Thermal Spray Methods and Splat Formation

Thermal Spray Methods and Splat Formation

Wei Xie (Seaway Advanced Materials Co. Ltd., China)
DOI: 10.4018/978-1-5225-4194-3.ch001


This chapter describes how surface coatings play a significant role in manufacturing industries due to improvements in the properties of the engineering components that lead to longer service life and reliability. Thermal spray is well suited for large structures and can be easily repaired. Previous publications concerning the principle of thermal spray processing; powder and their fabrication methods; the effect of substrate surface conditions on splat formation and morphologies; the effect of process parameters on splat formation and morphology; and thermal spray coating morphology are reviewed. Also described in detail is physical behaviour, such as thermal conductivity and wetting ability at impact between the thermal spray particle and the substrate, influences the individual splat geometry and coating build-up and, consequently, the coating properties.
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Principle Of Thermal Spraying

Thermal spray belongs to the family of granular methods of deposition. Fine particles of polymer or ceramic are propelled using a flow of carrier gas through a flame. The particles are heated, softened and ejected towards an often heated substrate where they collide, flatten and assemble to form a coating that consists of hundreds of thousands of well-adhered flattened particles.

Thermal Spray Techniques

Plasma, wire arc, and combustion spraying, including conventional flame and high velocity oxygen fuel (HVOF) processes, constitute the major thermal spray processes (Figure 1).

Figure 1.

The thermal spray process family

Xie, 2013.

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