In this work, process models combining statistics, materials science, and mechanics were developed to optimize and qualify HVOF sprayed coatings as if for aerospace application. In an attempt to correlate process variables with typical coating properties, a preliminary microstructure model was developed using statistical data obtained from 34 design-of-experiments runs. A second model, based on fatigue testing, was also developed. The fatigue model was subsequently used to guide the selection of variables for a final model that is shown to aid in both process qualification and the optimization of process-operating parameters.

Experience has shown that qualified supervisors and skilled workers are essential for manufacturing premium-quality thermal spray products. This paper describes the training defined by EWF guidelines and reviews prevailing curricula. Changes and reforms associated with DIN EN ISO 14922 and ISO Norm 14918 are also presented along with emerging trends in thermal spray training and certification.

Stripping systems for thermal spray coatings tend to use many hazardous acids which require critical safety procedures and produce heavy volumes of environmentally unfriendly waste streams. A new technology, filed under application numbers 2009/0120804A1 and 2009/0229636A1, and additionally covered under U.S. patent numbers 8262870 and 8377324 has been created using a very safe and environmentally friendly percarbonate based chemical system with minimal DC rectified voltage. It was successfully qualified at Tinker Air Force Base and is currently in production use throughout the facility. It has safely stripped WCCo and CrC-NiCr coatings such as WCCo and CrC-NiCr from Ti 6-4 and IN718 substrates showing minimal stock loss in 48 hr exposure testing. Many lessons were learned during this qualification process which will be shared and documented. Both plasma and HVOF coatings can be stripped with this process in the pH 10-12 range. The system can also be combined with a refining system that purifies the waste water and condenses the coating sludge into a condensed volume, eliminating the tremendous volume of waste chemicals. Numerous case studies and actual stripping data will also be presented and discussed.

This paper provides an overview of ISO standards, EWF education and training guidelines, and GTS certification, explaining how they work together to improve the proficiency and productivity of individuals and organizations involved in thermal spraying.

In the thermal spraying technology a lot of things have been and still are happening in education and training of personnel and in quality management. The QM-system that was established by the GTS e.V.– the Association of Thermal Sprayers – was pioneer and does an excellent job concerning its requirements. These GTS QM-requirements are meanwhile completed by newly created and internationally accepted EWF-education and training guidelines of supervising personnel and thermal spray workers. These guidelines involve also the new ISO standards of the Thermal Spraying Coordinator and the Approval Testing of Thermal Sprayers. Meanwhile the ETS (European Thermal Sprayer) and the ETSS (European Thermal Spraying Specialist) education and training courses are very much in demand. For the QM-System the standard ISO 14922 Part 2-4 (Quality requirements of thermally sprayed structures) is established, which includes the standard ISO 14918 (Approval Testing of Thermal Sprayers). Here, different destructive testing procedures are required depending on the spray process, which provide useful statements concerning the quality of sprayed coatings. With the GTS-Certification, the EWF-Qualifications and the ISO Standards a System is installed, which meets the increased Demands of Trade and Industry for High Quality Sprayed Coatings.

This paper reviews the new DIN EN ISO personnel qualification and quality management standards and EWF training guidelines for European thermal sprayers. EWF education and training programs run for a period of three weeks, filling critical gaps in knowledge and experience. The primary aim of the ISO standards is to facilitate a reproducible process for spraying coatings of a consistent quality. Paper text in German.

A commercial air carrier has replaced the chrome plating on line-of-sight landing gear installed on several aircraft with HVOF sprayed WC-Co-Cr coatings. Pending the results of ongoing testing and service evaluations, the carrier plans to switch to HVOF coatings on all line-of-site landing gear and possibly other structural and engine components. This paper discusses the infrastructure that will be necessary to build, qualify, and maintain a high-velocity oxyfuel spraying facility that will serve one of the largest fleets of aircraft in the world. Paper includes a German-language abstract.

Working with qualified personnel means for each industrial company effectiveness and competitiveness. International standards and guidelines help to continue not only on the domestic market. In the recent years a considerable standardisation was made specially in the European Community. In the field of thermal spraying EN standards were and will be worked out, which fix the approval testing of thermal sprayers and the tasks and responsibilities of spraying co-ordinators. At the same time EWF guidelines were created to define the minimum requirements for training and educating spraying personnel. These standards and guidelines will be introduced, showing connections between them. Paper text in German.

A comprehensive approach is presented for facilitating the implementation of advanced plasma spray processing technology in the manufacture, repair, and refurbishment of industrial components. This approach employs an integrated methodology for combining several advanced computer-based methods, including: 1) an interactive multimedia-based education and training tool to effectively store and retrieve plasma spray processing information in a variety of formats; 2) an expert system to select plasma spray feedstock material for a specific coating function; 3) a one-dimensional plasma spray process model that allows simulation of plasma spray processing conditions for identifying operational envelopes for a selected feedstock material; 4) an interface fracture model for identifying appropriate acceptance criteria for reduced cracking along the coating/substrate interface; and 5) a set of computer-based nondestructive test methods for performing quality assurance and control. This comprehensive approach and the integrated methodology provide an advanced engineering tool for the selection, optimization and implementation of specific advances in plasma spray processing technologies. A major outcome is the reduced need for expensive and time-consuming trial-and-error methods in evaluating the application of plasma spray coatings for the manufacture, repair, and refurbishment of specific industrial components. This comprehensive approach and integrated methodology can be extended to include other thermal spray processing technologies as well.