Thermal-spray coating processes

Petr LOUDA

IntroductionThe trend in mechanical engineering has long been characterized by

conflicting requirements: on the one hand, customers want increasingly compact and
lightweight parts while on the other hand, more stringent rewuirements are being
imposed on engineered parts in terms of performance, reliability, and service life. In
addition, customers insist on reducing energy consumption and the use of
ecologically safer coolants, lubricants and similar consumables in the smallest
possible quantities.
Extreme requirements must be fulfilled by the components and component
surfaces of machines with key functions, whose failure would cause considerable
downtime expense. The same applies to systems built for longevity and/or high
operating reliability.
The surface is whats important
One decisive criterion for the functional reliability and longevity of precision
components is their frictional behavior, largely determined by the properties of their
surfaces. Accordingly, great importance is attached to the wide range of surface
treatment methods which improve the wear resistance of parts and raduce friction.

Major thermal-spray coating processes

! Plasma spray: Uses a plasma-forming gas (typically argon or nitrogen) as both
the heat source and propelling agent for the coating material. A highvoltage arc
struck between an anode and cathode within the gun ionizes the gas, which is
then forced through a convergent/divergent nozzle. As the gas exits the nozzle, it
reverts to its natural state, liberating large amounts
of heat. Powdered coating material is injected into
the hot gas stream, where it is melted and
projected at high velocity onto a prepared
substrate. Advantages: Coatings are dense and
strongly bondede to the substrate. In general, they
have higher intergrity and perform better than
coatings
applied
by
other
thermal-spray
processes.

! Wire flame spray: Applies coatings of any metal that can be drawn into a wire
and has a melting point below that of a combustion flame. Drive rolls feed the
wire through a flame-spray gun to its nozzle.
There the wire is melted in an oxygen/fuel-gas
(oxyfuel) flame. Compressed air atomizes the
metal and projects it onto a prepared surface.
Advantages: Best choice for all-purpose
spraying. Coatings can be applied rapidly and
at low cost.
! Electric-arc spray: Applies metal coatings in wire form. Push/pull motors feed
two electrically charged wires through the spray gun. When their tips touch at the
gun head, an arc is created which melts the wires at temperatures above 3,980
C. Compressed air atomizes the molten metal and
projects it onto a prepared surface. Advantages:
Excellent choice for applications that require a thick
coating or where large areas must be sprayed.
Builtin flexibility permits tailoring of coating
characteristics, such as hardness and sufrace
texture.
! Poxder flame spray: Applies coatings of metals, alloycarbides, oxide ceramics,
and cermets. Powder is gravity - or pressure-fed
into the gun and carried to the nozzle where the
oxyfuel flame melts and projects it onto a prepared
surface. Advantages: Wide range of coating
materials makes this process wellsuited to
applications requiring high wear resistnace, a
combination of wear and corrosion resistance, and
heat or oxidation resistance.
! High-velocity oxyfuel (HVOF): Uses high-velocity combustion of mixtures of
oxygen and a fuel gas to heat and propel semimolten-to-molten powdered
materials. The sprayed particles impact the substrate with extremely high kinetic
energy and
with
negligible
owidation
of
the
coating
material.
Advantages: Compared with other thermalspray processes, the HVOF method
produces coatings that have the highest
bond strength and lowest porosity. Coatings
also have low internal stresses, which allow
thick layers to be deposited, and fine assprayed surface finishes. HVOF is well
suited to producing high-quality tungstenand chromium-carbide coatings.

Table 1: Property and characteristic of major Thermal-spray coating processes.

Comparison of major
Thermal-spray coating processes
Process
Property or
characteristic

Bond
strength
[Mpa]
Density,
%that
of equivalent
wrought
material

Hardness

Rermeability

Coatingthickness
limitation
[mm]

Wire
flame
spray

Powder
flame
spray

Electric
arc

Plasma
spray

Highvelocity
oxyfuel
(HVOF)

Ferrous met.
Nonferrous
metals
Self-fluxing
alloys
Ceramics
Carbides

14

28

41

34+

62

21

21

41+

34+

70

69+

62

14-34

21 +

34-48

55-69

83+

Ferrous met.
Nonferrous
metals
Self-fluxing
alloys
Ceramics
Carbides

90

90

90

95

98+

90

90

90

95

98+

100

100

95

95+

90

95+

98+

Ferrous met.
Nonferrous
metals
Self-fluxing
alloys
Ceramics
Carbides

35 HRC

35 HRC

40 HRC

40 HRC

50 HRC

40 HRC

20 HRC

80 HRB

40 HRC

55 HRC

30-60 HRC

60 HRC

50-65 HRC

50-70 HRC

50-60 HRC

50-60 HRC

65 HRC

Ferrous met.
Nonferrous
metals
Self-fluxing
alloys
Ceramics
Carbides

Medium

Medium

High

Low

Negligble

Medium

Medium

High

Low

Negligible

None

None

Medium

Low

Low

Low

Negligible

Ferrous met.
Nonferrous
metals
Self-fluxing
alloys
Ceramics
Carbides

1.25-2.5

1.25-2.5

1.25-2.5

1.25-2.5

1.25-2.5

1.25-5

1.25-5

1.25-5

1.25-5

2.5-5

0.4-2.5

1.25

0.4

0.4

0.4

0.4

0.6

Coating
type

General requirements

The reliability, economy and quality of the powder coating process are highly
influenced by the characteristics of the powder spray gun. Table 2 shows the
technical objectives and consequences in optimzing the powder application with
regard to a reliable powder coating cycle.
Table 2: Technical objectives in optimizing powder application.
Technical objectives in
Consequences with respect to powder coating
optimizing powder
cycle reliability, economy, and film appearance
application
Low powder feed rate and smali quantity
High transfer efficiency during
of overspray small
powder deposition on the
Quantity of powder circulating in the powder
workpieces
coating line:
" reduced contaminants introduction in the
circulating powder
" reduced agglomeration and separation of
powder particles
" reduced air volume in the booth (booth size!)
! avoidance of unnecessary powder consumption
Avoidance of local excess
due to (locally)
film thickness on substrates
high film thickness
! low powder feed rate and small quantity
of overspray
! avoidance of visible differences in appearance
Avoidance of accumulation of fines in the powder
Minimization of particle size
coating line:
separation during powder
" avoidance of shift in transfer efficiency and film
deposition on the workpieces
thickness
" avoidance of problems regarding powder
fluidization and feeding, filter clogging, etc.
" avoidance of coating defects
(e. g., agglomeration, impactfusion)
References:
[1] CUDAZZO, M.: New Approaches in Improving the Reliability of Power Application
and Recovery, PCE 2000, Amsterdam, (2000)
[2] DEMBOVSK, V.: Plazmov metalurgie, Praha, SNTL, (1978)
[3] BROSZEIT, E.: Plasma Surface Engineering, DGM Informationsellschaft,
Oberursel, (1989).
Petr LOUDA, Katedra materil, Technick univerzita v Liberci,
Hlkova 6, 461 17 Liberec, tel. (048)535 3116, E-mail: petr.louda@vslib.cz.