international thermal spray and surface engineering

TM

May 2008Volume 3 • Issue 2

I N T E R N A T I O N A L

Thermal Spray &Surface Engineering

I N T E R N A T I O N A L

Thermal Spray &Surface Engineering

T H E O F F I C I A L N E W S L E T T E R O F T H E A S M T H E R M A L S P R A Y S O C I E T Y

tss.asminternational.org

Your Thermal SprayInformation Partner

Industry News

Diamond Engine

CoatingsJTST

HighlightsTSS News

and Events

Industry News

Diamond Engine

CoatingsJTST

HighlightsTSS News

and Events

TSSSM

ASM Thermal Spray SocietyAn Affiliate Society of ASM International®

10 TSS RRegional EEvents: Aerospace CCoatings aand IImproving Reliability aand CConsistency iin Thermal SSpray

14 Synthetic DDiamond CCoating Helps JJet EEngines Withstand HHostile EEnvironment

16 Application NNote: Corrosion PProtection BBack oon Ross-sshire EEngineering’s PPlate

Departments2 Editorial

3 Industry News9 ASM Thermal Spray Society News

18 JTST Highlights20 Products/Technical Resources

ADVANCED MATERIALS & PROCESSES/MAY 2008 671

Editor Christopher C. Berndt

Managing EEditor Ed Kubel

Art DDirector Barbara L. Brody

Production MManager Joanne Miller

Publisher Joe Zion

National AAccount MManagerKelly Thomas, CEM.CMPMaterials Park, Ohiotel: 440/338-1733 e-mail: [email protected]

Thermal SSpray SSociety Executive CCommittee

Peter Hanneforth, President

Richard Knight, Past President

Mitchell Dorfman, Vice President

Charles Kay, Secretary/Treasurer

Thomas S. Passek, Executive Director

About tthe ccoverCryogenic nitrogen vapor maintains parttemperature within ±20°F during thermalspray coating applications.Courtesy of Air Products, Allentown, Pa.

International Thermal Spray & Surface EngineeringTM

is published quarterly by ASM International®, 9639 Kinsman Road, Materials Park, OH 44073; tel: 440/338-5151; www.asminternational.org. Vol. 3, No. 2. Copyright© 2008 by ASM International®. All rights reserved.

The acceptance and publication of manuscripts inInternational Thermal Spray & Surface Engineeringdoes not imply that the editors or ASM International®

accept, approve, or endorse the data, opinions, andconclusions of the authors. Although manuscripts published in International Thermal Spray & SurfaceEngineering are intended to have archival significance,author’s data and interpretations are frequently insufficient to be directly translatable to specific design,production, testing, or performance applications without independent examination and verification of their applicability and suitability by professionallyqualified personnel.

MAY 2008 • Volume 3 • Issue 2

Zirconia (synthetic diamond)helps to protect jet enginecomponents against high-temperature corrosion.

Thermal spray coatings provide corrosion protectionfor a range of componentsat water plants throughout

the UK.

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FROM THE EDITOR

e all make transitions in life, which allow revitalization and growth to occur. While suchopportunities arise in our personal environments, how does growth occur for a

technology? What are tipping points for the advancement of surfacing technologies suchas thermal spray, hardfacing, PVD, etc., and how can individuals play a role that suits theirpersonal career goals?

Is technology the driver or engine for innovation? The answer is no. The real drivers arepeople who dedicate their careers to make the impossible possible, responding to an intrinsic curiosity to do what is considered by their peers as undoable and the need to solvespecific engineering applications challenges.

Has thermal spray reached its technological limit? This often seems the case on a year-to-year basis when new developments appear to progress at glacial speed. Yet a literature and the state-of-the-art search in 5- or 10-year increments reveals that people whoappear within relatively old conference proceedings are still publishing, which suggests thatthermal spray provides a sustainable long-term career. There also is a steady progression ofpeople passing through the field of thermal spray technology, growing at an annual rate ofabout 15-20%. Furthermore, there is growth in the number and diversity of companies involved in both publishing and exhibiting at conferences, which indicates a healthyprospect for thermal spray with new players and new associated technologies contributingto synergistic growth.

Is there is a limited need for specialists in coatings technology? To survive as a relevanttechnology, it is not enough to maintain (for example) a $3-billion annual global market. This will not lead to sustainability, and thermal spray will devolve to essentially a boutique technology for special applications rather than the household word that denotes true acceptance. New basic and applied R&D programs are needed to achieve the above goal.Furthermore, technology-savvy people are desirable to start, manage, and implement theseprograms. Where will these people come from and what incentives are there for a young professional to enter the surface engineering field? The answers to these questions are disappointing. Many young people find science and engineering “too hard,” and surface engineering technologies are suffering. On the positive side, professional societies includingTSS, ITSA, DVS, GTS, and many others are playing a significant role in specialized educationand training for technologists of all types.

The born-again technologist is a person who meshes the three themes presented so next-generation products can be developed. This technologist, by keeping an open mind,holds the key to the leap-frog technology that surface engineering continues to create.

Chris Berndt, FASM, EditorEditor Emeritus: The Journal of Thermal Spray TechnologyIRIS, Faculty of Engineering and Industrial SciencesSwinburne University of TechnologyMail 66 PO Box 218Hawthorn, Victoria 3122 AUSTRALIATel: +61 (0)3 9214 8706Tel: +61 (0)428 237 [email protected]

68 ADVANCED MATERIALS & PROCESSES/MAY 20082

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WBorn Again as a Technologist

Increasingly higher gasoline pricesare driving car manufacturers to im-prove the fuel economy of motor ve-hicles. To address this situation, Hi-tachi Ltd., Tokyo, Japan, developeda valve lifter incorporating a hy-drogen-free DLC (diamond-likecarbon) coating. The coating has lowfriction with very good conformityto the engine oil, which improves fueleconomy in engine valve-train sys-tems. Overcoming some of the manyhurdles in the way of developing acoating based on existing coatingtechnology that has good adhesionto the base metal, Hitachi claims tohave produced a highly reliablecoating through the development oflapping and special washing tech-nologies prior to the treatment.www.hitachi.com.

DLC CoatingBoosts Valve Lifter

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Atomizing Systems Supplies ‘Anti-Satellite’ Gas Atomizer

Inert-gas atomization is supposed to produce spherical metal powders, but suffersfrom a problem called satelliting, in which most particles have smaller particles stuckto their surfaces, a problem that becomes worse as powders are made finer. This con-dition results both in reduced flow properties and lower than expected packing density.One way to avoid satelliting is to quench the gas-atomized powders in water, whichproduces spherical powders, but produces excessive oxygen levels for certain applica-tions and alloys. Standard dry gas atomizers produces lower oxygen content, but de-grade sphericity.

Atomising Systems Ltd. (ASL), Sheffield, UK, delivered what is said to be the world’sfirst “anti-satellite” gas-atomizing systemto Castolin Eutectic Ireland Ltd. (CEIL),a division of the Messer group of com-panies based in Frankfurt, Germany.CEIL supplies a wide range of specialNi, Co, and Fe alloy powders used inthermal spray, welding, and brazingprocesses. The 8-m (26 ft) high system,fitted with two 350 kW, 250 kg (550 lb)melters, incorporates ASL’s anti-satel-lite technology. The atomizer also isfitted with an induction-heated tundishto allow long pouring times. www.atomising.co.uk.

