Thermal spray coatings enhance the surface characteristics of different components, the surfaces can be enhanced for several desired properties including corrosion and/or wear resistance, electrical insulation, high temperature oxidation protection among many others while effectively improving part performance.
Choosing the right thermal spray coating and optimum coating process technique is key to realizing the full benefits of this technology. At Fisher Barton, our TST Engineered Coating Solutions division offers several options for thermal spray coating application techniques, each offering superior quality and a diverse range of benefits. We’ll share some key considerations, different coating methods, and material options to help you select the best option for your next project.
PROJECT SPECIFICATIONS
Thermal spray coatings can meet a range of requirements; however, there are several important factors that go into selecting the right coating option for your application:
Component Material
First, you’ll want to think about the type of surface you’ll be coating. Many plastics, composites, ceramics, and metals are compatible with the versatile coating process.
Environmental Exposure
Determining the conditions the coating must endure is key to improving the performance of the coated component.
Key Performance Characteristics
You’ll want to consider the desired coating characteristics for your application. These might include corrosion protection, electrical Insulation, protection from high temperatures, or wear resistance.
Other important considerations include cost needs and the specific thermal spray process’s capabilities and limitations.
COATING TECHNIQUES
With more than a century of technical expertise, Fisher Barton has the necessary capabilities to provide thermal spray coating services for a range of applications and purposes. The thermal spray processes we can utilize include the following:
HIGH-VELOCITY OXYGEN FUEL (HVOF)
Thermal coating techniques incorporating high-velocity oxygen fuel (HVOF) rely on confined combustion to accelerate and heat powdered materials. HVOF operating conditions use the thermal energy created by fuel combustion and kinetic energy produced by hypersonic gas velocities to achieve a thermal coating with the following benefits:
- Corrosion Resistance
- Excellent Adhesion
- High Density
- Low Porosity
- Surface Hardness
- Wear Resistance
PLASMA SPRAYING
Plasma spraying can be used to coat a range of materials, including metals, ceramics, and polymers, with a high bond strength and customizable properties. It utilizes a DC electric arc to ionize a gas (plasma) and generate a high-temperature heat source. The heated plasma heats and accelerates a powder to create a softened molten material. When sprayed onto the surface of a workpiece, the molten powder rapidly solidifies to form a dense, hardened, and durable coating.
FLAME SPRAYING
Flame spraying is an economical thermal process that employs combustion to melt wire, powder or rod material. Much like arc spraying, the molten material is atomized and then propelled onto the surface of a component via dry compressed air. However, this technique creates less dust and fumes.
Flame spraying offers moderate spray rates and is considered one of the most cost-effective methods for thermal coating. It can provide excellent protection against wear, abrasion, and corrosion to extend the lifespan of the coated component.
ARC SPRAYING
Arc spraying is both productive and economical, and exhibits the highest deposition rate out of all the thermal coating spray processes. DC power and an electric arc are required for coating application, as well as a consumable feedstock in the form of a conductive wire. Arc spraying requires less power than other thermal spray coating methods and is ideal for applications that require:
- Excellent bond strength
- Substrate metalizing
- Thermal sensitivity
MATERIALS
At Fisher Barton, we work with the following materials to provide our clients with precision thermal spray coating services:
ABRADABLES
Abradable thermal spray coatings consist of soft materials that deliver low structural integrity. They are typically used on the internal walls of gas turbines and jet engines to provide a tight clearance control between the coated walls and blade tips. The tip preferentially abrades or wears into the softer coating.
Abradable thermal spray coatings can be engineered to perform in different temperature ranges and can be used to improve efficiency in combustion or compressor engines.
CARBIDES
Carbides are very hard ceramic materials that are cemented together with metals such as cobalt, cobalt/chrome, and nickel. These carbide cermets can be turned into coatings to create extremely hard surfaces. Metal carbides provide excellent wear resistance and exhibit high hardness properties, making them best suited for several wear resistant coating applications.
Tungsten carbide is often used in thermal spray coatings to protect against factors like abrasion, erosion, fretting, and galling, with other common carbides including:
- Chromium carbide (Cr3C2)
- Tantalum carbide (TaC)
- Titanium carbide (TiC)
Cemented carbides consist of metals, such as nickel or cobalt to produce a greater toughness than pure ceramic or carbide.
CERAMICS
Ceramics typically consist of one of the following materials:
- Carbide
- Metal oxide
- Nitride
These are hard, brittle substances that can withstand high temperatures (from 1,000 ºC to 1,600 ºC), with advanced ceramics often used in medical or electrical applications to provide a dependable layer of electrical or thermal insulation. Most ceramics are engineered to resist chemicals and heat, making them ideal for highly corrosive, refractory, or wear-resistant applications.
METALS AND METAL ALLOYS
The following materials are commonly utilized in thermal spray processes:
- Ferrous metals
- Non-ferrous metals
- Metal alloys
- Pure metals
Titanium-based alloys, molybdenum, nickel, iron, and steel can harden a surface and provide ongoing protection from abrasion and wear. Aluminum, zinc, and other non-ferrous metals can effectively treat steel surfaces through galvanic and anodic coating to improve their corrosion and oxidation resistance.
CONTACT THE EXPERTS AT FISHER BARTON
With decades of proven experience, Fisher Barton Group is a trusted manufacturing partner renowned for advanced surface engineering capabilities. Our highly talented engineers and designers are innovators in material behavior and have the necessary skills and expertise to develop invaluable proprietary thermal spray coating solutions for the markets we serve.
This transformative and innovative approach extends the lifespan of many components, going well beyond our core manufacturing capabilities, which include:
Bending
Casting
Cutting
Forming
Machining
Stamping
Welding
Contact us today to learn more about our world-class thermal spray coating services and how they can meet the demands of your next project. Our skilled team is ready to help and would love to discuss any application challenges or technical questions you may have.
