METAL SPRAYING / METALLIZING / FLAME SPRAYING THERMAL SPRAYING

Definitions
Metallizing or Metal Spraying is the process of applying molten metal to a base metal surface in the form of a fine spray that bonds to the base metal and forms a metal coating. Flame Spraying defines the deposition of materials, both metallic and non-metallic, by the use of a combustion flame. Thermal Spraying is a process that deposits finely divided particles of metals, intermetallics, metallic oxides or plastics in the molten or semi molten condition to form an adherent coating on a suitable substrate.

Surface properties of material/part

Wear

mechanical; corrosive-mechanical. Criteria: wear resistance (by mass/volume, relative)

Methods of surface reinforcement

peening; surface alloying and hardening; coatings (sprayed coatings, vapor deposited coatings, cladded coatings, galvanic coatings, diffusion coatings); metal cladding (bimetal materials).
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Coatigns processes
CHEMICAL
ELECTROCHEMICAL THERMOCHEMICAL

THERMOCOATING
VAPOR DEPOSITION MECHANICAL

Comparison of the coating processes

Thermal spray methods

Thermal spraying

CHEMICAL ELECTROCHEMICAL THERMOCOATING VAPOR DEPOSITION MECHANICAL

cold gas spraying (CGS)

laser spraying (LS)

molten-metal flame spraying

Sprayed coatings structure

Typical structure of a coating

Sprayed coatings materials

Surface Preparation
(i) Rough threading, (ii) Grit blasting, (iii) Electric bonding, (iv) Studding, (v) Sanding or grinding, (vi) Rough machining or grooving, (vii) Spray bonding (molybdenum and exothermically reactive materials)

Flame spraying

WIRE SPRAYING

- flame temperature: acetylene/oxygen 3160 C; propane/oxygen 2850 C; hydrogen/oxygen 2660 C.

- sprayed materials: wire: metals and metal alloys; powder: pure metals, alloys, oxides, cermets, composite powders.

POWDER SPRAYING
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Arc spraying

temperature inside the arc: 6500 C; voltage 18 40 V, current 50 150 A; sprayed materials: electroconductive alloys, ceramics can be deposited, when using core wires.

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Plasma spraying

plasma temperature: up to 30000 C. virtually all existing materials.

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Plasma transfered arc spraying (PTA)

Fe, Ni, Co, Cr based alloys, stainless steels, cermets

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Laser cladding

virtually all metal alloys, cermets and ceramics.

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Detonation gun spraying

flame temperature: 4000 C.

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High-velocity oxy fuel spraying (HVOF)

gas temperature: 3000 C; sprayed materials: virtually all existing materials, in practice mostly carbide/metal and carbide / self-fluxing alloy mixtures.

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Cold spraying

gas temperature: under the phase transition temperature; sprayed materials: pure Al, Zn, Cu, Ni and babbites.

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Thermal energy vs. kinetic energy in thermal spray

WARCS

Wirearc Spray PS FS Plasma Spray Flame Spray

Thermal Energy

Melt or partially melt

HVOF

High velocity oxy fuel

Solid
Kinetic Energy

CS

Cold Spray

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Applications of Sprayed Coatings

Sprayed coatings are applied, to: Obtain corrosion resistance by spraying Zn and Al. Build up worn out surfaces of machine components e.g. motor armature shafts. Mechanically size a component that has not been produced to correct specifications. Hard face a component to achieve desired hardness, wear resistance, etc. Provide thin coatings of noble metals to small areas where conventional plating would not be economic. Obtain reflecting surfaces (e.g. AI is sprayed on the back of glass). Obtain conductive surface on a poor conductor (e.g. Cu or Ag is sprayed on glass or plastics). Provide decorative effects on architectural works.
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Applications (1)

wear resistant coatings (pumps, compressors, camshafts, etc.) except for cold spraying; corrosion resistant coatings (pipelines, building constructions, etc.);

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Applications (2)

temperature resistant and dielectrical coatings (gas turbines, flue tubes); antifriction coatings (sliding bearings); size restoration (shafts, bearings, etc.)

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Applications (3).
HVOF sprayed pot rolls for continuous galvanizing line for steel strips.

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Applications (4)
Sprayed coatings in an aircraft engine

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Applications (5)
Process automation. Flame spraying by Kuka robot.

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Advantages of Sprayed Coatings

Porosity and oil retention capacity of the sprayed metal is a major advantage of sprayed coatings. A metal of the right characteristics can be surfaced at a particular point only where needed. During spraying, the parts are kept cool there by avoiding the danger from warpage. For corrosion resistance purposes, Zn and Al can be applied to any practical desired thickness.
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Disadvantages of sprayed coatings

All sprayed metal is brittle and therefore is limited to use on machine elements where it is not necessary for the coating to add strength.

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THANK YOU

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