Sulzer Metco Celebrates 75th AnniversaryThis year, 2008, marks the 75th year of the founding of

the Metallizing Engineering Co., now known as Sulzer Metco.Rea Axline opened the doors of Metallizing Engineering Co.,Westbury, N.Y., in 1933 to meet industry needs of increasingcomponent service life by preventing corrosion and salvagingworn parts to serviceable condition.

Today, customers continue to require surfaces that keep thecomponents they market in service longer, with better perform-ance than ever before. Sulzer Metco, as part of its 174-year old parent company, Sulzer, with more than 1,900 employeesworldwide, continues to take on the challenges of new industries that require new surface solutions. www.sulzer.com.

Many equipment advancements have occurred during Sulzer Metco’s 75-year history.

ASTM Metallic CoatingsCommittee to Meet

ASTM International’s Metallic and In-organic Coatings Committee (B08) willmeet on October 23 at ASTM headquar-ters in West Conshohocken, Pa. All inter-ested individuals may attend ASTM meet-ings. For more information about theupcoming meetings, call Diane Rehiel,ASTM International at 610-832-9717; e-mail: [email protected]; or visit the com-mittee Web page at http://www.astm.org/COMMIT/B08.htm.

Accuwright IndustriesAchieves ISO 9000 Certification

Accuwright Industries Inc., Gilbert, Ariz., a metal-spray tech-nology company offering a wide range of flame spray servicesincluding training and consultation was audited by QAS Inter-national to the quality management systems, standards, andguidelines for ISO 9001:2000 and achieved certification. Flamespray processes are applied to a wide range of products in theaerospace, automotive, electronics, and semiconductor markets.ISO 9001 is the internationally recognized quality managementsystem that verifies that a company can provide a consistentlevel of quality products. The system documents steps neededto deliver such quality, from initial design through final deliveryand product support. Regular re-certification by a qualified registrar ensures that the Quality System remains in place andis effective. www.accuwright.com.

Raymor Acquires SE Techno Plus

Raymor Industries Inc., Boisbriand, Quebec, Canada, a de-veloper and producer of single-walled carbon nanotubes,nanomaterials, and advance materials, announced that itswholly owned subsidiary, Raymor Aerospace Inc. purchasedSE Techno Plus Inc., Saint-Leonard, Quebec, a company spe-cializing in the manufacturing, repair, and precision grindingwith super finishing of industrial and aerospace components.The acquisition allows Raymor Aerospace to implement itsone-stop-shop facilities for its coating services and developa larger market presence for Raymor’s other subsidiaries.The aerospace sector includes commercial, regional, and

business aeronautics, and general and military aviation.Boeing predicts the aeronautic world fleet will double overthe next 20 years, which should bring a demand of 28,600new aeronautics during the period. www.raymor.com.

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STechnogenia (headquartered in Seynod, France) opened a new office in Atlanta, Ga.,

to develop its business in North America. A leader in hardfacing technology, Technogeniaoffers a wide range of anti-abrasion material for use in wear applications such as in the oildrilling, mining, foundry, aluminum, iron and steel, paper, food, ceramic and tile, andwaste-recycling industries. Anti-abrasion protection is imperative in industries that useheavy-duty parts for mixing, grinding, or other techniques that subject the tools to signif-icant wear. Replacing these parts can be costly and time consuming, slowing productionand reducing quality of results. Technogenia developed a special tungsten-carbide powderknown as Spherotene that provides very good anti-abrasion when deposited on a tool’ssurface. The carbide particles are applicable by means of a welded-on cast-nickel cord,thermal spray, special castings, or precision laser, providing almost ten times longer servicelife than that of traditional chrome-carbide hardfacing. Technogenia is represented byBolton Alloy LC in Houston, Tex. (tel: 713-460-8870). www.technogenia.com.

Technogenia Opens Business Office in Atlanta

New Technogenia office in Atlanta, Ga.


Praxair Surface Technologies Inc., Indianapolis, Ind., a whollyowned subsidiary of Praxair Inc., will complete a multi-milliondollar investment to add capacity for advanced coatings in early2008. In response to strong global demand from industrial gasturbine original equipment manufacturers, state-of-the art coat-ings technology is being added to the company’s facilities inCharlotte, N.C., and Schluechtern, Germany. The capacity in-crease is driven by strong demand for industrial gas turbine en-gines in the power generation sector, as well as the increaseduse of advanced coatings, according to David Brackins, vicepresident of business development. Industrial gas turbine man-ufacturers continue to produce engines having increased effi-

ciency, higher reliability, and reduced environmental emissions.Thermal spray coatings applied using plasma coating processessignificantly enhance the ability of key components to operatewithin the severe conditions of the engine.

In other news, Praxair Surface Technologies received Sup-plier-of-the-Year honors from Dresser-Rand, providing thecompany with thermal spray coatings for fluidic catalyticcracking hot gas expanders and reciprocating process com-pressors. Dresser-Rand cited its satisfaction with Praxair’sconsistency and reliability in product quality, responsive-ness to customer needs, and on-time delivery performance.www.praxairsurfacetechnologies.com.

Praxair Surface Technologies to Expand Coating Capacity

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Researchers at John H. Glenn ResearchCenter, Cleveland, Ohio, discovered that at-omization of a molten mixture of BaF2 andCaF2 is superior to crushing of bulk solid BaF2-CaF2 as a means of producing eutectic BaF2-CaF2 powder for use as an ingredient of the powder feedstock of a high-temperature solid lubricant material known as PS304. Thematerial was developed to reduce friction andwear in turbomachines that incorporate foilair bearings, and is applied to metal substrates using plasma spray. PS304 consists of an 80 Ni-20 Cr alloy, Cr2O3, Ag, and the BaF2-CaF2 eutectic (specifically, 62 BaF2-38 CaF2.

Using atomization to produce eutecticBaF2-CaF2 powder produces more desirableparticle shape having significantly improvedpowder flow properties: atomized powder ismore rounded compared with the angular particles producedthrough crushing. PS304 feedstock powder containing the morerounded particles flows more freely and more predictably, whichis preferable for plasma spray.

Gas and water atomization processes were compared withcrushing to produce eutectic BaF2-CaF2 powders (see figure).The particles produced by gas atomization are the most nearlyspherical, but each batch contains only a small proportion of

particles in the size range (20 to 100 �m) suit-able for plasma spray and a much larger pro-portion of undesired finer particles. Water at-omization yields particles that are less sphericalin character but still more rounded than thoseproduced by crushing, and it yields a greaterproportion of usable particles. The flow prop-erties of PS304 powders containing water-at-omized BaF2-CaF2 are intermediate to thoseof PS304 powders containing equal propor-tions of gas-atomized BaF2-CaF2 and thosecontaining equal proportions of crushed BaF2-CaF2. Because water atomization is less ex-pensive and better suited to high-volume pro-duction than gas atomization, wateratomization could be preferable for applica-tions in which the shapes of the eutectic BaF2-CaF2 particles are not required to closely ap-

proximate spheres and the intermediate flow properties areacceptable. This work was done by Christopher DellaCorte ofGlenn Research Center and Malcolm K. Stanford of the Uni-versity of Dayton. Inquiries concerning rights for the com-mercial use of this invention should be addressed to NASAGlennResearch Center, Innovative Partnerships Office; Attn: SteveFedor, Mail Stop 4-8, 21000 Brookpark Rd., Cleveland, Ohio44135. Refer to LEW-17709-1.

