by flame spraying, 

onto which the YSZ-Ni anode, YSZ or ScSZ electrolyte and a 

lanthanum strontium manganate oxide cathode layer are plasma 

sprayed layer by layer. 

The maximum open circuit voltage of the cell assembled with 

the ScSZ electrolyte layer infiltrated by a nitrate solution reached 

1.1 V at 900 °C (1650 °F), which is approximately equal to the 

theoretical value. Moreover, a maximum power density of 

890 mW/cm 2 and a current density of 1.7 A/cm 2 at 1000°C 

(1830 °F ) were obtained (Fig. 2b) for the cell with 40 mm thick 

ScSZ. The challenge is to develop more effective interfaces between 

the electrode and electrolyte to reduce the activation 

polarization and integration of the high performance cell on one 

long tube for high power output. 

Development of dye-sensitized solar cell (DSC) 

through vacuum cold spray 

Fine solid ceramic particles can also be employed to deposit 

dense ceramic coatings under a reduced atmosphere referred to 

as the aerosol deposition process. This process has been utilized 

at XJTU to deposit different coatings with controlled microstructures 

for different applications. Since this process is consistent 

with cold spray deposition in which solid particles are used, we 

preferably refer to the process as vacuum cold spraying. Besides 

dense, thin ceramic coatings, nano-porous and meso-porous ceramic 

coatings have been developed aimed at different applications 

such as photocatalyst and photoanodes in a dye-sensitized 

solar cell. 

ITSC 2009. 

It’s a sure thing. 

Capture the energy of Las Vegas. 

Learn from industry leaders through the 

expanded technical program. Take 

advantage of the business opportunities at 

the expo. Sign up for an education short 

course. And enjoy the entertainment value 

of the location. Get it all at ITSC 2009! 

Features in 2009: 

• Market Talks 

• Legends of Thermal Spray 

• Expanded Exposition 

• Unlimited Networking Opportunities 

Organized by 

The ASM Thermal Spray Society (TSS) 

DVS – German Welding Society 

IIW – International Institute of Welding 

iTTSe, The Official Media Sponsor 

DSC is a promising competitor to traditional Si-based solar 

cells due to the advantages of low cost and high efficiency. The 

study is focused on the control of the microstucture of nano- 

TiO2 coatings by vacuum cold spray in terms of the pore network 

through optimization of spray conditions and design of 

fine spray powders. A cell with energy conversion efficiency of 

6.7% and short circuit current density of 17.6 mA/cm 2 was successfully 

assembled with vacuum cold sprayed nano-TiO2. The 

improvement of the cell output is in progress through improving 

the ion diffusion in porous TiO2 coatings by controlling pore 

structures. Based on the features of vacuum cold spray, TiO2 

photoanodes can be deposited for development of a variety of 

DSCs. Typical examples are the novel flexible DSC and doublelayer 

photoanode DSC proposed by our lab. Flexible DSC is 

a challenge because low temperature deposition of nanoporous 

TiO2 coating is required. A good cohesion between nano-particles 

is expected resulting from the high velocity impact of 

spray particles on a flexible polymer substrate surface. Moreover, 

with a novel DSC with the double layer photoanode deposited 

by vacuum cold spray, the wavelength band which can 

be adsorbed by the cell can be extended to the near the infrared 

range. iTSSe 

For more information: Contact Prof. Chang-Jiu Li, e-mail: 

licj@mail.xjtu.edu.cn; Web: http://unit.xjtu.edu.cn/thermalspray/; 

tel: ++86-29-82660970; fax: ++86-29-83237910. 

Expanding Thermal Spray Performance 

to New Markets and Applications 

May 4-7, 2009 

Flamingo Hotel 

Las Vegas, Nevada 

Custom Sponsorship 

and Advertising 

Opportunities Available! 

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Now is the time to reserve your space 

and lock in your booth location. Contact 

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Visit www.asminternational.org/itsc for details. 

