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Plasma Spray Torches

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Handbook of Thermal Plasmas

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Abstract

Plasma spraying belongs to a wide range of thermal spray processes in which finely divided metallic or nonmetallic materials are deposited on the substrate in a molten or semi-molten condition to form a coating. The coating material may be in the form of powder, ceramic rod, or wire which is introduced into the plasma jet, melted, and projected toward the surface of the substrate forming a coating of thickness that can vary between a few microns to several millimeters. The rapid development and acceptance of the technology as a reliable material processing technique is based on a solid understanding of the fundamental processes involved. According to (Fauchais et al. 2014), the motivation for coating structural parts can be summarized by the following needs:

  • Decouple surface properties from the bulk properties of the materials by modifying their surface properties such as tribological, wear, and corrosion resistance

  • Improve functional performance of the materials by, e.g., allowing higher temperature exposure using thermal barrier coatings

  • Improve component life by reducing wear due to abrasion, erosion, and corrosion

  • Recycling of worn parts through rebuilding them to their original dimensions avoiding the need for replacing the entire component

  • Improved economics using low-cost bulk materials combined with high functionality coatings

Emil Pfender: deceased.

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Abbreviations

APS:

Atmospheric plasma spraying

CAPS:

Controlled atmosphere plasma spraying

CARS:

Coherent anti-Stokes Raman spectroscopy

CBL:

Cold boundary layer

CGDS:

Cold gas dynamic spraying

CNTs:

Carbon nanotubes

CS:

Cold Spray

DC:

Direct current

D-gun:

Detonation gun

EBCs:

Environmental barrier coatings

EB-PVD:

Electron beam-physical vapor deposition

ERW:

Electric Resistance Welding

FS:

Flame spraying

HVOF:

High-velocity oxy-fuel flame

i.d.:

Internal diameter

ISPC:

International Symposium on Plasma Chemistry

ITSC:

International Thermal Spray Conference

LIF:

Laser-induced fluorescence

LPG:

Liquefied petroleum gas

LPPS:

Low-pressure plasma spraying

NTSC:

National Thermal Spray Conference

PS-PVD:

Plasma spraying-physical vapor deposition

PTA:

Plasma Transferred Arc

RF:

Radio frequency

SHS:

Self-propagating high-temperature synthesis

SOFCs:

Solid oxide fuel cells

SWAS:

Single-wire arc spraying

TBCs:

Thermal barrier coatings

TGO:

Thermally grown oxide

UTSC:

United Thermal Spray Conference

VPS:

Vacuum plasma spraying

WPS:

Water plasma spraying

YSZ:

Yttria-stabilized zirconia

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Author information

Authors and Affiliations

  1. Department of Chemical and Biotechnology Engineering, University of Sherbrooke, Sherbrooke, QC, Canada

    Maher I. Boulos

  2. Sciences des Procédés Céramiques et de Traitements de Surface (SPCTS), University of Limoges, Limoges, France

    Pierre L. Fauchais

  3. Department of Mechanical Engineering, University of Minnesota, Minneapolis, MN, USA

    Emil Pfender

Authors
  1. Maher I. Boulos
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  2. Pierre L. Fauchais
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  3. Emil Pfender
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Corresponding author

Correspondence to Maher I. Boulos .

Editor information

Editors and Affiliations

  1. Department of Chemical and Biotechnology Engineering, University of Sherbrooke, Sherbrooke, QC, Canada

    Maher I. Boulos

  2. Sciences des Procédés Céramiques et de Traitements de Surface (SPCTS), University of Limoges, Limoges, France

    Pierre L. Fauchais

  3. Department of Mechanical Engineering, University of Minnesota, Minneapolis, MN, USA

    Emil Pfender

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Boulos, M.I., Fauchais, P.L., Pfender, E. (2023). Plasma Spray Torches. In: Boulos, M.I., Fauchais, P.L., Pfender, E. (eds) Handbook of Thermal Plasmas. Springer, Cham. https://doi.org/10.1007/978-3-030-84936-8_49

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