TALK : GIVEN BY SURFACETECH SDN.

BHD

THERMAL SPRAY

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.
 Typical cross section of a thermal spray coating

3 Types of thermal spray coating

a) Corrosion resistant zinc, aluminum, and zinc-aluminum alloy coatings. Zinc,

aluminum, and zincaluminum alloy
 This types are important for anticorrosive coatings because they are anodic to steel
 On the other hand, aluminum coatings are harder, have better adhesion, and form a
protective oxide layer that prevents self-corrosion

 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.

b) Polymer coatings
 Thermal spray polymers are thermoplastic powders applied by flame or plasma
spray. The polymer must have a melt temperature that is conducive to thermal
spray. In addition,
 the polymer must not polymerize, degrade, or char in the flame.
c) Other thermal spray coatings.
 used for special applications.
 Special metal alloy coatings are commonly used for hardfacing items such as wear
surfaces of farm equipment, jet engine components, and machine tools.

 Ferrous metal alloys are often used for restoration or redimensioning of worn
equipment. Inert ceramic coatings have been used on medical prosthetic devices and
implants such as joint replacements.

 Conductive metal coatings are used for shielding sensitive electronic equipment
against electric and magnetic fields.

Powder gun cross section

Typical two-wire arc spray gun
w
y
t
i
c
o
l
e
v
)
g
F
O
f
-
d
n
u
s
p
r
b
m
a
h
(
e
n
u
r
g
'
i
d
a
D
w
o
c
m
l
p
f
s
t
a
m
s
l
p
d
c
r

wire t
e
l ow ve
rle
non-
l hO
ol
l a
wns
a
cm
' D' s
powde
pla
f
( a
m
e
ct
pla

Coating functions
rd
a
ar

1. Wear resistance
cir
hetr
ont
O
r
t
gun
nvi
m
om
c ve
c
e
ha
s
ac
f
pr
ma
ha
r
os
f
ic
i a
F
m
r
ne
e
bus
ma
o
l
ns
e
ol
i
r
t s
r
s
onm
a
m
r c
ni
THERMAL SPRAY PROCESS

l oc i
e ng
hi
c
t ur
pr
phe
be
c
r t
i
e
f
l
g
ay
a
t y
r
h
de
c on)
y
t
m
s
r r
e
nt

2. Heat and oxidation resistance

3. Electrical characteristic
4. Thermal characteristic
r d

5. Atmospheric corrosion resistance

6. Chemical corrosion resistance
7. Chemical corrosion resistance
8. Restoration of dimensions
9. Clearance control
Thermal spray uses

Corrosion protection

 Coatings of zinc, aluminum, and their alloys are anodic to steel and iron and will
prevent corrosion in a variety of service environments including atmospheric,
 Coatings of aluminum are frequently used in marine environments.

 Cathodic coatings such as copper-nickel alloys and stainless steels can also be used to
protect mild steel from corrosion

 Zinc thermal spray coatings are sometimes used to prevent the corrosion of reinforcing
steel imbedded in concrete. For such applications, the zinc is deposited onto the
concrete and is electrically connected to the steel.

 Thermal spray coatings are also used for electrical applications. Conductive metals
such as copper can be used for conductors. Ceramic materials may be used for
electrical insulation. Conductive metals are also used to magnetically shield sensitive
electronics.
Plasma spray technology

 Gas, usually argon or nitrogen, with hydrogen or helium admixed in some cases, flows
through a cylindrical copper anode which forms a constricting nozzle. A direct current
arc is maintained between an axially placed tungsten cathode and the outer or
expanding portion of the anode.

 Powder, with a particle size ranging up to about 100 microns, is fed into the plasma
stream in a variety of ways and locations. The gases chosen for plasma do not usually
react significantly with the powder particles; however, reaction with the external
environment, normally air, may lead to significant changes in the coating.

 To reduce degradation during deposition even further, 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. Argon is usually used in both cases as the inert gas.
References

 Praxair S.T. Technologies

 Teledyne Hastings Instruments.
 www.asminternational.org/content/ASM
 Handbook of thermal spray technology by Michael E.Brown,(1998) Publisher by
Elsevier
 Journal of Thermal Analysis and Calorimetry (1969-2010)
 MST691
SPECIAL TOPIC IN ADVANCED MATERIALS

TOPIC : THERMAL SPRAY

PREPARED BY : AZLINI BINTI AB.AZIZ

(2008402626)

PROGRAMME: AS230

GROUP : ASB6X (MATERIALS TECHNOLOGY)

PREPARED FOR : DR.MAHESH KUMAR TALARI

DATE OF SUBMISSION : 4 MARCH 2011