15 


iTSSe

Expanding Thermal Spray 

Performance to 

New Markets and Applications 

Plenaries, market talks, invited talks, symposia, networking sessions, poster sessions, round table 

discussions, expert panel forums, and a dynamic vendor exposition are the reasons ITSC 2009 is the 

world’s premier meeting for thermal spray technologists, researchers, manufacturers, and suppliers. 

The four day event offers eight symposia organized by recognized leaders in the thermal spray industry. 

Four are one day events focusing on markets and applications. The other four symposia span all four days 

of the conference. here is a preview of the program planned for ITSC 2009. 

For full details, visit: www.asminternational.org/ITSC. 

Plenary Sessions 

and Market Talks 

PLENARY SPEAKERS 

Mr. Sylvain St-Onge 

Supply Chain Development for Thermal Spray 

Applications 

Mr. Akira Nakahira 

Current Status and Future Prospect of Thermal Spray 

Coating Applications and Coating Service Market of 

Job Shops in Japan 

MARKET TALKS 

Prof. Xiaoou Huang 

Important Market of Thermal Spray Industry and 

New Trend of Thermal Spray Applications in China 

Prof. Changhee Lee 

Market Direction & Application opportunities for 

Thermal Spray Growth in Korea 

Dr. G. Sundararajan 

New Markets & Applications for Thermal Spray Coatings 

in India 

Dr. P. Nylen 

Industrial and Research Activities in Thermal Spray 

Technology in the Nordic Region of Europe 

General Symposia May 4-7 

Symposium on Applications and Case Studies 

Presentations will focus on applications in fields as diverse 

as aerospace, electronics, automotive, and the steel industry. 

New applications that benefit from the use of thermal spray 

processes are found, and presentations will identify various 

thermal spray processes that are used in studies for optimizing 

coatings. 

Papers presented will show results for 

• detonation spraying to produce superabrasive diamond 

grinding tools, 

• metal matrix composites and WC based coatings for wear 

resistance, 

• application of thermal sprayed, wear resistant coatings for 

CFB boiler applications. 

General Technical Symposium 

A wide range of topics will be covered in this four day 

track. The sessions in this symposium will address international 

markets, coating characterization and testing, surface 

treatments, innovative equipment and processes, general 

materials and suspension, and material applications. 

Environmental and safety issues specific to the thermal spray 

industry will be addressed with attention to hazard analysis, 

protective equipment, monitoring, safety by design, and regulatory 

status. Case studies will be presented through a panel 

discussion. The Thermal Spray and Surface Engineering session 

will include CVD, PVD, and electroplating as surface 

engineering design options. Organized as an interactive 

International Thermal Spray 

Conference & Exposition 

May 4-7, 2009 

Las Vegas, Nevada 

iTSSe 

16 


forum, the audience in this session will have the opportunity 

to submit questions to a panel of experts. 

Symposium sessions: 

• Commercial/Industry Developments 

• Pre- and Post-Treatments 

• Safety, Health, and Environmental Issues 

• Thermal Spray and Surface Engineering for 

Design/Operational Solutions 

Symposium on Equipment, Processes and Modeling 

The sessions highlight the most recent advances in modeling 

of thermal spray technologies. New sensing technologies 

and control strategies for optimizing coating properties, as 

well as methods for consistent spraying and reliable production 

of coatings will be covered. Session topics include 

hybrid techniques, non-conventional and innovative processes, 

liquid thermal spray, spray gun and equipment development, 

diagnostics and controls, characterization, guidelines 

and standardization, and applications. 


• HVOF Spray 

• New Equipment and 

These include conventional thermal spraying of hydroxyapatite 

for the promotion of osteo-integration of prostheses, as 

well as various novel developments related to the control of 

cell-surface interactions, cell adhesion mechanisms, cell proliferation 

etc. Issues relating to the tailoring of surfaces will 

include biochemical compatibility, the scale and morphology 

of surface roughness and surface-connected porosity, coating 

adhesion, tribological properties etc. 


