Thermal Sprayed Coatings
Manish Roy
Department of Metallurgical and Materials Engineering
National Institute of Technology, Jamshedpur
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Definition
Thermal spraying is an industrial process that applies materials onto
a substrate to improve surface properties using heat to melt or soften
feedstock material which is then propelled at high velocity to form
a strong, adherent, layered coating.
Features
Excellent protection against
Repair or refurbishment
Versatility
Possible to deposit thick Coating.
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History of Thermal Spraying
1910, Dr. Schoop
1912, Flame Spraying
1958, Detonation Spraying, Union Carbide
1960, Atmospheric Plasma Spraying
1970, Vacuum Plasma Spraying
1980, Low Pressure Plasma Spraying
1980, High Velocity Oxy Fuel
1982, Jet Kote Spraying
1990, Cold Spraying
2006, Warm Spraying
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Classification of Thermal Spraying
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Operating Window of Thermal Spraying
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EPD or E-deposition
It is a rapid, cost-effective, and versatile colloidal processing technique
where charged particles suspended in a liquid medium migrate under
an electric field and deposit onto an oppositely charged electrode to
form a dense coating or film. It is commonly used for creating
ceramic, metallic, and polymer coatings, often followed by sintering.
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EPD
Features
Particles suspended in a solvent gain a surface charge and move
toward an electrode (cathode or anode) under a DC electric field.
Widely used for creating coatings, thin/thick films, nanomaterials,
biomaterials, and ceramic composites.
High efficiency, ability to coat complex geometries, precise
control over coating thickness and structure, and suitability for
various materials
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Cold Spraying
Cold spraying (or cold gas dynamic spraying) is a high-velocity
coating/repair process that uses supersonic gas (300-1400 m/s)
to accelerate solid metal powders (1-50 mm) on to a substrate
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Features
Powder particles are injected into a pressurized, heated gas
stream (nitrogen, helium, or air) and accelerated through a
convergent- divergent nozzle to supersonic velocities.
Upon impact, the kinetic energy causes rapid plastic deformation
and fracture of oxide layers, creating a strong metallurgical bond,
even though the process operates below the melting point of the
material.
Because it is a "cold" process, it prevents thermal degradation,
oxidation, or distortion of the substrate. It allows for high-rate
deposition of materials like aluminum, copper, titanium, and nickel
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Microstructure of Ni-Cr Coating
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Detonation Spraying
Detonation Spraying (D-gun) is a high-velocity thermal spray process
that uses controlled, repeated explosions of oxygen-fuel gas (typically
acetylene) to heat and propel powder materials onto a substrate at
supersonic speeds (>800 m/s).
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Detonation Spraying
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Detonation Spraying
Features
Powder, oxygen, and fuel are injected into a water-cooled
gun barrel and ignited by a spark. The resulting detonation
wave melts the powder and accelerates it, depositing it onto
the surface in overlapping, thin, circular layers
Particles travel at supersonic speeds, exceeding 800-1000 m/s.
Coatings have high density, porosity typically less than 1%.
Produces strong adherence between the coating and substrate.
Processes operate at temperatures around 4000 °C
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J.P. 5000 Spraying
Microstructure of NiCr-Cr2C3 coating obtained
by JP 5000 gun
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Jet Kote Process
WC-Co Coating
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Continuous Detonation/Top Gun Spraying
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Plasma Spraying
Plasma spraying is a high-temperature thermal coating process that
uses a plasma jet, reaching up to 15000oC, , to melt materials
(metals, ceramics) and spray them onto a surface, creating dense,
durable coating
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Plasma Spraying
Features
An electrical arc (usually argon or hydrogen gas) creates a plasma
jet. Powdered coating material is fed into this jet, melts, and is
propelled at high speeds onto a substrate, where it cools instantly
Enables the application of materials with high melting points.
Produces dense and well-adhered coatings.
It is a versatile process
Applied for aerospace, automotive and medical usages.
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Comparison of D-Gun, HVOF and Plasma Spray
Plasma sprayed WC-Co coating
Plasma sprayed TBC system
Detonation sprayed WC-Co coating
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Plasma Sprayed Components
Roller of paper mill
Aviation components
Textile components
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High Velocity Air Fuel
HVAF is a thermal spray process that uses compressed air and
fuel (like LPG) to accelerate coating particles to high velocities
(600–840 m/s) at lower temperatures than HVOF, producing
dense, low-oxide coatings.
Combines compressed air with fuel to create a low-temperature,
high-velocity gas stream that melts or softens particles and sprays
them onto a substrate.
Attributes
1) High Density and low oxides
2) Cost Effective
3) High Materials Efficiency (Fine powder)
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High Velocity Air Fuel
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High Velocity Air Fuel
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HVOF UHVOF HVAF
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High Velocity Air Fuel
Tensiometer Roll Coated with 1.8 mm WC-10 Co-4 Cr
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High Velocity Air Fuel
Sulphur Condenser Vessel of Refineries Coated with Hastalloy
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High Velocity Air Fuel
Hydraulic Rod of Dock Cranes Coated with WC-10 Co-4 Cr
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Recent Development of Thermal Spraying
Cold gas dynamic spray
Electromagnetic powder deposition technique
Suspension thermal spraying
Hypersonic plasma particle deposition
Hybrid thermal spraying
a) Plasma Spray-PVD
b) Plasma Spray-CVD
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JP 5000 Gun
Jet Kote Gun
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Thank You
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