Fig. 2 Thermal spray coating. Buildup of a thermal spray coating is a chaotic process. Molten particles spread out and deform (splat) as they strike the substrate, at first keying onto asperities on the substrate surface, then interlocking to one another. Voids can occur if the growing deposit More

Fig. 3 Current and potential thermal spray coating applications for aircraft turbine engine parts. Source: Ref 4 More

Fig. 1 Thermal spray coating microstructure showing common features More

Fig. 6 Typical thermal spray coating defects More

Fig. 4 Design of substrate geometry for thermal spray coating processes More

Fig. 2 Design of substrate geometry for thermal spray coating processes More

Fig. 10 Sealant penetration into thermal spray coating More

Fig. 4 Estimated service life of Zn-15Al thermal spray coating in selected environments for a given coating thickness. Sealed coatings are recommended for saltwater immersion service. Adapted from Ref 14 More

Fig. 5 Estimated service life of aluminum thermal spray coating in selected environments for a given coating thickness. For wear, abrasion, and impact applications, Al-10%Al 2 O 3 is preferred. Adapted from Ref 14 More

Fig. 7 Schematic showing the buildup of a thermal spray coating. Molten particles spread out and deform (splatter) as they strike the target, at first locking onto irregularities on the substrate, then interlocking with each other. Voids can occur if the growing deposit traps air. Particles More

Fig. 13 Examples of as-polished and etched thermal spray coating specimens. (a) Ni-Cr/Al alloy, as-polished. 200×. (b) Ni-Cr/Al alloy, etched in 10% oxalic acid for 3 s. 400×. (c) Co-Mo-Cr-Si (Laves phase) alloy, as-polished. 200×. (d) Co-Mo-Cr-Si (Laves phase) alloy, etched in 10% oxalic acid More

Fig. 29 Thermal spray coating process sometimes used in roll refurbishment. Source: Ref 163 More

Fig. 14 Rotating single-wire (RSW) torch head used to apply thermal spray coating on the internal surface of a cylinder liner. Source: Ref 15 More

Fig. 4 Forms of porosity can be categorized within a thermal spray coating. Explanation in text. Source: Ref 13 More

Fig. 13 Schematic showing the buildup of a thermal spray coating. Molten particles spread out and deform (splatter) as they strike the target, at first locking onto irregularities on the substrate, then interlocking with each other. Voids can occur if the growing deposit traps air. Particles More

Fig. 8 Scribed, sealed and painted thermal spray coatings on steel substrates compared to a scribed, painted steel panel after 42 months of severe marine atmospheric exposure. See the article “Corrosion of Metallic Coatings” in this Volume. More

Fig. 1 Percent of area corroded on single-element powder thermal spray coatings after 34 years of marine atmospheric exposure in the 250 m (800 ft) lot at Kure Beach, NC. Source: Ref 1 More

Fig. 3 Comparison of scribed, sealed, and painted thermal spray coatings on steel substrates to a scribed painted steel panel after 42 months of severe marine atmospheric exposure. (a) Flame-sprayed aluminum on steel, sealed/painted. (b) Painted steel panel (one coat MIL P24441 F150 primer More

Fig. 9 Comparison of thermal spray coatings deposited on macroroughened and smooth surfaces. (a) Sprayed metal over grooves; shrinkage constrained by grooves. (b) Sprayed metal on smooth surface; effect of shear stress on bond due to shrinkage. Adapted from Ref 3 More

Fig. 8 Comparison of thermal spray coatings deposited on macroroughened and smooth surfaces. (a) Sprayed metal over grooves; shrinkage constrained by grooves. (b) Sprayed metal on smooth surface; effect of shear stress on bond due to shrinkage. Adapted from Ref 2 More