The Science and Engineering of Thermal Spray Coatings

Abstract

Preface to the Second Edition. Preface to the First Edition. Acronyms, Abbreviations and Symbols. 1 Materials Used for Spraying. 1.1 Methods of Powders Production. 1.1.1 Atomization. 1.1.2 Sintering or Fusion. 1.1.3 Spray Drying (Agglomeration). 1.1.4 Cladding. 1.1.5 Mechanical Alloying (Mechanofusion). 1.1.6 Self-propagating High-temperature Synthesis (SHS). 1.1.7 Other Methods. 1.2 Methods of Powders Characterization. 1.2.1 Grain Size. 1.2.2 Chemical and Phase Composition. 1.2.3 Internal and External Morphology. 1.2.4 High-temperature Behaviour. 1.2.5 Apparent Density and Flowability. 1.3 Feeding, Transport and Injection of Powders. 1.3.1 Powder Feeders. 1.3.2 Transport of Powders. 1.3.3 Injection of Powders. References. 2 Pre-Spray Treatment. 2.1 Introduction. 2.2 Surface Cleaning. 2.3 Substrate Shaping. 2.4 Surface Activation. 2.5 Masking. References. 3 Thermal Spraying Techniques. 3.1 Introduction. 3.2 Flame Spraying (FS). 3.2.1 History. 3.2.2 Principles. 3.2.3 Process Parameters. 3.2.4 Coating Properties. 3.3 Atmospheric Plasma Spraying (APS). 3.3.1 History. 3.3.2 Principles. 3.3.3 Process Parameters. 3.3.4 Coating Properties. 3.4 Arc Spraying (AS). 3.4.1 Principles. 3.4.2 Process Parameters. 3.4.3 Coating Properties. 3.5 Detonation-Gun Spraying (D-GUN). 3.5.1 History. 3.5.2 Principles. 3.5.3 Process Parameters. 3.5.4 Coating Properties. 3.6 High-Velocity Oxy-Fuel (HVOF) Spraying. 3.6.1 History. 3.6.2 Principles. 3.6.3 Process Parameters. 3.6.4 Coating Properties. 3.7 Vacuum Plasma Spraying (VPS). 3.7.1 History. 3.7.2 Principles. 3.7.3 Process Parameters. 3.7.4 Coating Properties. 3.8 Controlled-Atmosphere Plasma Spraying (CAPS). 3.8.1 History. 3.8.2 Principles. 3.8.3 Process Parameters. 3.8.4 Coating Properties. 3.9 Cold-Gas Spraying Method (CGSM). 3.9.1 History. 3.9.2 Principles. 3.9.3 Process Parameters. 3.9.4 Coating Properties. 3.10 New Developments in Thermal Spray Techniques. References. 4 Post-Spray Treatment. 4.1 Heat Treatment. 4.1.1 Electromagnetic Treatment. 4.1.2 Furnace Treatment. 4.1.3 Hot Isostatic Pressing (HIP). 4.1.4 Combustion Flame Re-melting. 4.2 Impregnation. 4.2.1 Inorganic Sealants. 4.2.2 Organic Sealants. 4.3 Finishing. 4.3.1 Grinding. 4.3.2 Polishing and Lapping. References. 5 Physics and Chemistry of Thermal Spraying. 5.1 Jets and Flames. 5.1.1 Properties of Jets and Flames. 5.2 Momentum Transfer between Jets or Flames and Sprayed Particles. 5.2.1 Theoretical Description. 5.2.2 Experimental Determination of Sprayed Particles' Velocities. 5.2.3 Examples of Experimental Determination of Particles Velocities. 5.3 Heat Transfer between Jets or Flames and Sprayed Particles. 5.3.1 Theoretical Description. 5.3.2 Methods of Particles' Temperature Measurements. 5.4 Chemical Modification at Flight of Sprayed Particles. References. 6 Coating Build-Up. 6.1 Impact of Particles. 6.1.1 Particle Deformation. 6.1.2 Particle Temperature at Impact. 6.1.3 Nucleation, Solidification and Crystal Growth. 6.1.4 Mechanisms of Adhesion. 6.2 Coating Growth. 6.2.1 Mechanism of Coating Growth. 6.2.2 Temperature of Coatings at Spraying. 6.2.3 Generation of Thermal Stresses at Spraying. 6.2.4 Coatings Surfaces. 6.3 Microstructure of the Coatings. 6.3.1 Crystal Phase Composition. 6.3.2 Coatings' Inhomogeneity. 6.3.3 Final Microstructure of Sprayed Coatings. 6.4 Thermally Sprayed Composites. 6.4.1 Classification of Sprayed Composites. 6.4.2 Composite Coating Manufacturing. References. 7 Methods of Coatings' Characterization. 7.1 Methods of Microstructure Characterization. 7.1.1 Methods of Chemical Analysis. 7.1.2 Crystallographic Analyses. 7.1.3 Microstructure Analyses. 7.1.4 Other Applied Methods. 7.2 Mechanical Properties of Coatings. 7.2.1 Adhesion Determination. 7.2.2 Hardness and Microhardness. 7.2.3 Elastic Moduli, Strength and Ductility. 7.2.4 Properties Related to Mechanics of Coating Fracture. 7.2.5 Friction and Wear. 7.2.6 Residual Stresses. 7.3 Physical Properties of Coatings. 7.3.1 Thickness, Porosity and Density. 7.3.2 Thermophysical Properties. 7.3.3 Thermal Shock Resistance. 7.4 Electrical Properties of Coatings. 7.4.1 Electrical Conductivity. 7.4.2 Properties of Dielectrics. 7.4.3 Electron Emission from Surfaces. 7.5 Magnetic Properties of Coatings. 7.6 Chemical Properties of Coatings. 7.6.1 Aqueous Corrosion. 7.6.2 Hot-gas Corrosion. 7.7 Characterization of Coatings' Quality. 7.7.1 Acoustical Methods. 7.7.2 Thermal Methods. References. 8 Properties of Coatings. 8.1 Design of Experiments. 8.2 Mechanical Properties. 8.2.1 Hardness and Microhardness. 8.2.2 Tensile Adhesion Strength. 8.2.3 Elastic Moduli, Strengths and Fracture Toughness. 8.2.4 Friction and Wear. 8.3 Thermophysical Properties. 8.3.1 Thermal Conductivity and Diffusivity. 8.3.2 Specific Heat. 8.3.3 Thermal Expansion. 8.3.4 Emissivity. 8.3.5 Thermal Shock Resistance. 8.4 Electric Properties. 8.4.1 Properties of Conductors. 8.4.2 Properties of Resistors. 8.4.3 Properties of Dielectrics. 8.4.4 Electric Field Emitters. 8.4.5 Propert