SHORT COURSES – Monday 5 December

Thermal Spray Technology

Professor Christopher C. Berndt
Professor of Surface Science and Interface Engineering – Swinburne University of Technology, VIC

Course Overview

Thermal spray technology and coatings solve critical problems in demanding environments. They provide “solutions” to engineering needs involving wear, high temperature and aqueous corrosion, and thermal regulation and degradation. Thermal spray is being increasingly used to manufacture net-shapes, advanced sensors and materials for the biomedical and energy/environmental marketing sectors. These and a vast array of emerging applications take advantage of the rapid and cost-effective capabilities of thermal spray technology in the OEM and repair industries.

Thermal spray processes; including twin wire-arc, combustion, high velocity oxy-fuel (HVOF), cold spray and plasma spray, as well as associated technologies, can deposit virtually any material as a surface coating onto a wide range of other materials. Coating reliability and effectiveness necessitates that these overlay coatings be selected, engineered and applied correctly.

This course provides (i) a thorough grounding and understanding of thermal spray processes, (ii) depicts the quite complex scientific concepts in terms of simple physical models, and (iii) integrates this knowledge to practical engineering applications and commonly accepted thermal spray practices. Note that NO mathematics is used in order explain the processes or materials/mechanical engineering.

  • Thermal spray technology as a cost-effective solution for many applications requiring resistance to wear, heat and corrosion.
  • Processes including electric arc, combustion and plasma spray can apply almost any material to the surface of another.
  • Coating systems must be engineered and applied correctly to operate successfully as an overlay surface.
  • The interaction of thermal spray processing to create a material structure that can accommodate severe operational environments.

Learning Objectives:

  • The historical basis for thermal spray technology and the development of equipment and materials as it pertains to the present-day technology.
  • The terminology, principles and underlying theory of thermal spray technology.
  • A contrast and comparison of thermal spray technologies with respect to other competing coating technologies (e.g., PVD, CVD, hardfacing, electroplating etc.).
  • The differences between the various thermal spray processes and how to select a process for various feedstock materials.
  • The methods of manufacturing feedstock materials so that they can be designed for a particular thermal spray process, and hence the relationship to the end-market application.
  • Testing methods and currently accepted industrial practices used for quality control of coatings.
  • How to integrate processes, materials, applications and testing, and characterization of thermal spray coatings.
  • Financial models for the costing of coatings, numerous applications and case histories, how to solve materials and equipment problems, design issues for coating components and much more!

Who Should Enrol:

This course, directed toward technologists, engineers and technicians, provides an understanding of thermal spray processing science as well as applications and practice. Graduate students and other professionals entering the thermal spray field or who wish to update their knowledge will also benefit greatly from this course. You will learn and understand how the thermal spray process allows favorable interactions, which permit the design envelope of conventional components to be extended. You will also gain insights into future challenges and markets for this exponentially growing manufacturing sector. Participants are encouraged to contact the instructor(s) prior to the course so that any particular application or problem may be addressed as a case history or exemplar.

Course Outline:

1. Surface Science: Wear, corrosion, hardening, carburizing, nitriding, electroplating, electroless plating, phosphating, vapor deposition, hard facing, relative attributes and deficiencies of these processes.

2. Equipment & Theory: History, methodology, flame spray, HVOF, D-gun®, twin wire-arc spray, plasma spray, emerging technologies (e.g., cold spray, vacuum wire processes, etc.) material feed systems, cooling needs, gas supply systems, controls, sensors and automation, spray booth design, health and safety.

3. Processing & Design: Bonding, cleaning, processing, masking techniques, substrate surface preparation, temperature control, spray pattern, process variation, automation, fusing, densification, finishing, stripping, deposition efficiencies, good design practices for substrates.

4. Materials: Feedstock production methods and how this is reflected in the feedstock morphology; blended and composite materials; quality indicators for feedstocks; feedstock flow and its critical importance to achieving an economic process; particle classification methods; quality control; material specifications and standards.

5. Applications: Aerospace (thermal barrier coatings, abradables, wear resistant coatings etc.), automotive, biomedical, ceramic & glass, marine, anti-skid, electronics, printing, processing industries, textiles, infrastructure. 6. Testing & Characterization: Sectioning, mounting, grinding, polishing, etching, hardness testing tensile adhesion/cohesion, powder size/chemistry/ phase, porosity determinations.