Water-Atomized Metal Fluoride Powder for Better Flow Characteristics

Water atomization producesparticles intermediate in shape tothose produced by gas atomization and crushing.


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SArcelorMittal, Luxembourg, Belgium, inaugurated its innova-tive Arceo industrial prototype for a vacuum plasma steel coatingline located in Liege, Belgium. What is claimed as a break-through technology, Arceo was developed by the Group’s Re-search and Development in partnership with the Walloon Re-gion, and is expected to open up many new uses for flat steelproducts. Coated steel can serve as a sensor, a reflector, an an-tibacterial, or self-cleaning surface; can have improved corro-

sion resistance; or just simply be more aesthetic. The process isenvironmentally friendly; it does not use solvents or chemicalpreparations; neither does it generate effluents or gases thatrequire treatment. ArcelorMittal is the world’s number one steelcompany, with 320,000 employees in more than 60 countrieswith combined revenues (2006) of USD 88.6 billion and a crudesteel production of 118-million metric tons, representing around10% of world steel output. www.arcelormittal.com.

ArcelorMittal Inaugurates Vacuum Plasma-Coating Line

Longevity Coatings, Pen Argyl, Pa., a thermal spray coating-service company founded in 2005, relocated its production fa-cility to a site near Allentown, Pa., occupying 8,800 ft2 in two

buildings. The company specializes in the application ofthermal spray coatings (carbide, ceramics, and metals) to wearand machine parts used in a wide variety of industrial appli-

cations. Various thermal spray coating processes,including HVOF, plasma, twin wire arc, and com-bustion flame spray and fused coatings (diffusionbonded), are applied using computer-programmedequipment.

Mark Purington, founder and president ofLongevity Coatings, notes that manufacturers’ de-sire to extend the life of equipment has led to sig-nificant growth for the company and for the thermalspray industry in general. The new facility isequipped to handle completely manufactured,coated, and ground components, including parts inexcess of 18 ft long and up to 50 in. diameter (5.5m and 1,270 mm). www.longevitycoatings.com.

Biomet Celebrates Hip Stem’s25th Anniversary

Biomet Inc., Warsaw, Ind., celebrated the 25th anniversary of its Ta-perloc hip stem. According to the company, the flat, tapered wedge de-sign of the Taperloc stem with its porous plasma-spray coating continuesto offer surgeons and their patient’s consistent, reproducible results. Thehip stem is said to be one of the industry’s best performing implants andthe milestone celebration is a tribute to its excellent long-term clinicalsuccess. Biomet currently offers three stem options for the Taperloc hip,including the original standard stem, a reduced distal stem, and the Taperloc Microplasty stem. www.biomet.com.

Thermal Spray Coater Relocates, Expands Plant


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Tribofilm Research Inc., Raleigh, N.C., received a patent(U.S. Patent No. 7,264,669) for its StaClear abrasion-resistantcoating, claimed to be a breakthrough in hard-coat technology.Test results of the abrasion resistance of the two-coat gradientcomposition performed by Colts Laboratories, Clearwater, Fla.(www.colts-laboratories.com) demonstrate very good abrasionresistance. Three distinct coating properties of interest to coat-ings and materials specialists that set it apart from most com-mercially available hard coats are:

• A Bayer Index of 5.87 • An anti-graffiti, easy-to-clean surface, which is both hy-

drophobic and oleophobic

• A minimal effect on the impact resistance of polycarbonate,unlike many commercially available hard coats

StaClear is predominantly a water-based system, which, there-fore, is not sensitive to humidity during coating. It can be di-luted with water and clean up can be accomplished using aqueousdetergent. It also is resistant to common organic solvents andhas excellent impact resistance. Properties can be achieved witha hard coat thickness as low as 3.5 mm. The coating is particu-larly useful for use on substrates such as polycarbonate, CR-39,biaxially oriented Mylar and many engineering polymers. Sta-Clear basecoat has a long shelf life (>6 months at room temper-ature). www.tribofilmresearch.com.

Breakthrough in Hard Coat Technology

FEI Co., Portland, Oreg., received a technology award at NanoTech 2008 in Tokyo, Japan, for technical excellence in evalua-tion and measurement of its Titan 80-300 S/TEM (scanning/trans-mission electron microscope). The award recognizes both in-novative technology and the contributions the Titan S/TEM hasenabled nanotechnology research. Professor Tomoji Kawai,chairman, Nano Tech Executive Committee, noted that FEI hasbeen a major contributor to the science of nanotechnology sinceits inception. The introduction of aberration-corrected TEM isa major breakthrough that gives scientists the ability to directlyvisualize nanostructures with sub-Angstrom imaging resolu-tion. A new model with high resolution EELS (electron en-ergy loss spectroscopy) that can provide analytical results with

the same high resolution has alsobeen put into practical use. Un-like conventional S/TEMs,which require complex compu-tational procedures to recon-struct high resolution images, theTitan S/TEM’s aberration-cor-rected electron optics is said toprovide directly interpretable image resolution at the atomicscale. FEI is involved in pioneering technologies and applica-tions that deliver imaging solutions for three-dimensional char-acterization, analysis, and modification/prototyping with reso-lutions down to the sub-Angstrom level. www.fei.com.

Technology Award Recognizes Contributions to Nano Research

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The Thermal Spray Society Board at its March 2008 meetingunanimously approved the safety document “Guidelines for theUse of Personal Protective Equipment in Thermal Spraying,”which was created by the Thermal Spray Society Safety Com-mittee (chaired by Greg Wuest). Personnel Protective Equip-ment (PPE) is intended to provide information consistent withthe U.S. Occupational Safety and Health Administration’s(OSHA) Personal Protective Equipment Standard (29 CFR1910.132-138). All information is presented in the context ofThermal Spray.

These guidelines are written within the context of the pre-vailing internationally accepted practices and standards, as wellas United States laws and regulations. They are intended to haveworldwide application.

The full document can be viewed on the TSS CommunityWeb site at www.ineedaurlthatworks.com

Student Board-Member Program

The Thermal Spray Society Board unanimously approved thecreation of a TSS Student Board Member Program recommendedby the TSS Nominating Committee (chaired by Rick Knight).The program and Board Mentor Guidelines are modeled afterthe ASM Board of Trustees Student Member Program.

Looking for CandidatesTSS is looking for two student members. To be eligible, a

person must be a registered undergraduate or graduate studentduring the 2009-2010 academic year studying or researching inan area closely related to the field of thermal spray technology.

Student-Application DetailsTo apply, a student must submit an application package com-

prising:• A current resume/CV• Atwo-page essay (typed and double-spaced, in English) ad-

dressing his/her interest in participating in the program, including(1) what experiences led to his/her interest in this program, and(2) what qualities, characteristics and skills he/she has that willmake them a strong candidate to serve as Student Representa-tive to the TSS Board

• What he/she hopes to learn/gain from this program• Two or three letters of recommendation from facultyApplications will be reviewed by the TSS Nominating Com-

mittee, which will forward recommendations to the TSS Ex-ecutive Committee for approval. Applications are due no laterthan April 1, 2009. The two selected participants will be noti-fied by May 1, 2009 and will each begin their nonrenewable and

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TSS NewsTS Safety Document Approved by TSS Board


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non-voting, one-year term as Student Representatives to theTSS Board of Directors, at the spring 2009 TSS Board meetingin Las Vegas.