• Thermal Spray Coatings for Biomedical Purposes 

• Developmental Surface Engineering Techniques for 

Biomedical Applications 

• Bio-mechanical Characteristics of Tailored Surfaces for 

Biomedical Applications 

• Characterization of Coating Surfaces and Correlation 

with Cell Proliferation and Integration Behavior 

Symposium on Electronic and 

May 5 • Semiconductor Applications 

Thermal spray coatings are used in a broad range of applications 

in the semiconductor equipment, flat panel display, 

and electronics industries. Thermal 

Technologies: Very Low 

Pressure Plasma Spraying 

• Cold Spray 

• Modeling and Diagnostics 

Technical Program 

at a Glance: 

Plenary Sessions 

spray ceramic coatings are used to 

control electrical resistivity, dielectric 

constant, and dielectric 

strength; for chemical and corro- 

• Plasma Spray and Plasma 

and Market Talks 

sion-resistance to components; and 

Transfer Arc 

more. In semiconductor equip- 

• Wire Arc and Laser Spraying General Symposia 

ment applications, metallic coat- 

Special Symposia 

ings are used for a range of applica- 

Symposium on Science and 

Technology of Thermal Spray Legends of Thermal Spray 

tions including reducing particle 

generation in process chamber 

Materials 

operations during thin film deposition. 

The development and evolution of new classes of materi- This symposium will provide a forum for researchers, 

als and the improvement of the current feeds are among the engineers, manufacturers, and end-users to present the latest 

crucial issues for the advancement of thermal spraying. This developments and to discuss critical issues involving the use 

is paramount to consolidate the presence and future of ther- of coatings. Topic areas will include coating design considmal 

spraying in the academic and industrial sectors. In addierations in semiconductor chamber equipment, particle 

tion to improving and maintaining the existing markets, it reduction and contamination control, coating chemical and 

will open new markets and horizons for the application of this corrosion resistance, surface texturing/surface roughness, 

exciting coating technology. The R&D activities of at least adhesion strength and thermal cycling, dielectric properties, 

ten countries including Canada, Czech Republic, Finland, standards, and advances in materials, coatings and diagnos- 

France, Germany, India, Japan, Spain, UK, and USA will be tics. 

represented. 

A round table panel session will be conducted to address 


critical issues facing the industry. Organizations participating 

• Hybrid Deposition Systems and High Performance in this event include universities, semiconductor equipment 

Coating Development 

manufacturers, semiconductor and electronic component man- 

• Nanostructured Coatings and Material Systems ufacturers, thermal spray companies, semiconductor coating 

• Materials and Coatings for Suspension/Solution and cleaning companies, thermal spray powder and equipment 

Processing 

manufacturers, and research and development organizations. 

• Mechanical and Physical Applications of Thermal Spray Symposium sessions: 

Coatings 

• The Role of Coatings in the Semiconductor Equipment, 

• Powder Processing and New Materials 

Flat Panel Display and Electronics Industries 

• New Materials for Anti-Wear and Corrosion Applications • Plasma Sprayed Ceramics in Semiconductor Equipment 

Special Symposia 

and Electronics Applications 

• Advances in Coatings, Processing and Diagnostics for 

May 4 • Biomedical Symposium 

Semiconductor Equipment and Electronics Applications 

This symposium focuses on developments in thermal spray • Thermal Spray Metallic Coatings for Use in 

and related surface engineering technologies to produce coat- Semiconductor Defect Reduction 

ings and surface conditions for biomedical applications. 

Continued on page 22 iTSSe 

17 


iTSSe 

18 

JTST 

HIGHLIGHTS 

The Journal of Thermal Spray 

Technology (JTST), the official journal 

of the ASM Thermal Spray Society, 

publishes contributions on all aspects 

– fundamental and practical – of 

thermal spray science, including 

processes, feedstock manufacture, 

testing, and characterization. As the 

primary vehicle for thermal spray 

information transfer, its mission is to 

synergize the rapidly advancing 

thermal spray industry and related 

industries by presenting research and 

development efforts leading to 

advancements in implementable 

engineering applications 

of the technology. 

