| Thermal Spray Coating 1. Themal Spay Dstnton an etry 2. Terma prey Characters {8 Thoma pray Aopen by Cat 4. Thamal Spray Apa by eusty | What is Thermal Spray? Thermal spraying fs a group of coating processes in which finely divided ‘metallic or nonmetalic materials are deposited in @ molten or semimolton condition to form a coating. The coating material may be in the form of powder, ceramie-red, wire, or molten materials. (FrankJ, Hemanek, Theral Spay Terminology and Company Origins, 2001) ASS) . -Q)-<- a wiser SEH Std sot gat| ‘Thermal Spray Myth [Myths it that Max Utich Schoop developed the concept when playing “soldiers” with his son and observing the deformation of lead pellets being {fired from a toy carnon against a brick wall. Whatever the rationale, itcan be stated thatthe cloneer work of Schoop resulted Inthe discovery and deovelopent of metal spraying and subsequent the “Thermal Spray rocess" Hot Toad Potential ofa mei sat——_Schoop, father" ofthermal spray technology $__ Siremerceme ss: ROD CE PIR wots 18 Fig. Tmtine of themal spray development, equipment, proces, and materials| What is Thermal Spray? Thermal Spray's the technology that forms films with smashed Particles of moten power or wire typed fm materials(ceramic, alloy ‘and plastics) by the high tomperature heat source(gas, plasma, arc) into the materials at high speed harfacing technique. ‘Thermal Spray Techniques + Thermal Spray Processes, Chemica (Combustion) Heat Source Pima Where HVOF Dgun Flame Spray Spray prey Spray SprayThermal Spray Process ‘ee Fame sory 2) Powder Fame Sray Micro Structure of Thermal Spray ° ed| ‘Thermal Spray Coating Characteristics Density/Porosity Oxidation (in metal coatings) Hardness Bond Strength Microstructure Surface Finish Machinability Residual Stress HVOF | Thermal Spray Coating Characteristics = Possible for all types of materials(metal, non- metal, ceramic, organic materials) = Various materials(metal, ceramic, composition materials, high molecule) « High speed of coating formation, easy thickness adjustment = Several types of coating layers = Less transformation of basic materials and thermal deformation(cold spray) = No limit in product sizeThermal Spray Application = Wear Resistant Coating abrasion Se ts [Thermal Spray Application = Corrosion Resistant Coating * lon Ener Thera spray HVOF, (ol Srey > Cola spray High Deny‘Thermal Spray Application = Thermal Insulation Coating Tec (SA 3B) = What is TBC? - TBC is Thermal Barrier Coating: bond and top coating - Bond Coating is an MCrAlY and may be applied by plasma or HVOF processes - Top Coating is usually yttria-stabilized zirconium oxide(YSZ) with a porosity of 8-20%, depending on the customer specificationThermal Spray Ar ‘on = Abradable and Abrasive Coating Nickevgraphite Nickelbentonite ‘Metal + Non-metal Filer Nicke/polyester ‘Aluminumipolyesier Thermal Spray Application | = Electro Magnetic Shieldling Coating MorMn Feri, Al, Ta, Nb‘Thermal Spray Application = Electrical Conductive Coating q {Al Cu, Ag Costing on Non-Metal Copper Epoxy EMI Coating Thermal Spray Application = Electro-Chemical Coating: Solid Oxide Fuel Cell = Heat Transfer Coating » Medical Coating = Polymer CoatingThermal Spray Application Landing gear, airbrakes Automobile ae Crank, Shaft Wear Sleeve, Sensor, side housing, Piston ring, dsc brake Industrial Gas Turbine Blades, abrasive coatings, combustion, ‘Transportation inéustly Fan/compressor bade, air folls, rotor biade ‘extension sleeve, main rotor staf, pivot sleeve Steel Industry Roller guide, ols, pay-off mandrel, temper mils Paper. Printing Calendar rol, dryer rol, paper timming ro, hydro roll blade (Oil and Gas Equipment Pump engines, seas, shelts, compressor shafts Medicine Implants, xray targets Textil Industry Grooved rolls, separator rll hater, hot plate, disk fed drum rp, fiction cisk, tow cutter blade, Thermal Spray Application humet oH COR) Pm, Yat kes an 2) vce “Form tae etc) Medea tn, Oe tomcie Hts wong = ert ove 5%)Coating on Aircraft Engine‘Automobile Industry Application‘Automotive Coating Application finder are cng (ASE a “ce ton gesting | Automotive Coating Application ahs vale eats = ibs Fame sprayed ad esd cooing 2488 AEH Sale using NEC} AWS 4748) _- N-CESE-R, Mor (APS) Tanoninion gee ‘cite re spray bron ‘Tenamieon shaft = STS, Mo coating Tubochsgerheusing~ APS-C HVOF coating Compressor = abradabe coating tn APs mo:[Thermal Spray Application| Chromium Oxide and Aluminum Oxide Coatings Applied by Air Plasma = Lithographic print rolls o High wear resistance a Excellent pattern retention = Ball valves, o Excellent resistance to acids/chemicals