The application package should be submitted by mail to:ASM World Headquarters

Attn: Sarina Pastoric9639 Kinsman Rd.

Materials Park, OH 44073-0002

UPCOMING TSS REGIONALEVENTSAerospace Coatings SymposiumOctober 15-16 2008Sheraton Bradley HotelBradley (Connecticut) International AirportSymposium organizers: Mr. Richard Bajan, BASF CatalystsLLC, and Mr. Mitchell Dorfmann, Sulzer Metco (US) Inc.

This 2-day event will cover some of the latest developmentsin thermal spray and other surface engineering technologies de-signed specifically for use in the aerospace industry. The pro-gram includes a Plenary Session, two technical sessions (coat-ing design and coatings implementation), and panel discussions.Plenary Session

Human Factors: The study of human capabilities and limitations in the workplaceMr. Andy BordickManager, Continuous Improvement & Strategy DevelopmentPratt & WhitneyEast Hartford, Conn.

Role of Thermal Spray Coatings in Advancing Systems Approach to Turbine Airfoil Design for Gas Turbine Engines

Dr. Sudha BoseFellow of High Temperature Materials and Coatings in Materials and Processes Engineering / Global Service EngineeringPratt & WhitneyEast Hartford, Conn.

Aerospace Standards for Thermal Spray CoatingsMr. Marc FroningManager of Engineering and DevelopmentBASF Surface TechnologiesEast Windsor, Conn.

Role of Material and Equipment Thermal Spray Suppliersin the Aerospace Industry Dr. Markus HeusserExecutive Vice PresidentSulzer Metco Thermal SprayWinterthur, Switzerland

Reliability and Consistency in Thermal Spray ProcessesDr. Christian MoreauGroup Leader – Surface TechnologiesIndustrial Materials InstituteNational Research Council CanadaBoucherville (Montreal), Quebec, Canada

For more information, contact ASM Customer service at [email protected], or visitwww.asminternational.org/tssaerospace08/.

TSS News, continued


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Conventional application processes,including HVOF & Twin Wire Arc Spraying

1-877-293-NANOwww.nanosteelco.com

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We aim to please.

Extend equipment life – and improve the reliability of your entire operation – with ASB Industries. Using the latest thermal spray technology, ASB develops

custom solutions for unusual wear and quality issues, from repairing mis-machined parts to meeting OE design specifi cations for new ones. All in an effort to increase

your production effi ciencies.

Get on target. Sign up for our Enewsletter at asbindustries.com today!

©2008 ASB Industries, Inc.

ASB Industries, [email protected]

Sponsorships Available. To learn more about tabletop ex-hibiting and sponsorship opportunities, or to discuss customizinga program to meet your specific needs; contact Kelly Thomas,Exposition Sales Manager at 440-338-1733; or e-mail [email protected].

Pre-Event SeminarMaterials and Processes for High Temperature Gas Turbine Components

October 13-14, 2008Sheraton Bradley AirportInstructor: Dr. Donald Boone, President, BWD Turbines Ltd.,

Walnut Creek, Calif.Seminar focuses on thermal spray and other surface modi-

fication processes critical to the aerospace industry. The courseis aimed at developing a firm understanding of materials,processes, and applications of gas turbine components oper-ating at the highest temperatures in the turbine section.

For more information, contact ASM Customer service at [email protected], or visit www.asminternational.org/tssaerospace08/.

Symposium on Improving Reliability andConsistency in Thermal SprayDecember 2-3, 2008Hyatt Regency MontrealQuebec, Canada

Co-sponsored by ASM Thermal Spray Society and NationalResearch Council Canada

Symposium features presentations by invited speakers cov-ering reliability and consistency of thermal spray processes andcoatings, poster session of recent research findings, and table-top exhibit. For more information, contact [email protected].

CALL FOR POSTERS: Submit 200-word abstract for con-sideration of presenting at the event to Lyso Russo at [email protected]. DEADLINE for submission is October 15, 2008.

To learn more about tabletop exhibiting and sponsorship op-portunities, or to discuss customizing a program to meet yourspecific needs; contact Kelly Thomas, Exposition Sales Man-ager at 440-338-1733; or e-mail [email protected].


OBITUARYPaula A. Didier, 48, of West Bend, Wis.,passed away January 30, 2008. Shebegan her career in materials engi-neering at J.I. Case in Wausau, Wis.;moved on to Praxair Surface Technolo-gies (formerly Miller Thermal Inc.) inAppleton, Wis., where she honed herengineering and management skills; andjoined Harley-Davidson Motor Co. atits Product Development Center in Wauwatosa, Wis., in 2001,where she remained until her death. Paula was a memberof the ASM Thermal Spray Society, and served as chair-person for the ASM/TSS Recommended Practices Com-mittee, Subcommittee on Metallography.

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EVENTS

2008 International Thermal Spray Conference and Exposition (ITSC 2008) Thermal Spray Crossing BordersJune 2-4, 2008MECC Maastricht Congress CentreMasstricht, The Netherlands

ITSC, the world’s foremost international conference and exposition for thermal spray technologists, researchers,

suppliers, and end-users will be held this year in Maastricht,

The Netherlands. ITSC 2008 followsthe successful path of the previous

events in Basel (2005), Seattle(2006), and Beijing (2007), and will

present the latest status of application, research and

development in the field of thermal spray.

ITSC 2008 will take place at theMECC Maastricht Congress Centre,

a state-of-the-art conference and exhibition center designed with the

conference attendee in mind. Visitors can attend ITSC 2008, dine,

and also have their room accommodations at the center.

Everything is under one roof.This outstanding annual event in

the world of thermal spray technology is jointly organized by

the German Welding Society (DVS),the ASM Thermal Spray Society

(TSS) and the International Instituteof Welding (IIW). Event sponsors are

NIL - Netherlands Institute ofWelding and VTS - Vereniging voor

Thermische Spuittechnieken. The organizing team looks for-

ward to meeting you in Maastricht. ITSC 2008 is an event not to be

missed!

For mmore iin fformation aabout ITSC 22008, ccontact

Customer SService CCenter, ASM IInternational MMaterials

Park, OOhio, tel: 8800-3336-55152 ((ext. 00), or 4440-3338-55151 ((ext. 00); e-mmail: [email protected],

or vvisit www.asminternational.org.

Thermal SSpray CCourses aat IITSC 22008(All courses held at Maastricht Expositie & Congres Centrum Maastricht, The Netherlands, prior to the technical conference) For registration details, visit http://asmcommunity.asminternational.org/portal/site/ASM/ITSC2008/.Instruction LLanguage: All course instruction and materials will be in English.

Thermal SSpray TTechnology May 229-331 8:00 aa.m. –– 55:00 pp.m.

This course provides: (1) a thorough grounding and understanding of thermal spray processes,(2) depicts the quite complex scientific concepts in terms of simple physical models, and (3) in-tegrates this knowledge to practical engineering applications and commonly accepted thermalspray practices. Participants receive the Handbook of Thermal Spray Technology and hard-copy of the instructor’s presentation materials. The instructors have been collaborating on thiscourse since 1996.