Several articles from the March issue 

18(1), as selected by JTST editor 

Christian Moreau, are highlighted here. 

In addition to the print publication, 

JTST is available online through 

www.springerlink.com. 

For more information, please visit 

www.asminternational.org/tss. 

Scanning electron micrograph of the CP titanium 

powder used in this study 

“Recrystallization of 

Cold Spray Fabricated CP 

Titanium Structures” 

Saden H. Zahiri, Darren Fraser, 

and Mahnaz Jahedi 

Cold gas dynamic spray (cold spray) is a 

promising rapid deposition technology in 

which particles deposit at supersonic velocities. 

The effect of isothermal annealing on 

recrystallization and mechanical properties 

of commercial purity (CP) titanium structures 

that were directly fabricated through 

cold spray deposition is studied. The optimized 

cold spray parameters led to a dense 

cold spray structure. Results show that annealing 

improves ductility of the cold sprayed 

CP titanium structure. The mechanism of 

softening is nucleation and growth of equiaxed 

grains which include an ultra fine grain 

structure. A physical based model for recrystallization 

of the cold spray CP titanium is 

proposed. The results show that recrystallization 

does not eliminate preferred orientation 

inherited from the cold spray 

material. 

SEM micrograph of the Al2O3 nanopowder 

“Microstructural and 

Tribological Investigation 

of High Velocity 

Suspension Flame 

Sprayed (HVSFS) Al2O3 

Coatings” 

Giovanni Bolelli, Johannes 

Rauch, Valeria Cannillo, Andreas 

Killinger, Luca Lusvarghi, and 

Rainer Gadow 

Al2O3 coatings were manufactured by the 

High Velocity Suspension Flame Spraying 

(HVSFS) technique using a nanopowder 

suspension. Their structural and microstructural 

characteristics, micromechanical 

behavior, and tribological properties 

were compared to conventional 

atmospheric plasma sprayed (APS) and 

HVOF-sprayed Al2O3 coatings. The 

HVSFS process enables near-full melting 

of the nanopowder particles, resulting in 

very small and well flattened lamellae 

(thickness range 100 nm – 1 µm), almost 

free of transverse microcracking, with 

very few unmelted inclusions. Porosity 

is much lower and pores are smaller than 

in conventional coatings. Such strong interlamellar 

cohesion favors much better 

dry sliding wear resistance at room temperature 

and at 400°C. 

Integrated diagnostic system used in the experiments 

“A Universal Method for 

Representation of 

In-Flight Particle 

Characteristics in 

Thermal Spray 

Processes” 

Wei Zhang and 

Sanjay Sampath 

This paper examines the critical attributes 

of in-flight process diagnostic measurements 

and the applicability of the nondimensional 

group parameters as a mapping 

strategy for data visualization. Specifically, 

1st order process maps (process-particle interactions) 

have been addressed by converting 

the Temperature (T)-Velocity (V) of 

particles obtained via diagnostics into nondimensional 

group parameters [Melting 

Index (M.I.)-Reynolds number (Re)]. This 

approach provides an improved description 

of the thermal and kinetic energy of particles 

and allows for cross-comparison of diagnostic 

data within a given process for different 

materials, comparison of a single 

material across different thermal spray 

processes, and detailed assessment of the 

melting behavior through recourse to 

analysis of the distributions. 


