thermal spray coatings in the printing · pdf filethermal spray coatings in the printing...
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![Page 1: THERMAL SPRAY COATINGS IN THE PRINTING · PDF fileTHERMAL SPRAY COATINGS IN THE PRINTING INDUSTRY JOHN BONAR ... forming droplets that are propelled by ... Arc Spray (6% porosity)](https://reader031.vdocuments.site/reader031/viewer/2022021421/5a8798837f8b9a9f1b8ddba5/html5/thumbnails/1.jpg)
THERMAL SPRAY COATINGS IN THE PRINTING INDUSTRY
JOHN BONAR MATERIALS & PROCESS
TECHNOLOGIES
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THERMAL SPRAY MARKET
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OVER $1 B
AEROSPACE POWER GENERATION MEDICAL IMPLANTS
GENERAL INDUSTRIAL
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THERMAL SPRAY TECHNOLOGY
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a Thermal Spray Components
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a Complete System Components
Acoustical Room Robot
Spray Lathe
Dust Collector
Chiller
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COATING SYSTEM CHARACTERISTICS
TECHNOLOGY BOND POROSITY APPLIED STRENGTH COST ____________________________________________________ WIRE SPRAY MOD-HIGH HIGH LOW PLASMA MOD MOD-LOW MOD HVOF HIGH VERY LOW HIGH
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WIRE SPRAY
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a Arc Spray Process The wires are fed into a “gun” where they are
electrically charged and directed together to create an arc. The resulting heat melts the wire, forming droplets that are propelled by compressed air or gas to the part surface.
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WIRE SPRAY CHARACTERISTICS
• LOW COST • LOW TO MODERATE BOND STRENGTH • HIGH POROSITY, OXIDES, UNMELTED
PARTICLES
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PLASMA SPRAY PROCESS
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a Plasma Spray Process
Electric & Combustion Energy
Utilizes Argon, Helium, Hydrogen, Nitrogen or Combinations
High performance coatings of all types
Thermal barrier (TBC) Most complicated thermal
spray process Highest thermal energy
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PLASMA SPRAY CHARACTERISTICS
• MODERATE COST • MODERATE TO HIGH BOND STRENGTH • MODERATE TO LOW POROSITY, OXIDES • COMPLEX CONTROL
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HVOF TECHNOLOGY
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a HVOF Processes Powder Feedstock Combustion Energy
• Oxygen-Kerosene • Oxygen-Gaseous Fuel
High integrity metallic and carbide coatings
• Particle velocity = density • Low oxides • High bond strength • High spray rates
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HVOF CHARACTERISTICS
• HIGH COST • VERY HIGH BOND STRENGTHS • VERY LOW POROSITY, OXIDES • NEAR THEORITICAL DENSITY
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a Coating Quality Comparison
Inconel 718 Arc Spray (6% porosity)
Inconel 718 Combustion Wire (10% porosity)
Inconel 718 HVOF (<2% porosity)
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COATING MATERIALS
• WIRES • POWDERS • BLENDS • AGGLOMORATED • FULLY ALLOYED
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METALS
• PURE – Al, Cu, Ta, Ti, Zn, Zr etc.
• ALLOYS – Bronze, Stainless Steel, Co, Ni, Al
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INTERMETALLICS
• CARBIDES – WC, Cr2C3, TaC, TiC – MIXTURES – ALLOYED WITH METAL MATRIX MATERIALS
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CERAMICS
• AL2O3 • TIO2 • CR2O3 • ZRO2 • VARIOUS SOLID SOLUTIONS
– MgAl2O4, 3Al2O3-2SiO2, ZrSiO4
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SEALERS
• ORGANICS – EPOXIES – POLYESTERS – SILANES – SILOXANES
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SEALERS
• INORGANICS – SILICATES – ALUMINATES – PHOSPHATES – CHROMATES
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SELF RELEASE COATINGS
PREVENT PICK-UP PREVENT ADHESION
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COATING PROPERTIES
GENERALLY BALANCED CAN BE SKEWED
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a Thermal Spray Benefits Cost Effectiveness
Lower total cost than
replacement Downtime reductions High resource
utilization Less machining
required Inexpensive base
material option
Cost of Coating < Cost of an Alternative
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PRINTING & CONVERTING
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IDLER ROLLS
• BARE AND POLISHED • THERMAL SPRAY COATED WITH SELF RELEASE • ANODIZED
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ANALOX ROLLS
• HIGH PERFORMANCE CERAMICS
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GRIPPER ROLLS
• COATING MUST BE WEAR RESISTANT • COATING SHOULD ALSO BE SELF RELEASE
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CORONA TREATER ROLLS
• SILICONE SLEEVES, TAPE • GLASS • HIGH PERFORMANCE CERAMIC
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THERMAL SPRAY COATING FOR THE PRINTING INDUSTRY
JOHN BONAR
MATERIALS & PROCESS TECHNOLOGIES