Titanium boron composite coatings with superior wear performance were selected for use in materials experiments on the International Space Station. The titanium-boron nitride composite coatings were prepared using an atmospheric plasma spray technique from engineered composite powders. The coatings were subjected to extensive characterization and tribological studies. The results show tremendous improvement in the wear performance.

Identifying metallographic TSC artifacts, specifically in air plasma spray zirconia-based thermal barrier coatings.

Innovations built into a new plasma spray torch address shortcomings of previous axial injection equipment.

Thermal barrier coatings (TBCs) with segmented or cracked microstructures exhibit enhanced thermal cyclic behavior and erosion resistance, along with improved application economics, over conventional TBCs.

Radio frequency inductively coupled plasma (RF-ICP) spraying is shown to be a promising method for producing oxidation-resistant W and W-Cr coatings on plasma-facing surfaces in fission and fusion reactors.

This case study addresses the use of online diagnostic tools to adjust spray parameters to ensure consistent results.

This article describes work being done at the University of Limoges to develop thermal spray coatings for use in new nuclear power plant designs.

This case study reviews the considerations in applying plasma spray thermal barrier coatings on augmenters used in military aircraft turbine engines to extend their service life.

Heat shields help protect vehicle-critical components that could delaminate and fail if exposed to high temperatures for any length of time. This article describes a solution that features ceramic platelets applied via plasma spray onto a metal substrate to create a heat shield that adds additional temperature resistance in comparison to standard pressed aluminum versions.

Zircotec Ltd., UK, originally developed its technologies for use in nuclear reactors. During the last decade, its coatings have been used in several other applications, including orthopedic implants, and the company has expanded into the defense sector with a greater emphasis on heat protection. This Technical Spotlight outlines some of the company's process capabilities.

Vacuum plasma and low pressure plasma spray technologies each provide unique solutions for achieving superior properties in metallic coatings that require low oxide content and high density. Applications include various turbine engine components, as well as biomedical and electronics components.

One of the most recent success stories for thermal spray in the automotive industry involves the development of plasma transferred wire arc (PTWA) for aluminum engine blocks. Driven by the demand to increase fuel efficiency, automakers are placing emphasis on decreasing overall vehicle weight as well as improving engine efficiency by reducing internal friction losses. The surface structure of the composite coating created by the PTWA process promotes favorable lubrication, low friction, wear resistance, improved heat transfer, and decreased bore distortion in engine block cylinders.

This article describes work to develop a cost-efficient plasma gun capable of high deposition rates. Engineers analyzed both gun components and gas flow dynamics to design a gun that improves plasma stability. Considerable effort was spent on characterizing the use of the gun for spraying yttria-stabilized zirconia (YSZ) for thermal barrier applications.

This article describes the design and operation of a high-deposition rate plasma nozzle developed for ambient pressure spraying.

This article provides a brief overview of the applications of multimodal alumina-titania (n-AT) coatings stemming from a five-year program on thermal spray nanocoatings sponsored by the U.S. Office of Naval Research (ONR). In the main example, plasma sprayed n-AT coatings are applied to the propulsion shafts of Mine Countermeasure ships, bringing a fourfold increase in service life.

This article explains how coating technology originally developed for use in nuclear power generating equipment is helping automotive engineers solve heat, wear, and performance challenges using new materials and design approaches.