Schematic of modified bonded interface technique 

“Modified Indentation 

Techniques to Probe 

Inelasticity in Ni-5%Al 

Coatings from Different 

Processes” 

W.B. Choi, Y. Wu, S. Sampath, 

and A. Gouldstone 

Two types of indentation experiments 

were performed on metallic (Ni-5%Al) coatings 

prepared by cold spray, high velocity 

oxy-fuel, and air plasma spray. In the first 

type, spherical tips were used with increasing 

loads, and sub-surface deformation was observed 

using a modified bonded interface 

technique. In the second, cyclic loading was 

imposed with a sharp tip, and tip displacement 

was continuously recorded. Results 

suggest that cold spray coatings are brittle 

under contact loads in their as-sprayed condition 

and exhibit a size effect quite different 

from those of the other coatings. Heterogeneities 

in mechanical behavior exist not as 

much on the single particle level as expected, 

but on a much larger scale of order 100 microns. 

This is attributed to long unbonded regions 

between particles, in a coating of otherwise 

high density. Fracture mechanics 

arguments support this hypothesis. 

Schematic of spherical (Hertzian) indentation 

with a tip of radius R, showing contact 

dimensions 

methods are based on existing techniques for 

brittle solids, and adapted for the finite geometry 

associated with coatings. Basic assumptions 

and derivations are given, along with 

guidelines for experimental measurement. 

Using these, indentation inelastic stress-strain 

curves are generated for NiCrAlY and Ni-Al 

bondcoats, as well as WC-Co cermet coatings. 

Elastic moduli are extracted for CoNi- 

CrAlY coatings. Results are briefly discussed 

in the context of the effect of feedstock material, 

process and post-process heat treatment 

on the intrinsic properties of splats as 

well as their in-coating cohesion. The 

methods presented are attractive, particularly 

for the thermal spray industry, due to the minimal 

specimen preparation and lack of intricate 

equipment required for measurement. 

“Ultra Fast Thermal 

Plasma Preparation of 

Solid Si Films with 

Potential Application in 

Photovoltaic Cells - 

a Parametric Study” 

Behnam Mostajeran Goortani, 

François Gitzhofer, Etienne 

Bouyer, and Mehdi Mousavi 

An innovative method namely; ultrafast 

plasma surface melting (UPSM) is developed 

to fabricate solid films of silicon with very 

high rates (150 cm 2/min). The method is composed 

of preparing a suspension of solid particles 

in a volatile solvent and spreading it on 

a refractory substrate such as Mo. After solvent 

evaporation, the resulting porous layer 

is exposed to the flame tale of inductively 

coupled RF plasma to sinter and melt the surface 

particles and to prepare a solid film of 

silicon. It is shown that by controlling the 

flow dynamics and heat transfer around the 

substrate, and managing the kinetic parameters 

(i.e. exposure time, substrate transport 

speed, and reaction kinetics) in the reactor 

we can produce solid crystalline Si films with 

the potential applications in photovoltaic cells 

industry. The results indicate that the optimum 

formation conditions with a film thickness of 

250-700 micron is when the exposure time in 

the plasma is in the range of 5-12.5 s for a 100 

mm by 50 mm large layer. By combining 

the Fourier’s law of conduction with the 

experimental measurements, we obtained an 

effective heat diffusivity and developed a 

model to obtain heat diffusion in the porous 

layer exposed to the plasma. The model further 

predicts the minimum and maximum exposure 

time for the substrate in the plasma 

flame as a function of material properties, the 

porous layer thickness and of the imposed 

heat flux. 

“Indentation of Metallic 

and Cermet Thermal Spray 

Coatings” 

W. B. Choi, L. Prchlik, 

S. Sampath, and A. Gouldstone 

Indentation methods are presented by 

which the elastic and inelastic stress-strain 

characteristics of metallic thermal spray coat- Profiles of velocity colored by velocity magnitude inside the reactor chamber. Left: Ar 

ings on substrates may be extracted. The plasma (without He). Right: With the presence of He. 

iTSSe 

19 


iTSSe 

ITSC 2009, continued 

May 6 • Symposium on Advances in Gas Turbine 

The symposium focuses on the latest developments in 

spray technology for protective and functional coatings, manufacturing 

method developments, and modeling in manufacturing 

contexts. Presentations will be given on coatings for 

polymer turbine blades, protective coatings for SiC/SiC turbine 

engine components, and emerging processes such as suspension 

plasma spraying and cold spraying. 


