HVOF spraying process is widely used to improve component life in service due to the high bond strength of the coatings, which is a result of the high particle velocity upon impact, and consequent low coating porosity. However, many parameters can affect metallic coatings properties, especially unmelted particles and oxidation level. Flame parameters, such as calorific power, combustion ratio and temperature, are of prime importance. Moreover, the fuel gas employed in this spraying process can lead to various coating properties and deposition efficiency. The aim of this work was focused on the influence of some fuel gases, namely propane, propylene (LPG) and hydrogen, on stainless steel coating characteristics. A specific domain common for those three gases was determined in order to effectively compare those gases with the same flame parameters. Flame characteristics were computed using a simple model for all the fuel gases considered. Temperature as well as calorific power were fixed. For different substrate temperatures, obtained through a special CO 2 cooling nozzle system, richness was varied from 1.4 to 1.6. Microstructure investigation as well as oxide content and microhardness measurements were conducted. For the same kinetic torch parameters, thickness-per pass gave an idea of the deposition efficiency. In the range studied, deposits properties were quite similar for both LPG fuel gases. Hydrogen led to better characteristics in term of oxide content, although its deposition efficiency was a bit lower. A general law was established to link oxide content within the coatings to the flame parameters. A reasonable regression analysis was obtained for all the coatings sprayed. The combination of cooling efficiency (i.e. CO 2 flow rate) and flame characteristics (i.e. interaction of the particle in flight) led to a good correlation. These correlations were further verified by spraying another metallic powder, namely Inconel 625.

In general, thermal spraying involves high temperatures that can be deleterious for the microstructure and deformation of the substrate. As a consequence, the use of a cooling system during spraying is often necessary. Meanwhile, in some cases, a too low surface temperature can induce a loss of properties, in particular concerning adherence and coating density. Therefore, it would be sometimes interesting to combine pre-heating and cooling stages with the plasma spray. A specific process, named HeatCool, was developed and patented to ensure a precise control of the temperature at the spraying location. The present work was focused on the study of the influence of pre-heating and cryogenic cooling conditions on the microstructure and mechanical characteristics of NiCrFeBSi self-fluxing alloy deposited by d.c. plasma spray technique. Firstly, a comparison between air and CO2 cooling was conducted to assess the efficiency corresponding to the specific use of cryogenic CO2. The main characteristics studied were the microhardness, roughness, porosity, mechanical deformations, morphology and crystallographic structures. Optimising the cooling methods and conditions combined with the process parameters improved microhardness of the plasma sprayed metal alloy and induced lower strain deformation of the substrate. Secondly, the pre-heating system was added to the device and the HeatCool process was evaluated. The process was demonstrated to be an efficient mean to enhance the structural and mechanical characteristics of coatings made of self-fluxing alloy.

Owing to high particle velocity upon impact, and consequently low porosity and high bond strength of so-obtained coatings, HVOF spraying process is widely used to improve components life in service. However, many parameters can affect metallic coatings properties, especially un-melted particles and oxidation level. Flame parameters, such as calorific power, combustion ratio and temperature, are of prime importance. The aim of this work was focused on the influence of these parameters on stainless steel coatings characteristics. For different substrate temperatures, maintained through CO2 cooling nozzles, those parameters varied independently. Flame characteristics were computed using a simple model for propylene as fuel gas. Microstructure investigation as well as oxide content measurements and microhardness were obtained. It appeared that combustion temperature, in the range studied (2600-2750K) was not a critical factor. However, combustion ratio and calorific power greatly influenced coating properties: an increase of oxide content, and consequently a higher microhardness, was observed when combustion ratio decreased as well as when calorific power increased.

Among the different wires used in arc spraying, copper is a material of choice in some applications. Its malleability is used to allow an easy machining procedure after spraying. This article focuses on the limitations of the oxidation of copper during arc spraying and its influence on coating process and properties. The aim of this series of experiments was to improve coating properties of copper sprayed with the electrical wire arc spraying process by substituting compressed air with nitrogen. These experiments show that coating properties, as well as electric wire arc spraying process, are strongly influenced by the gas employed as the atomising element.

Electrostatic fluidized bed spraying is a coating process that is often used for coating plastic. A novel flame spray technology with a controlled atmosphere was developed by Air Liquide in order to realize coatings with thermoplastics as well as composite coatings such as plastic/ceramic or plastic/metal. This technology expands the scope of the applications of plastic coatings especially for all types of shapes and materials as well as for on-site coating. Two types of powder, namely Rilsan and Gotalene were used in this study. The tests were carried out by HTI, which is Air Liquide's partner in the development of such applications. After introducing the principle of this process, this paper presents and discusses the coating process and the properties of such coatings. Then the advantages and limitations of the process are highlighted. Paper includes a German-language abstract.

Thermal spraying involves high temperatures which can be a serious problem for some applications. Among different possibilities existing to cool down a specimen during spraying, the use of liquid CO 2 is one of the most attractive. However, care has to be taken to obtain good results due to the specific characteristics of CO 2 . Moreover, there are still some remaining problems which limit the growth of such system. One of the most important is the condensation of air humidity at the exit of the atomising nozzle. Therefore, a new design of the nozzle has been developed. This design avoid ice building up and can be easily fixed on any kind of spraying set up. Examples of working conditions are presented.

Electrodes play an important role in the plasma-spraying process and must be frequently replaced to ensure good coating properties. The purpose of this work was to assess the effect of different plasma gases and oxygen and humidity levels on electrode lifetime. The change in arc voltage over time was recorded during spraying, and the elapsed time for a 5V drop was taken as the electrode lifetime. It was found that variations in oxygen and humidity in Ar-H2 gas mixtures have a major effect on lifetime and that the use of SPRAL22 gas could extend electrode life by a factor of three to four. These and other results are discussed in the paper.

Although high-velocity oxyfuel (HVOF) spray coating is a relatively new thermal spraying process, interest is growing rapidly along with the pace of development in areas such as torch design, powder quality, and modelling. The gases used in HVOF spraying are also important because they directly influence the state of the particle striking the substrate. This presentation reviews the HVOF combustion process with an emphasis on the gases used and their influence on coating quality.