Future Development of Thermal Spray Coatings

Types, Designs, Manufacture and Applications

Nuria Espallargas

• Publisher: Woodhead Publishing
• Year: 2015
• ISBN:
  9780857097743
• Topic: Physical Sciences
• Subtopic: Industrial & Technical Chemistry

Future Development of Thermal Spray Coatings discusses the latest developments and research trends in the thermal spray industry. The book presents a timely guide to new applications and techniques.

After an introduction to thermal spray coatings by the editor, Part One covers new types and properties of thermal spray coatings. Chapters look at feedstock suspensions and solutions, the application of solution precursor spray techniques to obtain ceramic films and coatings, cold spray techniques and warm spray technology amongst others. Part Two of the book moves on to discuss new applications for thermal spray coatings such as the use of thermal spray coatings in environmental barrier coatings, thermal spray coatings in renewable energy applications and manufacturing engineering in thermal spray technologies by advanced robot systems and process kinematics.

• Timely guide on the current advancements and research trends in thermal spray technology
• Reviews different types of thermal spray coatings
• Presents a wide variety of applications for this emerging technology

1

Introduction to thermal spray coatings

N. Espallargas

Abstract

The goal of this book is to show the new trends and future of thermal spray technology and applications focusing on new developments and research trends in thermal spray. There are many new areas of research and techniques being looked into at the moment. These techniques are spreading and the applications of thermal spray coatings are increasing rapidly, and it is therefore an area of great interest. This book will cover the new types of coatings and new feedstock manufacturing techniques, followed by a section looking at design and manufacturing techniques. This book will conclude by covering some of the new applications that thermal spray coatings are now used for. This chapter will show the current status of thermal spray and an overview of the current knowledge around the most commonly used thermal spray techniques. The aim of this chapter is to introduce the reader to the thermal spray technology starting with a short historical summary. A market overview and future possibilities for thermal spray technology will be briefly introduced at the end of the chapter.

Keywords

Thermal spray

Coatings

Market

Future trends

1.1 Introduction and historical overview of thermal spray

Thermal spray is a technology that involves a group of techniques and coating processes that improve the performance of a component by adding functionality to surfaces. Thermal spray techniques aim at increasing the lifetime of materials compared to their structural mechanisms of breakdown or to provide them with a specific property (e.g. optical and electrical). Thermal spray is a very versatile technology that can be used in many types of applications and virtually almost on any component. This is why it has grown to become a large worldwide market of several billion dollars since the first produced coatings in the early years of the twentieth century. Its versatility makes this technology suitable for use against wear, corrosion and aggressive and high-temperature environments and for repair and restoration of components.

In the late-nineteenth century and early-twentieth century, Dr. Max Ulrich Schoop (Zurich, Switzerland) and collaborators worked on the development of a series of equipment able to melt and propel metals in the form of powder towards surfaces to produce a coating. In the beginning of this invention, only metals with low melting point were used (i.e. tin and lead) and the process was called metallizing (Hermanek, 2014; Davis and Davis & Associates, 2005). Some years and patents later, Dr. Schoop and collaborators produced the first thermal spray device for spraying metal wires. This system was based on the melting of a metal wire in a flame generated by the combustion of fuel with oxygen. The melted metal was afterwards atomized by a compressed gas that propelled the metal droplets onto a substrate to build up a coating. This technique is known nowadays as flame spray, and it has been the basis for the development of more advanced techniques such as the high-velocity oxygen fuel (HVOF) in the late 1970s and establishes the big family of the combustion thermal spray techniques (Figure 1.1). In view of the need for new types of metals for corrosion protection, Dr. Schoop's group introduced the electric arc as an improvement in the metallizing technique. The electric arc allowed spraying metals with higher melting points (i.e. steel, zinc and stainless steel), being the basis for the development of the second big family of thermal spray techniques based on the use of electrical energy (Figure 1.1). The third and latest family of thermal spray techniques started in the 1980s, and it is based on solid-state spraying; this is propelling the feed...

Table of contents

• Cover image
• Title page
• Table of Contents
• Copyright
• List of contributors
• Woodhead Publishing Series in Metals and Surface Engineering
• 1: Introduction to thermal spray coatings
• Part One: Thermal spray coatings: New types and properties
• Part Two: New applications of thermal spray coatings
• Index