Repair Method: Metal or thermal spray

• Thermal spraying techniques are

coating processes in which melted
(or heated) materials are sprayed
onto a surface. The "feedstock"
(coating precursor) is heated by
electrical (plasma or arc) or chemical
means (combustion flame).
Metal spray
 Thermal spray process
A typical thermal spray system consists of the following:
1. Spray torch (or spray gun) – the core device performing the
melting and acceleration of the particles to be deposited
2. Feeder – for supplying the powder, wire or liquid to the torch
through tubes.
3. Media supply – gases or liquids for the generation of the flame
or plasma jet, gases for carrying the power etc.
4. Robot/man – for manipulating the torch or the substrates to be
coated
5. Power supply – often standalone for the torch
6. Control console(s) – either integrated or individual for all of the
above
 Thermal spray
• Thermal spraying can provide thick coatings
(approx. thickness range is 20 microns to
several mm, depending on the process and
feedstock), over a large area at high
deposition rate as compared to other
coating processes . Coating materials
available for thermal spraying include
metals, alloys, ceramics, plastics and
composites.
 Metal spray
• They are fed in powder or wire form,
heated to a molten or semi-molten state
and accelerated towards substrates in
the form of micrometer-size particles.
Combustion or electrical arc discharge is
usually used as the source of energy for
thermal spraying.
 Thermal spray
• Resulting coatings are made by
the accumulation of numerous
sprayed particles. The surface
may not heat up significantly,
allowing the coating of
flammable substances
 Metal spray
• Coating quality is usually assessed by
measuring its porosity, oxide
content, macro and micro- hardness,
bond strength and surface
roughness. Generally, the coating
quality increases with increasing
particle velocities.
 Types of thermal spray
• Plasma spraying
• Wire arc spraying
• Flame spraying
• High velocity oxy-fuel coating spraying (HVOF)
• High velocity air fuel (HVAF)
• Warm spraying
• Cold spraying
• Detonation spraying
 Metal spray
• A typical thermal spray system consists of the following:
• Spray torch (or spray gun) – the core device performing the
melting and acceleration of the particles to be deposited
• Feeder – for supplying the powder, wire or liquid to the torch
through tubes.
• Media supply – gases or liquids for the generation of the flame
or plasma jet, gases for carrying the powder, etc.
• Robot/man – for manipulating the torch or the substrates to be
coated
• Power supply – often standalone for the torch
• Control console(s) – either integrated or individual for all of the
above
 Welding
• Welding is a joining of two metals using heats,
with or without applying filler material or
electrode and with or without applying
pressure. or
• Welding is the process of joining metals by
using heat to melt and solidifying them with
or without applying filler material and
pressure
 Welding
• Welding is a fabrication process that joins
materials, usually metals or thermoplastics, by
using high heat to melt the parts together and
allowing them to cool causing fusion. Welding
is distinct from lower temperature metal-
joining techniques such as brazing and
soldering, which do not melt the base metal.
 Welding
• In addition to melting the base metal, a filler
material is added to the joint to form a pool
of molten material that cools to form a joint
which can be stronger than the base or
parent material. Pressure may also be used in
conjunction with heat, or by itself, to produce
a weld. Welding also requires a form of shield
to protect the filler metals or melted metals
from being contaminated or oxidized.
 welding
• Many different energy sources can be used
for welding, including
• a gas flame(chemical),
• an electric arc (electrical),
• a laser,
• an electron bean,
• friction etc.
 Repair of wear : Types of welding
1. Electric arc welding( arc, TIG, MIG, etc).
2. Gas welding (oxy-acetylene)
3. Resistance welding( spot welding, seam )
4. Radiant energy welding :Laser and electric
beam welding
5. Pressure welding or forge welding
 Arc welding
• These processes use a welding power supply to
create and maintain an electric arc between an
electrode and the base material to melt metals at
the welding point. They can use either
direct current or alternating current , and
consumable or non-consumable electrodes. The
welding region is sometimes protected by some
type of inert or semi-inert gas, known as a shielding
gas, and filler material is used as well.
Electric arc welding
Electric arc welding
Types of welding
Tungsten arc welding (TIG)

Inert gas is argon and helium to protect or shield welding pool.