Instructors: Dr. CChristoper CC. BBerndt, FASM, TSS HoF, Professor, Swinburne University ofTechnology, Hawthorn, Victoria, Australia; Dr. RRichard KKnight, FASM, Auxiliary Prof., DrexelUniversity, Philadelphia, Pa. Registration FFees ((US$): ON oor BBEFORE MMay 114 (AFTER MMay 114)

TSS/DVS/IIW Member 995 (1,045)ASM Member 1,055 (1,105)Non-Member 1,195 (1,245)Student 295 (345)

Understanding aand IImproving TThermal SSpray TTechnology May 330-331 8:00 aa.m. –– 66:30 pp.m.

This course will review the processing science of a wide range of thermal spray coatingprocesses. The theory of operation and practice of the coatings will be presented, includingthermal spray process control, coating application, characterization, and testing. Practicalcoating systems for electric arc, combustion, and plasma spray will be reviewed using casestudies.

Instructors: Dr. MMaher BBoulos, TSS HoF, Prof., University of Sherbrooke, Sherbrooke, Quebec,Canada; Dr. PPierre FFauchais, FASM, TSS HoF, Prof., Université de Limoges, Limoges, France;Dr. JJoachim HHeberlein, FASM, TSS HoF, University of Minnesota, Minneapolis, Minn. Registration FFees ((US$): ON oor BBEFORE MMay 114 (AFTER MMay 114)

TSS/DVS/IIW Member 795 (845)ASM Member 835 (885)Non-Member 975 (1,025)Student Fee 255 (305)

The MMetallographic PPreparation oof GGas TTurbine CCoatings May 331 8:00 aa.m. –– 55:00 pp.m.

This course covers a wide range of topics relating to the metallographic preparation andevaluation of gas turbine coatings with emphasis on equipment and consumables selectionand how these choices influence the observed coating structure. Common issues encoun-tered with various coating families (hardcoats, ceramic TBCs, etc.) also will be discussed.

Instructor: Mr. DDouglas GG. PPuerta, Director of Metallurgical Engineering, IMR Test Labs,Lansing, N.Y. Registration FFees ((US$): ON oor BBEFORE MMay 114 (AFTER MMay 114)

TSS/DVS/IIW Member 475 (525)ASM Member 525 (575)Non-Member 645 (695)Student Fee 195 (245)

iTSSe

Nitin PadtureDepartment of Materials Science and EngineeringOhio State University, Columbus

Engineers at Ohio State University, Columbus, are de-veloping a technology to coat jet engine turbine bladeswith zirconia (zirconium dioxide, or ZrO2) to protectthe components against high-temperature corrosion.

Zirconia (or synthetic diamond) chemically converts sand andother corrosive particles that build up on the blade into a newprotective outer coating; the surface of the engine blade in ef-fect continually renews itself. Ultimately, the technology couldenable manufacturers to use new kinds of heat-resistant mate-rials in engine blades, so that engines will be able to run hotterand more efficiently.

The project came to light when Nitin Padture, currently pro-fessor of materials science and engineering at the university,thought about needing such protection for military aircraft op-erating in a desert climate when he was a professor at Univer-sity of Connecticut, Storrs. In the desert, sand is sucked into theengines during takeoffs and landings, and there also are duststorms. Even in a non-desert environment, commercial aircraftand power turbines encounter small bits of sand or other parti-cles, which can damage turbine blades.

Because jet engines operate at very elevated temperatures,blades in the most advanced engines are coated with a thin layerof heat-resistant, thermally insulating ceramic to protect themetal blades. These thermal-barrier coatings are designed to ex-pand and contract with the metal. However, when sand hitsthe hot engine blade, it melts and becomes glass, and molten

glass is extremely aggressive and can dissolve nearly any material.

The hot glass attacks the ceramic coating, but the real damagehappens after the engine cools, and the glass solidifies into aninflexible glaze on top of the ceramic. When the engine heatsup again, the metal blades expand, but the ceramic coating cannotexpand because the glaze has locked it in place. The result isthat the ceramic breaks off, shortening the life of the engineblades.

The new diamond-like coating forces the glass to absorb chem-icals that convert it into a harmless (even helpful) ceramic. Thekey, according to Padture, is that the coating contains aluminumand titanium atoms inside the zirconia crystals. When the glassconsumes the zirconia, it also consumes the aluminum and ti-tanium. Once the glass accumulates enough of these elements,it changes from a molten material into a stable crystal, and itstops eating away at the ceramic. The glass literally becomes anew ceramic coating on top of the old one. When new glass isformed, the process repeats itself, continually renewing thecoating on the surface of the turbine.

Padture notes that the technology is in its infancy. The coat-ings have not yet been applied to complex shapes, and cost isa barrier as well as the process is energy-consuming. However,if process costs can be reduced and the technology matures, thepayoff could be hotter engines that burn fuel more efficientlyand create less pollution. In addition, manufacturers would beable to use more sophisticated ceramics that boost the heat re-sistance of engines. Eventually, the technology could go beyondaircraft and power-generator turbines and extend to automobilesas well.

The University of Connecticut has applied for a patent on thetechnique that Padture devised for embedding the aluminumand titanium into the zirconia. Padture is partnering with In-framat Corp., a nanotechnology company in Farmington, Conn.(www.inframat.com) to further develop the technology.

The research was funded by the Office of Naval Research(www.onr.navy.mil) and Naval Air Systems Command(www.navair.navy.mil). For more in formation, contact NitinPadture; tel: 614-247-8114; e-mail: [email protected]. iTSSe

Synthetic Diamond Coating Helps Jet Engines Withstand Hostile Environment

An airplane’s engines draw sand from a runway. Image courtesyof the Department of Defense.

Conventional ceramic coating destroyed by molten glass (left)and ceramic coating (in a thin layer on top) designed to resistmolten glass (right). The field of view of both images is about 0.5mm. Both images by Aysegul Aygun and Nitin Padture, courtesyof Ohio State University.

80 ADVANCED MATERIALS & PROCESSES/MAY 200814iTSSe

Ross-shire Engineering Ltd., based inthe Highlands of Scotland, has pur-chased new Flamespray Mark 73

equipment from Metallisation Ltd. (Dudley, West Midlands,UK) as part of its strategic decision to once again provide cor-rosion protection solutions to customers. Ross-shire Engineering,a long-time Metallisation customer, provides a complete turn-key industrial engineering service to its clients, from small fab-rication to power-station refurbishment. With the purchase of

the Flamespray Mark 73, the company alsocan provide long-term anticorrosion pro-tection to its customers.

Ross-shire Engineering has been usingMetallisation Arcspray equipment foraround 20 years, producing engineeredcoatings for shaft repairs and to replaceworn bearing surfaces in the water industry,

with Scottish Water and Scottish Southern Energy plc being well-established clients. The new Flamespray equipment will be usedto provide long-term corrosion protection for tubes/pipework,framework structures, security gates, and a range of general struc-tural fabrications at water plants throughout the UK.

