Thermal Spray Tips - Swinburne University of Technology

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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 2.19. Spray Tables for Thermal Spray Parameters Checklist for a plasma spray process Plasma processing equipment • Torch type (anode, cathode, injector ring), mm • Volts and amps = powder, kW • Primary gas and flow rate, slpm • Secondary gas and flow rate, slpm • Feed gas and flow rate, slpm • Standoff distance, mm • Powder injection, mm • Powder feed rate, g/min Hardware • Traverse speed of torch, m/s • Substrate cooling, m 3 /s • Spray footprint, mm 2 Checklists, or spray tables, can be defined as a list of primary thermal spray parameters that need to be specified and controlled during a specific coating operation. All of these parameters influence process economics and coating quality. In many instances, manufacturers indicate the physical properties, such as surface roughness, microstructure porosity, and adhesion, that can be expected if coatings are produced using their recommended spray parameters. These values should be used only as a rough guideline for coating properties. The physical properties of the substrate also are very important, being essential to the production of an appropriate surface profile. Even with similar thermal spray processes, the spray parameters are likely to change from process to process and between different equipment. Powders that are presumably identical may exhibit different spray parameters for each set of equipment. Source: C.C. Berndt, Material Categories for Thermal Spray Coatings, Handbook of Thermal Spray Technology, J.R. Davis (Ed.), ASM International, p 143, 2005. Information and data acquired from ASM International Thermal Spray Society website at http://asmcommunity.asminternational.org/portal/site/tss/SprayTips/ 28 Back to TOC Back to Overview
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 2.20. Cold-Spray Process Parameters Typical range of gas-jet parameters for cold spray coating Stagnation jet pressure, MPa (psi) 1 – 3 (145 – 435) Stagnation jet temperature, °C (°F) 0 – 700 (32 – 1290) Gas flow rate, m 3 /min (ft 3 /min) 1 – 2 (35 – 70) Powder feed rate, kg/h (lb/h) 2 – 8 (4 – 18) Spray distance, mm (in.) 10 – 50 (0.4 – 2) Power consumption, kW (for heating gas) 5 – 25 Particle size, μm 1 - 50 Process gases include nitrogen, helium, air, and mixtures of these gases. Nitrogen is a favored process gas because it can be used to spray some materials without promoting oxidation and because is much less expensive than helium. Helium is capable of providing the highest gas velocities, and therefore can be used in depositing the widest possible range of materials. Helium may also be diluted with nitrogen to improve the economics of the process, while providing particle velocities in excess of that achieved with nitrogen alone. Source: A. Papyrin, Cold Spray Technology, Adv. Mater. Process., Sept 2001, p 49-51; from Cold Spray Process, as published in Handbook of Thermal Spray Technology, J.R. Davis (Ed.), ASM International, p 78, 2005. Information and data acquired from ASM International Thermal Spray Society website at http://asmcommunity.asminternational.org/portal/site/tss/SprayTips/ 29 Back to TOC Back to Overview
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