Thermal Spray Coatings

Asst.Prof.Dr. Ali Sabea Hammood

Materials Engineering Department
Faculty of Engineering
University of Kufa
 Introduction:
Surface engineering techniques generally
consist of surface treatments, where the
composition or physical, chemical, and
mechanical properties of existing surface
are altered. They are achieved by adding
different material deposited as a thin or
thick layers (coatings) to creat anew
surface.
Laser coated by-pass valve spindle.
It should be noted that surface engineering
may be used effectively to improve the
surface properties, without changing the
chemical composition of the bulk
materials.

Is frequently used to satisfy engineering

requirements.
It provides an important
means of increasing the
life of engineering
component by increasing
oxidation, corrosion,
wear and erosion
resistance.
Surface Treatments:
Mechanical Processes:
• Shot preening.
• Rolling.
Thermal Treatments;
• Laser beam treatment.
• Electron beam treatment.
• Flame treatment.
• Induction treatment.
Thermochemical diffusion
treatments:
*Carburizing
*Carbonitriding
*nitriding
*Nitrocarburizing
*Chromizing
Physical vapor deposition.
Ion implantation
 Functionally Effective Coatings
Using Thermal Spray Coatings
The development of new technologies and processes requires suitable materials for their realization.
Since many forms of attack , such as:
-Corrosion
-Wear
-Heat
-Impact
- Radiation

;
Figure: Principle of laser coating.
Power = 2430 watts, Velocity = 4.23
mm/s ,Beam Diameter = 0.5 mm
Nickel Powder Thickness = 1.0 mm
 occur on the surface of
a component , or are transferred via
the surface into the component,
surface protection has a
considerable significance as
regards modern materials
technology.
 The purpose of surface technology
is to produce functionally effective
surface . This implies matching the
surface properties of a component to
its particular operating stresses.
The aim is to achieve improvement of :
- Operating life
- Reliability
- Economic performance
-Safety
-Output from products and processes
 :Thermal spraying consist of
1- Heating of the powder.
2- Melting of the powder.
3- Acceleration of the particles on to high
velocity.
4- Impacting the particles on to the
substrate and subsequent bonding.
Flame Spray Coating
Electron Beam Physical Vapor
Deposition
 An illustrative diagram of one type of PVD setup.
Source:
http://web.mit.edu/.../team2_f02/ Pages/processing.html
Schematic microstructure of a thermal barrier coating
(TBC) obtained by electron beam physical vapour
deposition (EBPVD). The columnar microstructure
considerably enhances the strain resistance and
therefore thermal cycling life.
Plasma Spray Coating
Schematic microstructure of a thermal barrier coating (TBC)
obtained by air plasma spray (APS). The structure provides
much less strain resistance than the EBPVD counterpart,
but is preferred for abradable seals (DeMasi-Martin, 1994)
Figure : Typical micrograph of HVOF coating (left) and APS
coating (right) Magnification is approx. 300x
Characterization of Plasma Spayed
Coatings
1- The high temperature enables
almost all materials to be sprayed.
2- Deposits are of high density and
strongly bonded to the substrate.
3- It is possible to control the coating
thickness or build overlapping layers
with different compositions to achieve
the desired requirement.
4- Easy to control the cooling rate by
heating or cooling the substrate during the
process.
5- Cheap base materials can be used as
substrate.
6- Expensive materials need only be used
for the coating.
7- Little or no dilution occurs between the
coating layer and the substrate.
8- Finishing may not be required
 Applications of plasma spray
coating
1- Wear protection against- abrasion,
scuffing and fretting corrosion.
2- Corrosion protection against- oxidation ,
hot gas corrosion and immersion
corrosion.
3- Thermal insulation ( thermal barrier).
4- Repairing parts by adding material on to
worn lactations , or reconstituting apart
which has been rejected due to faulty
material or incorrect machining.
 5- Surfaces with special properties such
as:
1- Electrically insulating or conducting.
2- Self –lubricating coatings.
3- Active or passive surface coatings.
4- Decorative coatings.
5- Coatings which are highly absorptive or
reflective to light.
6- Special applications , such as production
of sensors.
 Thermal barrier coatings
The main advantages of using thermal
barrier coatings are summarized below
1- Improving the creep and oxidation
resistance by decreasing the temperature
of the substrate.
2- Improving the thermal fatigue resistance
of the thermal system by decreasing the
thermal stress induced by strain.
3- Decreasing maintenance costs.
4-Improving engines components durability.
5- Enhancing reliability and performance of
advanced heat engines components.
6- Improving the efficiency of the engine by
reducing the volume of air required for
cooling.
 Laser Surface Sealing of Plasma
Sprayed Coatings
The main potential applications for laser
sealing of coatings are:
1- Sealing porosity: To increase the life of
coated components by eliminating the
access of corrosive gases and molten
salts to the underlying metallic substrate.
2- Modification microstructure : To improve
the structural homogeneity of coatings.
3- Producing a smoother surface finish:
To reduce the active surface for heat
absorption.
4- Increasing surface hardness:
Toenhance erosive and wear
resistance of the surface.
5- Improving fracture strength:
Figure : 6 kW CO2 laser coating with coaxial powder
nozzle at Fortnum Service Oyo Laser Coating Centre
Thank You For Your Attention