Resistance welding
Oxy-acetylene gas welding
Oxyacetylene flame
 Machining
• Machining is any of various processes in which
a piece of raw material is cut into a desired
final shape and size by a controlled material-
removal process. WIKipedia
 Machining
• Machining can be roughly defined as the
process of removing material from a
work piece using power-driven machine
tools to shape it into an intended design.
https://www.thomasnet.com/articles/cus
tom-manufacturing-fabricating/types-
machining
 Machining
• Machining is a part of the manufacture of many
metal products, but it can also be used on
materials such as wood, plastic, ceramic, and
composites.
• Machining operations
• The three principal machining processes are
classified as turning, drilling and milling. Other
operations falling into miscellaneous categories
include shaping, planing, boring, broaching and
sawing.
 Machining
• Turning operations are operations that rotate
the work piece as the primary method of
moving metal against the cutting tool. Lathes
are the principal machine tool used in turning.
• Milling operations are operations in which the
cutting tool rotates to bring cutting edges to
bear against the work piece. Milling machines
are the principal machine tool used in milling.
 Machining
• Drilling operations are operations in
which holes are produced or refined
by bringing a rotating cutter with
cutting edges at the lower extremity
into contact with the work piece.
Drilling operations are done primarily
in drill presses but sometimes on
lathes or mills.
Types of machining
Machining
knurling
Lathe Machine
Lathe operation
Milling Machine
Milling machine
Uses of milling machine

Slitting:cutting or saw milling , gushing : spouting or

pouring
uses of Milling operations
Milling operations
Drilling machine
Drilling operations
Uses of drilling
 Boring
• In machining, boring is the process of enlarging a
hole that has already been drilled (or cast) by
means of a single-point cutting tool (or of a boring
head containing several such tools), such as in
boring a gun barrel or an engine cylinder. Boring is
used to achieve greater accuracy of the diameter
of a hole, and can be used to cut a tapered hole.
Boring can be viewed as the internal-diameter
counterpart to turning, which cuts external
diameters.
 Boring Machine
• Boring machine, device for
producing smooth and accurate
holes in a work piece by enlarging
existing holes with a bore, which may
bear a single cutting tip of steel,
cemented carbide, or diamond or
may be a small grinding wheel.
 Boring
• Single-point tools, gripped in a boring head
attached to a rotating spindle, are moved
circularly against the sides of the existing
holes. The diameter of the hole swept out by
the tool is controlled by adjustment of the
boring head.
https://www.britannica.com/technology/bori
ng-machine
Boring operation
Horizontal boring machine
Vertical Bore machine
Vertical boring machine
 Boring
• Boring operations can be performed
on other than boring machines, such
as lathes, milling machines and
machining centers. Boring machines,
like most other machine tools, can
be classified as horizontal or vertical.
 Bore machine
• A line boring machine is used for
enlarging a hole that has already
been drilled or cast, using one or
more cutting tools held within a
boring head. In doing so, the
operation achieves greater accuracy
of the hole diameter
 Boring
• There are various types of boring.
• A) line boring :The boring bar may be
supported on both ends (which only works if
the existing hole is a through hole),
• B) Back boring: it may be supported at one
end (which works for both, through holes and
blind holes.
 boring
• Back boring is the process of
reaching through an existing hole
and then boring on the "back" side
of the work piece (relative to the
machine.
 Honing
• Honing is an abrasive machining process
that produces a precision surface on a
metal work piece by scrubbing an
abrasive stone against it along a
controlled path. Honing is primarily used
to improve the geometric form of a
surface, but may also improve the
surface texture.
 honing
• Typical applications are the finishing
of cylinders for
internal combustion engines,
air bearing spindles and gears. There
are many types of hones, but all
consist of one or more abrasive
stones that are held under pressure
against the surface they are working
 honing
• Honing uses a special tool, called a honing
stone or a hone, to achieve a precision
surface. The hone is composed of abrasive
grains that are bound together with an
adhesive. Generally, honing grains are
irregularly shaped and about 10 to 50
micrometers in diameter (300 to 1,500
mesh grit). Smaller grain sizes produce a
smoother surface on the work piece.
honing
Honing tool
Types of honing machine
honing
honing
• The end
 Plasma spray
• A supersonic plasma jet melts the wire, atomizes
it and propels it onto the substrate. The plasma
jet is formed by a transferred arc between a non-
consumable cathode and the type of a wire. After
atomization, forced air transports the stream of
molten droplets onto the bore wall. The particles
flatten when they impinge on the surface of the
substrate, due to the high kinetic energy. The
particles rapidly solidify upon contact
High velocity oxygen fuel spraying (HVOF
Metal spray (cold spray)
 Cold spray
• In cold spraying, particles are accelerated to
very high speeds by the carrier gas forced
through a converging–diverging
de Laval type nozzle. Upon impact, solid
particles with sufficient kinetic energy deform
plastically and bond mechanically to the
substrate to form a coating. The critical
velocity needed to form bonding depends on
the material's properties, powder size and
temperature