Thermal spray processes classification

The different thermal spray processes can be classified into 6 categories, 2

groups or 3 families.
6 categories
Flame spray
Arc spray
Plasma spray
Detonation spray
Supersonic spray ( HVOF )
Cold spray
2 Groups
Traditional processes: flame and arc
Advanced spray processes: supersonic, plasma and detonation
3 Families
They differ by their gas stream velocity and particles velocity.
Subsonic processes: flame and arc.
Sonic process: plasma
Supersonic processes*: JET KOTE, DIAMOND JET, CDS, TOP GUN, JP
5000, COLD SPRAY
* Called HVOF (High Velocity Oxy Fuel)

Flame spray process

Among thermal spray methods, the simplest and the cheapest way to
deposit coatings is flame spraying. Both wire and powder can be used as a
coating material.
The process relies on a chemical combustion reaction between oxygen and
a fuel (acetylene, hydrogen) to produce a heat source. This heat source
creates a gas stream.
The feed stock material to be sprayed is fed into the flame in the form of a
wire, and compressed air is then used to atomise the molten metal and
accelerate particles onto the substrate.

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The powder combustion process uses a similar technique, except that the
wire feed stock is replaced with a powder.
The main advantage of the combustion powder thermal spray process is
that a wide range of materials can be easily processed into powder from
giving a larger choice of coatings.
Materials with higher melting temperatures limit the flame spray process
than the flame can provide or if the material decomposes on heating.
Because of low flame temperature and particle velocity (40 m/s), coatings
are usually porous and bond strength of deposits is low as well as
adhesive strength between coating and substrate.

Arc spray process

The principle consists in creating an arc between two metallic wires acting
as consumable electrodes. Electric arc is generated between those
electrodes, because of a potential difference wires melt and compressed
air propels molten droplets into prepared work piece.
One advantage of the system is that two different wires can be used
simultaneously to produce a pseudo alloy. Cored wires are also available
producing coatings with unique properties.
The main applications of the arc spray process are anti-corrosion coatings
of zinc, aluminium and machine element works on large components.
Coating properties obtained by arc spraying are better than in flame
sprayed coatings. Reason for that is the higher particle velocity (100 m/s).

Projection Plasma

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The plasma spray process uses a DC electric arc to generate a stream of
high temperature ionised plasma gas, which acts as the spraying heat
source. The coating material, in powder form, is carried in an inert gas
stream into the plasma jet where it is heated and propelled towards the
substrate.
Because of the high temperature (15000°C) and high thermal energy of
the plasma jet, materials with high melting points can be sprayed.
The plasma spray gun includes a copper anode and tungsten cathode,
which are both water cooled. Plasma gas (argon, nitrogen, hydrogen,
helium) flows around the cathode and through the anode, which is shaped
as a constricting nozzle.
The plasma is initialised by a high voltage discharge, which causes
localised ionisation and a conductive path for a DC arc to form between
cathode and anode. The resistance heating from the arc causes the gas to
reach extreme temperatures, dissociate and ionise to form plasma. The
plasma exits in the anode nozzle as a free or neutral plasma flame
(plasma which does not carry electric current).
Plasma spraying produces a high quality coating by a combination of a
high temperature, high-energy heat source, a relatively inert spraying
medium and quite high particle velocities, typically 200–300 m/s.
Plasma spraying has the advantage that it can spray very high melting
point materials such as refractory metals like tungsten and ceramics like
zirconium. Plasma spray coatings probably account for the widest range of
thermal spray coatings and applications and make this process the most
versatile.

Detonation spray process

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Detonation gun is considered the first high velocity thermal spray process.
It consists of a long, closed at one end and open at the other end, water-
cooled gun barrel. Oxygen and fuel gas (acetylene C2H2 most common)
mixture is fed into the barrel together with coating material, which is in
powder form. The gas mixture is ignited by a spark plug. Following
detonation melts and accelerates the particles up to about a velocity of
600 m/s. After each detonation barrel is flushed with nitrogen (N2). There
are 1 – 15 detonations per second, depending on the equipment used.
The high kinetic energy of the hot powder particles on impact with the
substrate result in a build up of a very dense and strong coating.

HVOF (High Velocity Oxygen Fuel) spray process

The HVOF thermal spray process uses the combustion of gases, such as
propane, propylene, hydrogen, or a liquid fuel such as kerosene. Fuel and
oxygen mix and atomise within the combustion arc under conditions that
monitor the correct combustion made and pressure.
The process creates a very high velocity, which is uses to propel the
particles at near supersonic speeds before impact into the substrate. One
of the basis rules of spraying is that high combustion pressure = high gas
velocity, high particle velocity and resulting high coating quality.