In the late 1990s, Ross-shire provided corrosion protectionsolutions, but as demand diminished, they ceased providing suchservices. Now, as customers are demanding higher standards offinish and the extended lifetime of capital equipment, the needfor superior corrosion protection is increasing. Generally, cus-tomers want to extend the life of their assets by protecting themagainst corrosion, which, in turn, means minimum maintenancerequirements and reduced lifecycle costs. According to the Britishand other International Standards Institutes, metal-spray coat-ings will protect structures from corrosion for up to, and over,20 years, depending upon the coating thickness applied and thesurrounding environment.

In the Flamespray process, the raw material, which is in theform of a single wire, cord or powder, is melted in an oxygenfueled gas flame. The molten material is atomized by a coneof compressed air and propelled towards the work piece. Themolten spray solidifies on the component surface and forms adense, strongly adherent coating, suitable for corrosion protec-tion or component reclamation. The coating can also be used toprovide wear resistance, electrical and thermal conductivityor insulation, or freestanding shapes. Advantages of the Flame-spray process are that the coatings are available for almost in-

APPLICATIONNOTE

Corrosion Protection Back on Ross-shire Engineering’s Plate

Thermal Spray IndustryCrosses Borders.Attend ITSC 2008 in Maastricht, The Netherlands, June 2-4, 2008. ITSC brings together the global thermal spray community to meet, exchange information and conduct business. Learn the latest in applications, research and developments across the field of thermal spray from experts from around the world.

Register today for these outstanding pre-conference education courses. Choose from the following courses to complete your ITSC experience.

Thermal Spray TechnologyMay 29-31, 20088 a.m. - 5 p.m.Instructors: Dr. Christopher C. Berndt, FASM and Dr. Richard Knight, FASM

Understanding and Improving Your Thermal Spray ProcessesMay 30-31, 20088 a.m. - 6:30 p.m.Instructors: Dr. Maher Boulos, TS-HoF; Dr. Pierre Fauchais, FASM, TS-HoF; and Dr. Joachim Heberlein, FASM, TS-HoF

The Metallographic Preparation of Gas Turbine CoatingsMay 31, 20088 a.m. - 5 p.m.Instructor: Douglas G. Puerta

Make important business contacts at the expo. Exposition and custom sponsorship opportunities are still available. Contact Kelly Thomas, National Account Manager today to customize the package that best meets your needs. [email protected] or 440.338.1733.

From materials knowledge to innovation…ITSC 2008. Visit www.asminternational.org/events today to register for the conference, education courses and to take advantage of expo opportunities.

ASM International®

9639 Kinsman RoadMaterials Park, Ohio 44073-0002800.336.5152www.asminternational.org


Gain More Thermal Spray Knowledge.ASM International and the Thermal Spray Society present two regional events designed to further enhance specific knowledge within the thermal spray industry.

TSS Aerospace Coatings SymposiumOctober 15-16, 2008Sheraton Bradley HotelBradley International AirportHartford, CT

Scientists and engineers will learn new trends in technology, coatings application requirements and analyze case studies. Applicators, technicians and process engineers will focus on environmental health, safety issues, testing and characterization, quality and process improvements, metallography and pre/post processing challenges.

Add value to your symposium experience. Register for this specially-designed pre-conference education course.

Materials and Processes for High Temperature Gas Turbine ComponentsOctober 13, 8:30 a.m. - 4:30 p.m. and October 14, 8:30 a.m. - 4 p.m.Instructor: Dr. Donald BooneLearn design requirements, materials and processing details, protection system requirements degradation sequences, and repair and refurbishment strategies.

TSS Symposium on Improving Reliability and Consistency in Thermal SprayDecember 2-3, 2008Hyatt Regency Montreal Montreal, QuebecThis event will focus on identifying technologies, best practices, training and certification processes related to improving reliability and creating more consistency in the thermal spray industry. Engineers, scientists, educators, practitioners and suppliers will all benefit from attending this specialized symposium.

Exhibit and custom sponsorship opportunities are available.Contact Kelly Thomas, National Account Manager today, [email protected] or 440.338.1733 to customize the package that best meets your needs.

Visit www.asminternational.org/events today to register for the conferences, education course and to take advantage of exhibit and sponsorship opportunities.

Sponsored by iTTSE magazine.

ASM International®

9639 Kinsman RoadMaterials Park, Ohio 44073-0002800.336.5152www.asminternational.org

stant use, with no drying or curing time required, and there is no risk of damaging the component.

The Flamespray processproduces a fine coatingfinish having low porosity,ideal for steel structuresand surfaces. Structuralsteelwork can be sprayedusing a variety of differentcoatings (pure zinc and purealuminium and their alloys) depending on the cir-cumstances. The specific systemsupplied to Ross-shire will spray 0.1875 in. (4.76 mm) diam-eter zinc and aluminium wires, supplied in 25 kg (55 lb) coils.The design of the Mark 73 pistol allows the sprayer to intermit-tently stop and start the spraying without extinguishing and re-lighting the main flame. This, coupled with the large diameterwire, enables fast, efficient application of a high quality coatingwith minimal wastage.

To ensure the highest standards of quality are offered to theircustomers, Ross-shire also employed Metallisation to fully traintheir spray operators at their Muir of Ord site. The training wascarried out in a new blast and spray facility, specifically built toensure the highest quality coatings combined with the safety of

the operators and local environment. The single-day trainingcourse included basic principles of metal spray, health and safety,operation of the system, and routine maintenance. All operatorsattending the course received a certificate of competence.

Ross-shire can provide metal spray solutions on-site or in-house, depending upon the customer’s requirements. Projectscan include the refurbishment or the reclamation of equipmentand metal spraying new equipment within the distilling, water,power, and manufacturing industries. The new Flamespray equip-ment adds another dimension to the company’s services.

According to Allan Dallas, operations director at Ross-shireEngineering, Metallisation’s existing arc spray system had aproven track record in the company, and their knowledge, ex-pertise, and understanding of corrosion solutions, coupled withtheir after-sales service, fit perfectly with the objectives of Ross-shire Engineering. The Flamespray Mark 73 is reliable, easy touse, and offers flexibility. www.metallisation.com. iTSSe

ADVANCED MATERIALS & PROCESSES/MAY 2008 8317iTSSe

JTSTHIGHLIGHTS

The Journal of Thermal Spray Technology (JTST), the official journal

of the ASM Thermal Spray Society, publishes contributions on all

aspects—fundamental and practical—of thermal spray science, includingprocesses, feedstock manufacture,

testing, and characterization. As theprimary vehicle for thermal spray

information transfer, its mission is tosynergize the rapidly advancing

thermal spray industry and related industries by presenting research and

development efforts leading to advancements in implementable

engineering applications of the technology.

JTST editor Christian Moreau has announced that the June issue 17(1) is

a special issue focusing on suspension/solution thermal spray, anemerging technology. Guest editor for

this issue is Prof. Pierre Fauchais, University of Limoges. Several articles

are highlighted here.

In addition to the print publication, JTST is available online through

www.springerlink.com. For more information, please visit

www.asminternational.org/tss.

“Room Temperature Impact Consolidation(RTIC) of Fine Ceramic

Powder by Aerosol Deposition Method and

Applications to Microdevices”

Jun AkedoCeramic integration technology requires

downsizing and/or improvement of device per-formance in many applications, such as in thefabrication of microelectromechanical sys-tems, display devices, fuel cells, optical de-vices, and RF components. For these applica-tions, realization of high-speed deposition rate,low process temperature, and fine patterningin ceramic coating are very important. Theaerosol deposition (AD) method has many ad-vantages for above requirements comparedwith conventional thin-film method or thermalspray coating technology. In this article, ad-vantages of the AD method are highlighted byrealizing a comparison with conventional thin-film methods and thermal spray technology.Challenges are also highlighted. Examples ofintegration of AD method in the fabrication ofelectronic components are also given to showthe ease of use and integration of this methodin the device process flow.

