Thermal Spray Tips - Swinburne University of Technology

Compiled by Jo Ann Gan, Edited and advised by Christopher C. Berndt
Swinburne University of Technology Thermal Spray Group (SwinTS)
Please contact Prof. Christopher Berndt at cberndt @swin.edu.au for further enquiries
Table of Contents
1. OVERVIEW OF THERMAL SPRAY PROCESS 5
2. THERMAL SPRAY PROCESSES 6
2.1. COMPARISON OF MAJOR COATING METHODS 6
2.2. CLASSIFICATION OF THERMAL SPRAY PROCESSES 8
2.3. CHARACTERISTICS OF THERMAL SPRAY 9
2.4. THERMAL SPRAY PROCESSING CHARACTERISTICS 10
2.5. THERMAL SPRAY PROCESS VARIATIONS 11
2.6. EFFECT OF TORCH HARDWARE ON PARTICLE TEMPERATURE AND VELOCITY 12
2.7. FLAME SPRAY PROCESS 13
2.8. FLAME SPRAY GUNS 14
2.9. FLAME SPRAY USES COMBUSTIBLE GAS AS HEAT SOURCE TO MELT COATING MATERIAL 16
2.10. HYPERSONIC FLAME SPRAYING 18
2.11. ARC AND FLAME SPRAYING PROCESSES 19
2.12. ELECTRIC ARC WIRE SPRAYING 21
2.13. OXYFUEL WIRE SPRAY 22
2.14. REACTIVE PLASMA SPRAY FORMING 23
2.15. REACTIVE PLASMA SPRAY 24
2.16. TRANSFERRED PLASMA-ARC PROCESS 25
2.17. HIGH-VELOCITY OXY FUEL SPRAY PROCESS 26
2.18. DETONATION GUN THERMAL SPRAY PROCESS FOR CERAMICS 27
2.19. SPRAY TABLES FOR THERMAL SPRAY PARAMETERS 28
2.20. COLD-SPRAY PROCESS PARAMETERS 29
3. FEEDSTOCK MATERIALS 30
3.1. PRODUCTION OF THERMAL SPRAY POWDERS 30
3.2. GAS-PHASE PRODUCTION METHODS FOR ULTRAFINE POWDERS 31
3.3. ADVANTAGES AND DISADVANTAGES OF POWDER PRODUCTION PROCESSES 32
3.4. WATER ATOMIZATION 33
3.5. COMPOSITE MATERIALS 34
3.6. POWDER TESTING AND CHARACTERIZATION: IMAGE ANALYSIS 36
3.7. POWDER CHARACTERISTICS: MORPHOLOGY 37
3.8. PARTICLE SIZE DISTRIBUTION PLOTS 38
3.9. WIRE AND ROD FEEDERS 39
3.10. FLUIDIZED-BED POWDER FEEDERS 40
Information and data acquired from ASM International Thermal Spray Society
website at http://asmcommunity.asminternational.org/portal/site/tss/SprayTips/
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