• Modeling and Optimization for Robust Manufacturing 

and Predictable Performance 

• Latest Developments in Spray Technology for Anti-wear, 

Engine Sealing, Corrosion, Thermal and Environmental 

Barrier Coatings 

May 7 • Symposium on Technology Advances 

in Thermal Spray for New and Existing Markets 

Just 100 years ago, Dr. Schoop in Switzerland invented the 

flame spray coating process. The technology developed 

steadily as a practical and flexible surface treatment process 

responding to the needs of industry and attracting academics 

to improve understanding of the complex processes involved. 

Still there is extensive driving force to further extend the thermal 

spray technology to new markets, however, these markets 

often are not aware of the full potential of the thermal spray 

technology. 

This symposium will outline recent thermal spray applica- 

tions. Furthermore, it intends to bring together practitioners 

and academics from the thermal spray sector with industries 

looking for new, advanced coating solutions. 

Session topics include thermal spray coatings in severe 

environments such as molten salts, low temperature halogen 

plasma, and cavitation erosion situations; surface modification 

requirements for thermal spraying of non-metallic substrates, 

such as graphite and carbon fiber reinforced plastics; 

and thermal spray technology for improving the efficiency, 

durability, and cost-effectiveness of energy conversion systems 

such as fusion technology and solid oxide fuel cells. 


• Applications of Thermally Sprayed Coatings in Severe 

Environments & Allied Supporting Science/Technology 

• Thermally Sprayed Coatings for Non-Metallic Substrates 

• Thermally Sprayed Coatings in Energy Conversion 

Systems & Upcoming Application Fields 

Legends of Thermal Spray 

May 7 

Hear from the leaders in the thermal spray industry and get 

their inside knowledge and perspective on what the future 

holds for the industry. The thermal spray industry and its most 

influential people will be introduced in a special film. There 

will be a roundtable discussion, and an update on ASM’s materials 

education initiatives and programs will be presented. 

Stay Current. 

Take a course at ITSC. 

Get that competitive 

edge only Las Vegas 

and ITSC can bring. 

The ITSC education short 

courses are conveniently 

scheduled before the 

conference. They offer an intense, in-depth 

educational experience, giving you a leg up 

on the competition. 

Choose from four dynamic courses. 

Thermal Spray Technology 

April 30-May 2 

Instructors: Christopher C. Berndt, PhD, 

FASM, HoF and Richard Knight, PhD, FASM 

Understanding and Improving Your 

Thermal Spray Processes 

May 1-2 

Instructors: Dr. Maher Boulos, TS-HoF, 

Dr. Pierre Fauchais, FASM, TS-HoF, and 

Dr. Joachim Heberlein, FASM, TS-HoF 

The Metallographic Preparation and 

Evaluation of Thermal Spray Coatings 

May 2 

Instructor: Douglas G. Puerta 

Essential Skills for Career Development: 

Highly Effective Teams and Dynamic 

PowerPoint Presentations 

May 3 

Instructors: James J. Cummings 

and Nick Moroz 

It’s a challenging time. Stay current with 

the latest information, research, tools and 

processes in the thermal spray industry. 

Plan your future today at ITSC. 

Organized by 

For more information and to register go to www.asminternational.org/itsc 

20 


It’s Like Having Our Manufacturing Facility 

Right at Your Doorstep… 

Sulzer Metco Consumable Parts – Always Available! 

Sulzer Metco consumable components for your thermal spray gun are 

always in stock at all of our warehouse locations worldwide. Always 

available…Always the highest quality…Always your best value! 

It’s Your Secret of Staying Ahead! 

www.sulzermetco.com 

©2008 Sulzer Metco

Thermal Spray - ASM International

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