It may be necessary to perform surface

treatments in order to

Improve resistance to wear erosion, and indentation

(e.g., for machine-tool slideways, Wear surfaces of

machinery, and shafts, rolls, cams, and gears)machinery, and shafts, rolls, cams, and gears)

Control friction (on sliding surfaces of tools, dies,

bearings, and machine Ways)

Reduce adhesion (of electrical contacts)

Improve lubrication (surface modification to retain

lubricants)

Improve resistance to corrosion and oxidation (on

sheet metals for automobile bodies, gas-turbine

components, food packaging, and medical devices)

Improve fatigue resistance (of bearings and shafts

with fillets)with fillets)

Rebuild surfaces (on worn tools, dies, molds, and

machine components)

Modify surface texture (appearance, dimensional

accuracy, and frictional characteristics)

Impart decorative features (color and texture).

Thermal Spraying

Thermal spraying is a series of processes in which

coatings of various metals, alloys, carbides,

ceramics, and polymers are applied to metal

surfaces by a spray gun with a stream heated by surfaces by a spray gun with a stream heated by

an oxyfuel flame, an electric arc, or a plasma arc.

The earliest applications of thermal spraying (in

the 1910s) involved metals (hence the term

metallizing has also been used), and these

processes are under continuous refinement.

Advantages of thermal spraying

A major advantage of thermal spray processes is the extremely wide variety of materials that can be used to produce coatings. Virtually any material that melts without decomposing can be used. be used.

A second major advantage is the ability of most thermal spray processes to apply coatings to substrates without significant heat input.

Advantages of thermal spraying

Thus, materials with very high melting points,

such as tungsten, can be applied to finely

machined, fully heat-treated parts without

changing the properties of the part and without changing the properties of the part and without

excessive thermal distortion of the part.

A third advantage is the ability, in most cases, to

strip off and recoat worn or damaged coatings

without changing part properties or dimensions.

Limitations

A disadvantage is the line-of-sight nature of

these deposition processes.

They can only coat what the torch or gun can

see. Of course, there are also size limitationssee. Of course, there are also size limitations

The surfaces to be sprayed are first cleaned of

oil and dirt, and then roughened by, for

example, grit blasting, to improve their bond

strength . strength .

The coating material can be in the form of

wire, rod, or powder, and when the droplets

or particles impact the workpiece, they

solidify and bond to the surface.

Depending on the process, particle velocities typically range from a low of about 150 to 1000 m/s, but can be higher for special applications.

Temperatures are in the range from 3000 to 8000C. 8000C.

The coating is hard and wear resistant, with a layered structure of deposited material. However, the coating can have a porosity as high as 20% due to entrapped air and oxide particles because of the high temperatures involved.

Bond strength depends on the particular

process and techniques used and is mostly

mechanical in nature (hence the importance

of roughening the surface prior to spraying), of roughening the surface prior to spraying),

but can be metallurgical in some cases.

Bond strength generally ranges from 7 to 80

MPa, depending on the particular process

used.

Typical applications of thermal spraying include aircraft engine components (such as those used in rebuilding worn

parts),

structures,

storage tanks,

tank cars,

rocket motor nozzles, and components that require resistance to wear rocket motor nozzles, and components that require resistance to wear and corrosion.

In an automobile, thermal spraying typically can be applied to crankshafts, valves, fuel-injection nozzles piston rings, and engine blocks. The process is also used in the

The process is also used in the gas and petrochemical industries, for the repair of worn parts and to restore dimensional accuracy to parts that have not been machined or formed properly.

Thermal Spray Processes and

Techniques

Members of the thermal spray family of

processes are typically grouped into three

major categories:

flame spray, electric arc spray, and plasma arc flame spray, electric arc spray, and plasma arc

spray

Flame spray process

Flame spraying includes low-velocity powder

flame, rod flame, and wire flame processes

and high-velocity processes such as HVOF and

the detonation gun (D-Gun) processthe detonation gun (D-Gun) process

Flame powder

In the flame powder process, powdered feedstock is aspirated into the oxyfuel flame, melted, and carried by the flame and air jets to the workpiece.

Particle speed is relatively low (

Spray rates are usually in the 0.5 to 9 kg/h (1

to 20 lb/h) range for all but the lower melting

point materials, which spray at significantly

higher rates. higher rates.

Substrate surface temperatures can run quite

high because of flame impingement.

