Thermal spray coatings: features and applications
Thermal spray coating is a process whereby a surface (or substrate) is covered with molten droplets of a chosen material, typically with the intention of improving resistance or aesthetics. The process takes on many forms and utilises plenty of materials, so we’ve assembled an overview of the most common features and applications in this article.
How thermal spray coating is applied
Features
One interesting feature of thermal spray coatings actually comes before application – it can be done through an automated machine or carried out by hand. Both methods bring their respective advantages and disadvantages, but it’s nice to have the choice, regardless.
In terms of the actual coatings, they nearly always fall within the 0.1-10mm range of thickness, providing a range of benefits despite their modest size. These benefits can include resistance against heat, corrosion, wear and water, depending on the methods and materials used.
The method of plasma spray coating, for example, utilises plasma to burn materials at a higher temperature, allowing for more materials to be used (such as tungsten or zirconium, metals with higher melting points). This method mostly specialises in coating materials with thermal and abrasion resistance but is highly versatile. You can find advice and services for thermal plasma spray online from specialists such as https://www.poeton.co.uk/advanced-treatments/apticote-800-thermal-plasma-spray/..
Where thermal spray coating is used
There are plenty of other choices for thermal spray coating, but we can’t possibly cover them all in enough detail here. See this website for a thorough breakdown/.
Applications
Thermal spray coating is used in a range of industries but is most commonly seen in vehicular applications. Aluminium alloys are invaluable in reducing weight without sacrificing resistance to wear and the thermal properties of engines. These alloys are typically used for structural parts, meaning cars can have a vastly increased lifespan without being too taxing on manufacturers in terms of costs or production rates.
The practice is also popular in aerospace, thanks to its ability to make gas turbine engines abradable. Because the blades in turbine engines are so abrasive, the lifespan of turbine engines can plummet. However, the better materials created by thermal spray coating confer far greater resistance to wear.
Summary
Explains thermal spray coating, a process that covers a surface with molten droplets of material to improve resistance or appearance, describing how coatings typically range from 0.1 to 10mm thick and can resist heat, corrosion, wear and water, and covering common applications in vehicle engines and aerospace turbine blades, where it extends component lifespan.
Questions this article raises
- How does thermal spray coating compare in cost with other coating methods like galvanising?
- Which materials are best suited to plasma spray versus other thermal spray techniques?
- How long do thermal spray coatings typically last before needing reapplication?