“Technical and Economical Aspects ofCurrent Thermal Barrier

Coating SystemsFor Gas Turbine Engines

by Thermal Spray andEBPVD: A Review”

Albert Feuerstein, James Knapp, Thomas Taylor,Adil Ashary, Ann Bolcavage,

and Neil HitchmanThe most advanced thermal barrier coating

(TBC) systems for aircraft engine and power-generation hot-section components consist ofEBPVD applied yttria stabilized zirconia andplatinum-modified diffusion aluminide bondcoating. Thermal spray ceramic and MCrAlYbond coatings, however, are still used exten-sively for combustors and power-generationblades and vanes. This paper highlights the key

features of plasma spray and HVOF, diffusionaluminizing, and EBPVD coating processes.The coating characteristics of thermal sprayMCrAlY bondcoat, as well as low density anddense vertically cracked (DVC) Zircoat TBC,are described. Essential features of a typicalEBPVD TBC coating system, consisting of adiffusion aluminide and a columnar TBC, arealso presented. The major coating cost elementssuch as material, equipment, and processingare explained for the different technologies,with a performance and cost comparison givenfor selected examples.

“Rare Earth/Metal Composite Formation by

Cold Spray”Peter C. King, Saden H. Zahiri,

and Mahnaz Z. JahediNd2Fe14B permanent magnet/aluminum

composite coatings were produced by coldspray deposition. Isotropic Nd2Fe14B powderwas blended with aluminum powder to makemixtures of 20-80 vol% Nd2Fe14B, and thesemixtures were sprayed at temperatures between200-480°C. The hard Nd2Fe14B particlestended to fracture and fragment on impact,while aluminum underwent severe plastic de-formation, eliminating pores, and trappingNd2Fe14B within the coating. It was found thathigher spray temperatures and finer Nd2Fe14Bparticle sizes improved the retention rate ofNd2Fe14B within the composite structure. Thiswas explained from a contact mechanics view-point by calculating the effect of process pa-rameters on the rebound momentum ofNd2Fe14B particles. The magnetic propertiesof Nd2Fe14B remained unaffected by the coldspray process.

Schematic of aerosol deposition (AD) apparatus.

EBPVD TBC, featuring a plurality of vertical, loosely-bonded columnar grains.

As-deposited aluminum cold spray surface following exposure to coldsprayed Nd2Fe14B particles at 480°Cstagnation temperature; backscatteredimage.


“Tensile Test Specimens with a Circumferential Precrack for Evaluation

of Interfacial Toughness of Thermal-Sprayed Coatings”

Akio Kishi, Seiji Kuroda, Tadanobu Inoue, Takeshi Fukushima, and Hisami Yumoto

A new testing procedure to evaluate the interfacial toughness ofthermal spray coatings has been developed. The newly designed testspecimen is a modification of the pin test with an artificially introducedweak interface, which is expected to open up easily under tensile loadingand serve as a circumferential precrack along the interface between acoating and the substrate. This configuration makes it possible to cal-culate the stress intensity factor K Int at the tip of the precrack, whichcan be expressed as:

KInt = �0 �a • FI(a/R)

where �0 is the apparent average stress, a the crack length, R the spec-imen radius, and F I the geometrical correction function. Finite-ele-ment analysis was carried out to calculate the correction function F I

for various values ofa/R. In the experiments,the flat surface of a pinwas grit-blasted and aring-shaped area fromthe periphery was cov-ered with carbon using apencil and set into amating dice. SUS316Lstainless steel wasplasma-sprayed onto theflat surface of the pin andthe dice. Then, tensile load was applied to the pin to break the weak in-terface containing the carbon and finally the unmodified coating-substrate interface. The load required to pull out the pin was measuredfor various specimen parameters such as a and R. The results indicatethat the adhesion of the tested coatings can be represented by interfacetoughness of 1.9 ± 0.1 MPa m1/2. As a consequence, this testing pro-cedure can be considered as a viable method to evaluate adhesion ofa thermal-spray coating on a substrate.

“Microstructure and Creep Behavior ofPlasma-Sprayed Yttria Stabilized

Zirconia Thermal Barrier Coatings” Reza Soltani, Tom W. Coyle,

and Javad MostaghimiThe purpose of this study was to determine the creep/sintering char-

acteristics of thermal spray zirconia coatings and attempt to understandthe influence of microstructure on thecreep resistance of deposits. Themajor modification, compared withmore typical practice, was employ-ment of a new powder feedstock withagglomerated submicron size parti-cles (Nanox), which is compared toone of the best commercially avail-able powders (HOSP). Thick plasmaspray coatings were prepared, andtheir physical and mechanical prop-erties were characterized. Creep/sin-

tering experiments were then conducted to investigate the response ofthe materials when exposed to high temperatures under load. The re-sults showed that it could be possible to correlate the splat thickness tothe creep behavior of the coatings.

Procedure and configuration of the pintest

SEM images of etchedNanox and HOSP coatingsshowing splat boundaries.

ADVANCED MATERIALS & PROCESSES/MAY 2008 8519iTSSe

804 Newcombe Avenue • Hampton, VA 23669Phone: 757-723-6531 • Fax: 757-723-3925

www.teledyne-hi.com

• Repeatability• Accuracy• Fast Consistent Response

Surface Masking ResinsDymax Corp., Torrington, Conn., offers its SpeedMask masking

resins that provide reliable protection from most surface finishingprocesses including grit blast, peening, plating, acid cleaning, anodizing,plasma spray, high-friction polishing, and painting. SpeedMask resinsare 100% solids, have no nonreactive solvents, and are VOC free. Theyare quickly applied by syringe or through dipping, spraying, and screen-printing, and cure in seconds allowing for immediate use. Residue-freeremoval is achieved through peelable, water soluble, and burn-offgrades. Dymax also manufactures equipment to process SpeedMasklight-curable temporary masking resins. www.dymax.com.

Knoop/Vickers Hardness TestersWilson Instruments, an Instron company, Norwood,

Mass., offers its 400 Series Knoop/Vickers hard-ness testers, which are used to test metals, ceramics,and other nonmetallic materials.The testers areavailable with manual or automatic turrets for greater useflexibility, and feature eight dial-selectable test forcesranging from 10 to 1,000 g. An optional 2,000-g test forcesystem is also available. Optics offer total magnifica-tion of 100 and 400×, which allows clear, effortlessmeasurement of the test indention. For easy samplemounting and test point location, the instruments areequipped with a 100 mm × 100 mm precision x-yaxes stage with a 25 mm movement in each direc-tion. www.wilsoninstruments.com.

