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Plasma in the Thermal Spray Coating Industry

  • Living reference work entry
  • First Online:
Handbook of Thermal Plasmas

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Abstract

Thermal plasma spraying (TPS) offered distinct advantages compared to alternate cold spray or combustion-based thermal spray technologies. Early applications of wire arc spraying were in the area of corrosion protection of marine large infrastructure such as bridges. The high temperatures and high velocities attained by DC spraying combined with the excellent control of the properties and the purity of the spray medium, especially with radiofrequency induction plasma spraying (RF-IPS), have further propelled the thermal plasma technology to a wider range of applications. Its downside, however, mostly in its complexity and high investment and operation cost, has limited its initial industrial-scale applications to the coating of high-end, high added-value parts in the aerospace and medical fields. With the further development of the technology and improvements in spray process automation, processing cost has steadily dropped, allowing the TPS technology to penetrate new areas such as the textile, paper, and chemical process industries, and, more recently, the automobile industry.

In this chapter, following a brief review of the evolution of the thermal spray coating (TSC) industry on the international scale, a comparative analysis is made of the principal technologies, positioning the plasma-based technologies in comparison to alternate cold spray or combustion-based approaches. A survey of TSC applications by industrial sector is presented next, highlighting the areas in which TPS has been competitive and well-integrated on an industrial-scale production. The last part of this chapter is devoted to a technoeconomic analysis giving an order of magnitude of the investment cost associated with different thermal spray technologies and a comparative analysis of operating cost. Due to the dependence of the economic parameters on the regional infrastructure and local cost factors, emphasis is placed more on the methodology and the identification of the principal cost factors affecting the process economics rather than their absolute value that can change rapidly with time depending on the local economical context.

Emil Pfender: deceased.

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Abbreviations

ACP:

Amorphous calcium phosphate

ALTM:

Air lock transition module

APS:

Air plasma spraying

APS:

Atmospheric plasma spraying

AS:

As-sprayed

BAG:

Bioactive glass

BM:

Base material

BOF:

Basic oxygen furnace

BRT:

Burner rig test

CAGR:

Compound annual growth rate

CAPS:

Controlled atmosphere plasma spraying

CFRP:

Carbon fiber-reinforced plastics rolls

CMAS:

Acronym for CaO, MgO, Al2O3, SiO2

CNT:

Carbon nanotubes

CS:

Cold spray

C-SS-CS:

Composite of stainless steel and carbon steel

CTE:

Coefficient of thermal expansion

CVD:

Chemical vapor deposition

CW:

Corrosion wear

dBA:

Decibel

DC:

direct current

D-gun:

Detonation gun

DRC:

Diamond-reinforced composite

DWTS:

Direct write thermal spray

EAF:

Electric arc furnace

EBC:

Environmental barrier coating

EB-PVD:

Electron beam-physical vapor deposition

E–C:

Erosion–corrosion

EHC:

Electrolytic hard chrome

EIS:

Electrochemical impedance spectroscopy

EMI:

Electromagnetic interference

EW:

Erosive wear

FAC:

Fe-based alloy coatings

FBC:

Fluidized-bed combustor

fcc:

Face center cubic

FDA:

Food and Drug Administration

FG:

Functionally graded

FGC:

Functionally graded coating

FW:

Fatigue wear

GDC:

Acronym for, Ce0.8Gd0.2O1.9

GS:

Gas shroud

HA:

Hydroxyapatite Ca10 (PO4)6 (OH)2

HAT:

HA top coating

HB:

Hardness Brinell

HC:

Hard chrome

HCC:

Hard chromium coating

HEPS:

High-energy plasma spray

HIP:

Hot isostatically pressed

HPAL:

High-pressure acid leach

HPPS:

High-power plasma spray

HTBC:

HA/TiO2 (50 vol.% each) bond coat

HTH:

(HA)/HA + TiO2 bond coat

HVAF:

High-velocity air flame

HVFS:

High-velocity flame spraying

HVLF:

High-velocity liquid fuel

HVOF:

High-velocity oxy-fuel flame

HVPS:

High-velocity plasma spray

HV-SFS:

High-velocity SFS

IACS:

International Annealed Copper Standard

ICP:

Inductively coupled plasma

IGT:

Industrial gas turbine

IPS:

Induction plasma spraying

LaMA:

La MgAl11O19

LBT:

Land-based turbine

LPPS:

Low-pressure plasma spraying

LPPS®-TF:

LPPS-thin film

LSCF:

La0.6 Sr0.4 Co0.2 Fe0.8 O32-δ

LTA:

LaTi2Al9O19

LTE:

Local thermodynamic equilibrium

MLCC:

Multilayer ceramic capacitors

MMC:

Metal matrix composite

MSWI:

Municipal solid waste incinerators

NTSRS:

Net thermal spraying residual stress

ODS:

Oxide-dispersion strengthened

OEM:

Original equipment manufacturer

PA-12:

Polyamide 12

PAH:

Progressive abradability hardness

PE-CVD:

Plasma-enhanced CVD

PEEK:

Polyether ether ketone

PEI:

Polyether imide

PGDS:

Pulsed gas dynamic spraying

PM:

Post melted

PMC:

Polymer matrix composite

PS:

Plasma spraying

PSD:

Particle size distribution

PS-PVD:

Plasma spray PVD

PTA:

Plasma-transferred arc

PTS:

Polymer thermal spray

PVD:

Physical vapor deposition

QC:

Quality control

RCF:

Rolling contact fatigue

RF:

Radiofrequency

RF-IPS:

RF induction plasma spraying

RH:

Relative air humidity

SBF:

Simulated body fluid

SER:

Specific energy requirement

SFS:

Suspension flame spraying

SFW:

Surface fatigue wear

SPS:

Spark plasma sintering

TBC:

Thermal barrier coating

ULPPS:

Ultra-low-pressure plasma spraying

VPS:

Vacuum plasma spraying

WAS:

Wire arc spraying

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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), Université de Limoges, Limoges, France

    Pierre L. Fauchais

  3. Institute of Engineering Thermodynamiques, German Aerospace Center (DLR), Stuttgart, Germany

    Rudolf H. Henne

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

    Emil Pfender

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  1. Maher I. Boulos
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  4. Emil Pfender
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Boulos, M.I., Fauchais, P.L., Henne, R.H., Pfender, E. (2022). Plasma in the Thermal Spray Coating Industry. In: Handbook of Thermal Plasmas. Springer, Cham. https://doi.org/10.1007/978-3-319-12183-3_35-1

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