Introduction Definition of thermal spray Thermal spraying is a group of processes where materials like alloys, metals, nonmmetals was melted in hot source and involve heat. The thermal spray gun generates the necessary heat by using combustible gases or an electric arc.

Principles of thermal spray

Principles of thermal spray coating is based on process, flame,arc,hoof and plasma .As the materials are heated, they are changed to a plastic or molten state and are confined and accelerated by a compressed gas stream to the substrate. The particles strike the substrate, flatten, and form thin platelets that conform and adhere to the irregularities of the prepared substrate and to each other.

The coating that is formed is not homogenous and typically contains a certain degree of porosity, and, in the case of sprayed metals, the coating will contain oxides of the metal. Feedstock material may be any substance that can be melted, including metals, metallic compounds, cements, oxides, glasses, and polymers. The bond between the substrate and the coating may be mechanical, chemical, or metallurgical or a combination of these. The properties of the applied coating are dependent on the feedstock material, the thermal spray process and application parameters, and posttreatment of the applied coating.

and zincaluminum alloy y y This types are important for anticorrosive coatings because they are anodic to steel On the other hand. degrade. aluminum. The polymer must have a melt temperature that is conducive to thermal spray. b) Polymer coatings y Thermal spray polymers are thermoplastic powders applied by flame or plasma spray. and form a protective oxide layer that prevents self-corrosion y alloy of zinc and aluminum is a widely used thermal spray coating material because it is thought to have the best combination of attributes from both metals. Zinc. . aluminum. y the polymer must not polymerize. aluminum coatings are harder. In addition. or char in the flame. and zinc-aluminum alloy coatings. have better adhesion.Typical cross section of a thermal spray coating 3 Types of thermal spray coating a) Corrosion resistant zinc.

Special metal alloy coatings are commonly used for hardfacing items such as wear surfaces of farm equipment.c) Other thermal spray coatings. y y used for special applications. Inert ceramic coatings have been used on medical prosthetic devices and implants such as joint replacements. y Conductive metal coatings are used for shielding sensitive electronic equipment against electric and magnetic fields. and machine tools. Powder gun cross section . y Ferrous metal alloys are often used for restoration or redimensioning of worn equipment. jet engine components.

Typical two-wire arc spray gun .

Chemical corrosion resistance 7.T E L O E heating mechanism chemical (combustion ) electric arc plasma 'D' gun low velocit flame spray hOOF high velocity air plasma controlled environment nontransferred arc wire powder transfferd arc inert atmosphere llow pressure chamber Coati functions 1. Electrical characteristic 4. Chemical corrosion resistance 8. Clearance control . Thermal characteristic 5. Heat and oxidation resistance 3. Atmospheric corrosion resistance 6. Wear resistance 2. Restoration of dimensions 9.

y Cathodic coatings such as copper-nickel alloys and stainless steels can also be used to protect mild steel from corrosion y Zinc thermal spray coatings are sometimes used to prevent the corrosion of reinforcing steel imbedded in concrete. and their alloys are anodic to steel and iron and will prevent corrosion in a variety of service environments including atmospheric. y Coatings of aluminum are frequently used in marine environments. Ceramic materials may be used for electrical insulation. the zinc is deposited onto the concrete and is electrically connected to the steel. Conductive metals are also used to magnetically shield sensitive electronics.Thermal spray uses Corrosion protection y Coatings of zinc. Conductive metals such as copper can be used for conductors. y Thermal spray coatings are also used for electrical applications. . aluminum. For such applications.

. Argon is usually used in both cases as the inert gas.Plasma spray technology y Gas. flows through a cylindrical copper anode which forms a constricting nozzle. reaction with the external environment. y Powder. A direct current arc is maintained between an axially placed tungsten cathode and the outer or expanding portion of the anode. The gases chosen for plasma do not usually react significantly with the powder particles. y To reduce degradation during deposition even further. is fed into the plasma stream in a variety of ways and locations. with hydrogen or helium admixed in some cases. coatings may be produced using either an inert gas shield surrounding the effluent or by spraying in a vacuum chamber under a low pressure of inert gas. usually argon or nitrogen. however. normally air. may lead to significant changes in the coating. with a particle size ranging up to about 100 microns.

1998) Publisher by Elsevier y Journal of Thermal Analysis and Calorimetry 1969-2010) .Brown.T.References y y y y Praxair S.asminternational. www. Technologies Teledyne Hastings Handbook of thermal spray technology by Michael E.