Due to its easy handling and low operating costs, wire arc spraying has become one of the most established processes for applying protective coatings to components used in waste incineration plants. This paper discusses the development of relatively low-cost Fe-Cr-Si coating materials for incinerator applications and the corrosion and wear properties that have been achieved using conventional arc spraying methods.

The introduction of new wire arc spraying equipment with chopped power supplies offers many possibilities to improve the wire arc spraying process. These power sources provide higher process stability even at reduced voltages. On the one hand conventional applications can be enhanced and on the other hand new processes can be developed. Due to the high process stability the introduction of additional particles into the atomizing gas stream is possible. This can be applied to produce coatings with a high wear resistance as well as a high surface roughness. A combined technology of particle injection and the productive wire arc spraying process enables the economic production of innovative functional surfaces. In the last years ITSC, the injection of corundum particles had been presented. In this paper further strategies for inserting particles into the gas stream and experimental results are shown for iron based coatings. For the reinforcement different carbides were injected into the atomizing gas stream.

Casting molds in the aluminium industry show a short lifespan due to the high corrosiveness of aluminium melts and alternating thermal and mechanical loads. By using new materials, in example pseudoalloys containing tungsten, the lifetime of casting molds can be elongated up to hundredfold. Today, casting molds made of steel are state of the art. In spite of the advantages of pseudoalloys, high manufacturing cost and the increasing commodity price of tungsten prohibit the use of molds consisting of these progressive materials. By coating the standard steel molds with a FeNiW-layer, the excellent thermal and corrosive resistance of the pseudoalloy surface can be combined with minimal manufacturing costs. For present work steel substrates had been coated with FeNiW-pseudoalloys. Therefore, arc spraying and different deposit-welding methods (Laser, Plasma, TIG) had been compared. By modifying the machine parameter set, a smooth transition between substrate and coating was realized. Thermal and chemical resistance of the samples will be tested. In this paper first results are presented.

Since many years, aluminum alloys are established as lightweight construction materials. To reach a partial wear protection for aluminum components in conjunction with seal faces, inlays, made of wear resistant materials, are commonly used. Problems concerning this approach are the necessary space and the endurance strength of the inlay - part joint. New process equipment offers the potential to control the energy input into the substrate and so the formation of brittle intermetallic phases in the aluminum-steel interface as well as the thermal stresses. The usage of new nano crystalline solidifying wear resistant iron-based feedstock materials with advantageous physical and mechanical properties enables further applications beside the wear protection of surfaces, for example as metallic heat insulation layer with a low heat conductivity, close to the values of ceramics.

Aim of this project is to produce anti-corrosion coatings for high temperature applications by wire arc spraying. It is necessary to adjust the feedstock material as well as the spray equipment in order to control the coating composition and the coating morphology. The substitution of expensive Ni- and Co-based feedstock by Fe-based alloys leads to an economic benefit. In combination with wire arc spraying, the total coating costs can be reduced significantly. There is also an enomous potential for reduction of service costs in waste incineration plants due to an enhanced coating service life and shorter downtime for the anti-corrosion coating repair.

Since many years, aluminum alloys are established as lightweight construction materials. To reach a partial wear protection for aluminum components in conjunction with seal faces, inlays, made of wear resistant materials, are commonly used. Problems concerning this approach are the necessary space and the endurance strength of the inlay - part joint. In the following paper an alternative for the replacement of the inlays by cladding with an innovative and easy to handle short arc technology will be discussed. This technology offers the potential to control the energy input into the substrate and so the formation of brittle intermetallic phases in the aluminum-steel interface as well as the thermal stresses. The usage of new nano crystalline solidifying wear resistant iron-based feedstock materials with advantageous physical and mechanical properties enables further applications beside the wear protection of surfaces, for example as metallic heat insulation layer with a low heat conductivity, close to the values of ceramics.

A method for the production of particle reinforced coatings by wire arc spraying will be presented in this paper. This technology is based on twin-wire electric arc spraying (TWEA) process. Here, additional particles were injected into the atomizing gas stream and sprayed in a non molten state along with wire feedstock material onto the substrate. According to the reinforcing particles, the process can be applied to produce coatings with a high wear resistance as well as a high surface roughness. In a wide range of applications, these coating characteristics are required. Due to economic constraints, coatings of large surfaces have to be done in short times at low costs. Based on wire arc spraying, the thermal spray process with the highest deposition performance, the mentioned industry requirements can be fulfilled.