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How to select suitable thermal spray materials
2024-02-22
When selecting thermal spraying technology, it is necessary to choose the right coating material for our spraying. This not only ensures the performance of the coating but also its service life. When selecting coating materials, the working conditions of the workpiece, coating performance, materials used, batch size, economy, and thermal spraying method should be considered. Coatings can have different functions depending on the thermal spraying technology used. Different coatings can be categorized as corrosion-resistant coatings, wear-resistant coatings, friction-reducing and sealing coatings, high-temperature thermal barrier coatings, insulating or conductive coatings, and dimensional repair coatings, etc.
When selecting thermal spraying technology, it is necessary to choose suitable coating materials, ensuring both coating performance and service life. Material selection should consider the workpiece's operating conditions and the coating's performance, as well as the materials used, batch size, cost-effectiveness, and thermal spraying method. Different thermal spraying techniques yield different coating functions; coatings can be categorized as corrosion-resistant, wear-resistant, friction-reducing and sealing, high-temperature thermal barrier, insulating or conductive, and dimensional repair coatings, among others.
If workpiece damage or malfunction occurs after coating application, issues caused by coating failure can be ruled out. Since equipment damage can be definitively attributed to internal causes unrelated to the coating, a simple relationship between required operating conditions and coating performance may not always exist. Operating conditions should be thoroughly analyzed, considering coating structure, physical, chemical, and mechanical properties based on reference materials or experimental data, to determine one or more coating materials.
Plasma spraying for wear-resistant coatings is a major application area of surface coating technology. While a rough relationship exists between coating hardness and wear resistance, hardness does not fully represent the wear resistance of surface coatings. Different wear types require different material properties; impact, corrosion, fatigue, and temperature often accompany wear.
Surface coating material selection should not blindly pursue high-performance or high-priced materials, leading to unnecessary waste. Material price should not be the sole criterion for selection. While meeting operational requirements, cost-effective materials should be prioritized, particularly in mass production. For example, if nickel-based alloy coatings are suitable, cobalt-based alloy coatings are unnecessary.
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