Handbook of Thermal Spray Technology

Contents......Page 8
Introduction to Thermal Spray Technology and Surface Science......Page 10
Characteristics of Thermal Spray Coatings......Page 12
Thermal Spray Processes and Techniques......Page 14
Materials for Thermal Spray......Page 16
Markets and Applications......Page 17
Appendix: Historical Development of Thermal Spray Processing and Equipment......Page 18
Developments after World War II......Page 19
How Surfaces Interact with Their Environments......Page 23
Surface Hardening......Page 27
Thermochemical Treatments......Page 29
Electrochemical Treatments......Page 31
Hot Dip Coating......Page 33
Chemical Vapor Deposition (CVD)......Page 34
Physical Vapor Deposition (PVD)......Page 35
Thermal Spray Processes......Page 38
Hardfacing......Page 39
Comparison of Major Coating Methods......Page 41
Specifications, Standards, and Quality Control for Coatings......Page 45
Further Literature Sources for Thermal Spray......Page 48
Coatings, Equipment, and Theory......Page 50
Introduction to Coatings, Equipment, and Theory......Page 52
Thermal Spray Process Classification......Page 53
Processing Characteristics......Page 54
Splat......Page 56
Oxide Stringers......Page 57
Porosity......Page 58
Thermal Spray Coating Properties......Page 60
Thermal Spray Materials......Page 61
Flame Spray......Page 63
Detonation Gun......Page 64
High-Velocity Oxyfuel Spray (HVOF)......Page 65
Electric Arc Spray......Page 69
Plasma Spray......Page 71
Controlled-Environment Spraying......Page 79
Other Significant Plasma Spray Processes......Page 81
Emerging Developments in Thermal Spray Devices......Page 82
Cold Spray Process......Page 86
Deposition Efficiency and Coating Properties......Page 87
Coating Materials and Applications......Page 88
Conclusions......Page 91
Process Parameters......Page 94
Material Feed......Page 95
Powder Characteristics......Page 97
Powder Pulsing......Page 99
Gas Flow Measurement and Control......Page 100
Gas Quality Issues......Page 102
Thermal Spray Controls......Page 103
Plasma Arc Starting Problems......Page 104
Ancillary Equipment......Page 105
Ventilation and Heat Exhaust......Page 108
Noise......Page 109
Other Potential Safety Concerns......Page 110
Processing and Design......Page 112
Advantages and Disadvantages of Thermal Spraying......Page 114
Part Configuration and Coating Location......Page 117
Surface Preparation......Page 119
Preheating......Page 126
Spray Pattern......Page 129
Coating Buildup......Page 130
Process Variations......Page 132
Torch and Substrate Motion......Page 133
Statistical Design Techniques......Page 135
Information Management......Page 136
Finishing......Page 137
Densification......Page 138
Inspection......Page 139
Materials Production for Thermal Spray Processes......Page 142
Terminology......Page 144
Summary......Page 145
The Powder Feeding Problem......Page 146
Powder Feeding Systems......Page 147
Feedstock/TC Heat Source Interactions......Page 149
Process Parameter Problems and Health Concerns......Page 150
Classification According to Thermal Spray Process......Page 151
Classification According to Material Morphology......Page 152
Classification According to Chemical Nature of the Material......Page 154
Classification According to Applications......Page 155
Crushing and Milling......Page 156
Atomization......Page 159
Chemical Techniques......Page 162
Particle Morphology and Porosity......Page 168
Particle Classification Methods......Page 170
Quality Control and Feedstock Material Specification......Page 173
Applications for Thermal Spray Processing......Page 178
Coatings for Wear Resistance......Page 180
Coatings for Corrosion Resistance......Page 182
Thermal Spray Processes Described in the Article......Page 184
Aerospace Applications......Page 185
Thermal Spray Coatings for Land-Based Turbine Applications......Page 190
Automotive Applications......Page 193
Biomedical Coatings for Orthopedic and Dental Implants......Page 198
Glass Contact Coatings......Page 200
Corrosion Applications for Marine and Land-Based Infrastructure......Page 201
Processing Electronic Materials and Devices......Page 207
Printing Industry Applications......Page 209
Processing Industries and Corrosion Control......Page 210
Metals Processing Industries......Page 215
Electrical Utilities......Page 216
Recent Developments in Thermal Spray Application Technology......Page 217
Testing and Characterization......Page 224
Metallurgical and Materials Nature of Thermal Spray Coatings Compared to Wrought, Forged, and Cast Materials......Page 226
Testing and Characterization Methods as Response Generators......Page 230
Testing and Characterization as a Diverse Materials Engineering Opportunity......Page 231
Metallography and Image Analysis......Page 233
Sectioning Techniques......Page 235
Mounting Materials and Techniques......Page 236
Grinding......Page 240
Polishing......Page 248
Recommended Procedures......Page 255
Image Analysis......Page 261
Etchants......Page 268
Hardness Testing......Page 269
Tensile Adhesion Testing......Page 270
Corrosion Testing and Monitoring......Page 275
Testing of Thermal Barrier Coatings......Page 277
Residual-Stress Determination in Thermal Spray Coatings......Page 279
Research in Nondestructive Testing......Page 280
Particle Size......Page 282
Particle Chemistry......Page 284
Phase Analysis by X-ray Diffraction......Page 285
Reference Information......Page 288
Glossary of Terms......Page 290
Abbreviations and Symbols......Page 333
Metric Conversion Guide......Page 338
C......Page 341
E......Page 342
I......Page 343
P......Page 344
S......Page 345
T......Page 346
Z......Page 347