NeoScope Benchtop SEMNikon Instruments, Melville, N.Y., and JEOL, Tokyo, Japan, in-

troduce the NeoScope benchtopSEM that extends the depth of fieldand resolution far beyond the opti-cal microscope. The NeoScope, tar-geted at the bioscience research andindustrial inspection communities,fills the optical microscopist’s needfor advanced imaging capability that is both affordable and easy to use.Offering higher magnification without loss of depth of focus, the Neo-Scope will help accelerate the pace of research in the life sciences,forensics, and failure analysis of manufacturing materials. The Neo-Scope images both conductive and nonconductive samples withoutspecial preparation. It operates in both low and high vacuum modesand has three settings for accelerating voltage suitable for a varietyof applications. www.nikonusa.com.

SiC Sputtering TargetsThe CVD Materials business of

Morgan Advanced Ceramics (MAC),Bedford, Ohio (North American of-fice), introduces high-purity silicon-carbide (SiC) sputtering targets forphysical vapor deposition (PVD) ap-plications. The sputtering targets en-able the deposition of high-purity SiCthin films for demanding applications such as the manufacturing ofmagnetic disk drive heads. Dielectric SiC films deposited from thesetargets have higher density and thermal conductivity and lower expan-sion coefficient than dielectric aluminum oxide films, enhancing de-vice performance and enabling new device design structures. The highthermal conductivity allows using high-power process conditions toachieve a fast SiC film deposition rate via RF diode and RF or DC mag-netron sputtering. www.morganadvancedceramics.com.

Expanded Line of Sputtering TargetsGoodfellow Corp., Oakdale, Pa., the North American subsidiary

of Goodfellow Cambridge Ltd., offers sputtering targets in 62 differentmetals and alloys, as well as compounds such as borides, carbides, flu-orides, nitrides, oxides, selenides, silicides, sulphides, and tellurides.In addition, the surfaces of flat sheets up to 80 mm × 400 mm (3 × 15.75in.) can be heat treated, remelted, or alloyed using a continuous thermalprocess. Thin layers of metals or oxides can also be melted onto the surface, which is especially suited for the creation of double-layersheets and foils, or for ceramic superconductors on metallic or ceramicsubstrates, and for the creation of thin layers of solder on metals.www.goodfellow.com.

TECHNICAL RESOURCESMasking Tapes for Thermal Spray

DeWAL Industries, Saunderstown, R.I., offers a color brochure de-scribing a broad range of high performance masking tapes widely usedin the thermal spray industry to cover both sharp edges and intricatepart shapes. The brochure provides specifications and lists pertinentfeatures of non-carbonizing, aggressive-adhesion tapes used for gritblasting, ceramic, plasma and arc spraying, as well as HVOF. High-temperature applications are described for tapes as different as double-sided adhesive-coated glass fabric and silicone-coated double-ply com-posites of glass fabric and aluminum foil. The brochure also illustratesthe masking of channels and the application of elasticity-controlledplasma tapes. For a free brochure or more information, visit www.dewal.com.

There’s nothing commonabout this Cold (HpCS).

Extend your equipment’s life with High Pressure Cold Spray (HpCS) technology from ASB Industries.

ASB partners with CGT for North American equipment sales and Linde Gas to optimize coating properties and extend the range of possible materials – from copper, nickel, metal matrix composites and tantalum to niobium, titanium and more. All to produce the

most oxide-free tenacious surface coatings possible.

©2008 ASB Industries, Inc.

ASB Industries, [email protected]

Catch the Cold. Sign up for our Enewsletter at asbindustries.com today!

PRODUCTSPRODUCTS


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Gain exclusive, valuable access to this industry through these new media channels. Space is extremely limited. When they’re gone…they’re gone.

Get online today. Go to www.asminternational.org/access.

In print. Online. Or at the show. It’s all about ACCESS.

Target Your Customers with New, Exclusive Thermal Spray Society Online Marketing Solutions.ASM International has developed new and enhanced online products that mirror the evolving ways in which today’s business professional accesses information to make buying decisions.

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TSS CommunityExclusive Total Site SponsorshipOnly one sponsor per month.

TSS SprayTipsTutorial for the Thermal Spray ProfessionalLaunching May 2008. Twice monthly.Exclusive sponsorship opportunity.Only one sponsor per TSS SprayTips.

Celebrating 75 Years of Teamwork…

This year, 2008, marks the 75th year of the founding of the Metallizing Engineering Company, now known as Sulzer Metco.

We could tell you about our history, and the many thermal spray visionaries

who founded the many companies that later became Sulzer Metco, but

for that, you can read the history page on our web site. We could tell you

how young we are compared to our 174 year old parent corporation, Sulzer.

We could tell you about all of the technological innovations Sulzer Metco,

and our founding companies before us, brought to the thermal spray indus-

try. Or, we could tell you about the dedication and talent of our more than

1900 employees worldwide. Without doubt, all of these things define

Sulzer Metco.

Instead, we want to tell you about the foundation of any successful

company – you, our customer. Your continuing patronage, and devoted

loyalty to our organization throughout our 75-year history, have defined

Sulzer Metco and our extensive product portfolio.

When Rea Axline opened the doors of the Metallizing Engineering Compa-

ny during the Great Depression of 1933, industry needed a way to increase

component service life by preventing corrosion and salvaging worn parts

to serviceable condition. During World War II, our customers needed alter-

natives to materials that were difficult to source. As the size of passenger

aircraft grew, so did the critical concepts of fuel-to-weight ratios and un-

precedented safety, prompting the need for new classes of thermal spray

materials that included abradable materials and MCrAlY’s. Many of these

materials have chemistries that were specifically developed by our

customers.

To apply these new materials and achieve the surface properties that our

customers needed led to new thermal spray processes such as atmosphe-

ric plasma spray, chambered plasma spray and HVOF. In each case, a Sulzer

Metco company, such as Metco, Alloy Metals or EPI, in partnership with our

customers, brought these technologies to the marketplace. As customers

demanded better process control and repeatability, Plasma Technik, another

company that is part of Sulzer Metco’s heritage, developed the first truly

automated spray cells.

Today, our customers tell us they need faster processing speeds, less mate-

rial waste and even greater reliability. In addition, customers must meet

evermore stringent environment and safety regulations. To remain competitive,

our customers also require surfaces that keep the components they market

in service longer, with better performance than ever before. An example are

cylinder bore coatings on aluminum engine blocks, for automobiles that are

lighter, more fuel efficient and have improved on-road life. To apply these

coatings with the highest efficiency, fully automated, in-line production

systems were developed, that feature our MultiCoat® controller and multiple

spray guns manipulated by Sulzer Metco’s RotaPlasma®. TriplexPro®-200,

our new triple cathode plasma spray gun, can apply coatings at speeds and

deposit efficiencies that are up to 300% better than previous technologies,

and go more than 200 hours without maintenance.

As our world continues its technological advance, new industries arise that

need new surface solutions. Such is the case with solid oxide fuel cells.

Here, our customers need very thin, very dense ceramic coatings that can

be quickly applied to large surface areas. Sulzer Metco’s LPPS®-TF techno-

logy shows great promise in meeting these needs, applying fully dense ce-

ramic coatings that are only 10 μm thick at the rate of one square meter

per minute.

As you can see, the challenges set before us by our customers over the

past 75 years are our legacy. As our future is fully reliant on helping our cus-

tomers to succeed, we hope you will continue to present us with new and

exciting surface technology challenges in the future. We certainly look

forward to it.

The employees of Sulzer Metco join together to say,

www.sulzermetco.com

©2008 Sulzer Metco

international thermal spray and surface engineering

Documents