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 2.2. Classification of Thermal Spray Processes Thermal spray processes and subsets Members of the thermal spray family of processes typically are grouped into three major categories: flame, plasma arc, and electric arc. (Kinetic energy-driven spray, or cold spray, is a recent addition to the family.) Each of these processes encompasses many more subsets, and each has its own characteristic range of temperature, enthalpy, and velocity. These attributes, in turn, develop coating characteristics that are unique to each process, which in simplest terms include coating bond strength, porosity, inclusions (usually oxides), and hardness. Selection of the appropriate thermal spray method typically is determined by: • Desired coating material • Coating performance requirements • Economics • Part size and portability Source: J.R. Davis (Ed.), Handbook of Thermal Spray Technology, ASM International, 2004, p 44 Information and data acquired from ASM International Thermal Spray Society website at http://asmcommunity.asminternational.org/portal/site/tss/SprayTips/ Back to TOC Back to Overview 8
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 2.3. Characteristics of Thermal Spray Schematic of a typical thermal spray powder process Thermal spray is a generic term for a group of coating processes used to apply metallic or nonmetallic coatings. Three major categories of the processes are flame spray, electric arc spray, and plasma arc spray, with subsets under each category. (Cold spray is a recent addition that uses modest preheating, but is largely a kinetic energy process.) The energy sources heat the coating material (powder, wire, and rod form) to a molten or semimolten state. Heated particles are propelled toward a prepared surface via process gases or atomization jets, forming a bond with the surface upon impact. Subsequent particles cause thickness buildup and form a lamellar structure. Advantages of thermal spray processes include the ability to use a wide variety of coating materials, the ability of most thermal spray processes to apply coatings without significant heat input, and the ability, in most cases, to strip off and recoat worn or damaged coatings without changing part properties or dimensions. Source: J.R. Davis (Ed.), Handbook of Thermal Spray Technology, ASM International, p 4, 2004 Information and data acquired from ASM International Thermal Spray Society website at http://asmcommunity.asminternational.org/portal/site/tss/SprayTips/ Back to TOC Back to Overview 9
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Thermal Spray Tips - Swinburne University of Technology

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