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One of the key benefits of this high velocity system is the extremely high
coating density and low oxide content. The low oxides are due partly to
the speed of the particles spending less time within the heat source and
partly due to the lower flame temperature (around 3000°C) of the heat
source compared with alternative processes.
The very high kinetic energy of particles striking the substrate does not
require the particles to be fully molten to form high quality HVOF coatings.
This is certainly another advantage for the carbide cermet type coatings
and is where this process excels.

Some HVOF coatings can be sprayed very thick due to the exceptionally
high velocities producing coatings in compression instead of tension.
HVOF coatings are used in applications requiring the highest density and
strength not found in most other thermal spray processes.

Cold spray process

Cold spraying is a relatively new coating process by which coatings can be
produced without significant heating of the sprayed powder. The powder
particles are accelerated in a de-Laval-type nozzle with gas of moderate
temperature to velocities of more than 500 m/s. Upon impact they form a
dense and well adherent coating. Compared to thermal spray processes
like arc, flame, and plasma spraying, oxidation of the spray material and
the substrate can almost be avoided. Cold spraying can also be used to
create coatings up to several centimetres thickness as well as free
standing structures. This opens a wide field of new applications.

The Process
Cold spraying involves injecting microscopic powdered particles of metal
or other solids into a supersonic jet of rapidly expanding gas and shooting
them at a target surface. When these particles hit the substrate, they
‘splat’ so hard they stick and form a coating.
Differences between Cold Spraying and Thermal Spraying
Cold spraying more appropriately might be called ‘room-temperature
spraying’. Conventional thermal spray processes require preheating of the
sprayed materials so the particles are in a semi-molten state when they

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reach the substrate. This allows them to splash across the surface. But as
the ‘splats’ cool, they contract slightly, creating residual stresses or flaws
at the interface that can cause defects later. By contrast, cold sprayed
materials typically remain at, or near, room temperature until impact,
slamming into the substrate so fast (500-1.500 m/s) that a tight bond is
formed without the undesirable chemical changes and stresses associated
with conventional processes.
Characteristics of Cold Sprayed Coatings
Unlike thermal-sprayed materials, cold-sprayed materials experience little
to no defect-causing oxidation during flight and exhibit remarkably high
densities and conductivities once fabricated. In addition, deposition rates
comparable to traditional thermal spray processes can be achieved.
Feed Materials
It is believed that the process works by plastically deforming the materials
as the particles hit, which disrupts surface oxides and forces the metal
into intimate contact with the underlying material. Thus, it is suited to
ductile materials. Non-ductile materials such as ceramics can't be sprayed
as a pure material, but can be applied using ceramic/metal composite
powders. In this case the metal acts as a ductile matrix.

Spray Distance
Unlike thermal spray techniques, heat input into the substrate from a
flame or plasma is not a problem; such short distances can be used.
Typical stand-off distances are about 10 mm, while it is thought distances
of 40 to 50 mm will also work, as the process is fairly forgiving.
Feed Particle Size
Feed particle size is extremely important. Ideally, powders should have as
fine material as possible, with the low end being defined by the fact that
when this supersonic gas stream hits the target surface, you get a
shockwave on that surface. When you get down below five microns
(depending on the mass and momentum of the particles), they’ll follow
the gas flow and decelerate near the surface. So typically, particles in the
5 15 micron range are optimal, although, some materials up to 30 microns
still get decent results.
Substrate
Substrates choice is limited by their ability to absorb the impact energy
from the projected particles. Ceramics and metals are generally fine, but
plastics and composites tend to be cut or the particles become embedded
in the substrate rather than forming a coating. In short as ‘hard’
substrates can be coated by cold spraying.

Tableau récapitulatif

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Thermal spray process Flame Wire arc Plasma HVOF HP/HVOF
Gas stream velocity ( m/s ) 150 150 600 >1500 >2000
Particles velocity ( m/s )
300-
at impact ( measured with 20-50 100-200 100-300 400-700
500
DPV 2000 )
Gas stream temperature
2500 4000 15000 2800 2800
(°C)
Particles temperature (°C)
<2500 <2000 <2000
(measured with DVP 2000)
Coating porosity (%) 10 to 20 10 to 20 1 to 10 <2 <0.5
Tensile bond strength (MPa) 10-30 10-30 20-50 >60 >70
WC Co coating hardness
>90 >1000 >1200
(HVOF)
Low
porosity
Good
Low
Low bond
running Less expansive
running strength
costs Better bond
Advantages costs The most
Wide range strength
High spray versatile
of Very low porosity
rates Process
materials
approved
in
aeronautic
High
porosity
High
Low bond
porosity High
strength
Limitations Electrically running
Substrate
conductive costs
heating
wires
Limited
possibilities
Zn Every Carbides Metals
Materials
Al materials Cermets