Zinc and aluminum cover the range of active corrosion protection.

For exposure to aggressive chemicals, CrNi alloys are used.

For protection against mechanical wear, For protection against mechanical wear, molybdenum, metal carbides and ceramics are mainly used.

Ceramic materials such as Al2O3 and TiO2 are often used for mechanical seals on chemical plants. These can only be produced as powders.

Wire flame

In wire flame spraying, the primary function of

the flame is to melt the feedstock material.

A stream of air then atomizes the molten

material and propels it toward the workpiece.material and propels it toward the workpiece.

Spray rates for materials such as stainless steel

are in the range of 0.5 to 9 kg/h (1 to 20 lb/h).

Again, lower melting point materials such as

zinc and tin alloys spray at much higher rates.

Wire flame

Substrate temperatures often range from 95

to 205 C (200 to 400 F) because of the excess

energy input required for flame melting.

In most thermal spray processes, less than In most thermal spray processes, less than

10% of the input energy is actually used to

melt the feedstock material.

High-Velocity Oxyfuel

High-Velocity Oxyfuel

In HVOF, a fuel gas (such as hydrogen, propane, or propylene) and oxygen are used to create a combustion jet at temperatures of 2500 to 3100 C (4500 to 5600 F).

The combustion takes place internally at very high chamber pressures, exiting through a small-diameter (typically 8 to 9 mm, or 0.31 to 0.35 in.) barrel to generate a supersonic gas jet with very high particle speeds.

The process results in extremely dense,

wellbonded coatings, making it attractive for

many applications.

Either powder or wire feedstock can be Either powder or wire feedstock can be

sprayed, at typical rates of 2.3 to 14 kg/h (5 to

30 lb/h).

Where there are extra demands for sealing,

adhesion and wear resistance of the coatings

for example in engine construction high

velocity flame spraying is often used.velocity flame spraying is often used.

The most important application is wear

protection using hard solid alloys with metal

carbides (Tungsten- or Chromiumcarbides).

Detonation gun

Detonation Gun. In the detonation gun process, pre-encapsulated shots of feedstock powder are fed into a 1 m (3 ft) long barrel along with oxygen and a fuel gas, typically acetylene.

A spark ignites the mixture and produces a controlled explosion that propagates down the length of the explosion that propagates down the length of the barrel.

The high temperatures and pressures (1 MPa, or 150 psi) that are generated blast the particles out of the end of the barrel toward the substrate.

Very high bond strengths and densities as well as low oxide contents can be achieved using this process.

Flame spraying usually requires only low cost equipment.

It is suitable for single piece and series production and can be used in both stationary and mobile configurations.

Main applications are corrosion and wear protection. Main applications are corrosion and wear protection.

The use of wire or powder depends on the material and the application rate.

Zinc, aluminum and molybdenum are mostly sprayed as wire.

Most metal and hard-alloys are applied as powder.

Electric Arc

In the electric arc spray process (also known as the wire arc process), two consumable wire electrodes connected to a high-current direct-current (dc) power source are fed into the gun and meet, establishing an arc between them that and meet, establishing an arc between them that melts the tips of the wires.

The molten metal is then atomized and propelled toward the substrate by a stream of air.

The process is energy efficient because all of the input energy is used to melt the metal.

Generally materials such as copper-base and iron-base alloys spray at 4.5 kg (10 lb)/100 A/h. Zinc sprays at 11 kg (25 lb)/100 A/h.

Substrate temperatures can be very low, Substrate temperatures can be very low, because no hot jet of gas is directed toward the substrate.

Electric arc spraying also can be carried out using inert gases or in a controlled-atmosphere chamber

Plasma Arc Processes

The conventional plasma spray process is commonly referred to as air or atmospheric plasma spray (APS).

Plasma temperatures in the powder heating region range from about 6000 to 15,000 C (11,000 to 27,000 F), significantly above the melting point of any known material. material.

To generate the plasma, an inert gastypically argon or an argon-hydrogen mixtureis superheated by a dc arc.

Powder feedstock is introduced via an inert carrier gas and is accelerated toward the workpiece by the plasma jet.

Industries use thermal spray coatings because

they offer improved:

Wear resistance

Heat resistance (thermal barrier coatings) Heat resistance (thermal barrier coatings)

Clearance and dimensional control

Corrosion and oxidation resistance

Electrical properties (resistance and

conductivity)