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Thermal spray is a coating process where melted or heated materials are sprayed onto surfaces to enhance durability, protect against wear and corrosion, and repair worn components. It is used in aerospace for turbine blades and engine parts, automotive for engine components and exhaust systems, manufacturing for industrial machinery, and energy for power generation components. Gases such as oxygen and acetylene provide the necessary heat in combustion processes, hydrogen offers high heat output in plasma spraying, and nitrogen and argon serve as carrier and protective gases to prevent oxidation and ensure high-quality coatings. These gases are essential for creating durable, high-performance coatings in various industries.
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Thermal spray is a coating process that involves heating and accelerating particles of a material (metal, ceramic, or polymer) and projecting them onto a surface to create a protective or functional coating. This process enhances the surface properties of the substrate.
Thermal spray coatings are used in various industries for applications such as corrosion protection, wear resistance, thermal insulation, electrical conductivity, and surface restoration. Industries include aerospace, automotive, energy, and manufacturing.
Common gases used in thermal spray processes include oxygen (O₂), hydrogen (H₂), nitrogen (N₂), and argon (Ar). These gases are used as fuel, carrier gases, or to create the necessary thermal environment for the spraying process.
Oxygen is used as an oxidizer in fuel gas combustion processes such as flame spraying and high-velocity oxy-fuel (HVOF) spraying. It helps achieve the high temperatures needed to melt the coating material.
Hydrogen is used as a fuel gas in processes like plasma spraying and HVOF. Its high heat content and reducing properties make it suitable for generating the temperatures required to melt and propel coating materials.
Nitrogen is often used as a carrier gas in plasma spraying to transport the powder particles into the plasma jet. It can also be used to cool the sprayed part and control the temperature of the substrate during the process.
Argon is used as a plasma gas in plasma spraying to stabilize the plasma arc and provide an inert atmosphere. It prevents oxidation of the coating material and ensures high-quality coatings with minimal contamination.
The main types of thermal spray processes include flame spraying, plasma spraying, high-velocity oxy-fuel (HVOF) spraying, detonation spraying, and cold spraying. Each process has its specific applications and advantages.
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