Thermal Plasma Spray Coating Materials and Uses

The coating material chosen for Thermal Plasma Spray work can greatly affect the life of a part and its overall performance under heavy load, high temperature or corrosion.

Tungsten Carbide for Wear Resistance

Tungsten carbide cobalt coating is one of the most used coatings in Thermal Plasma Spray processes. Tungsten carbide cobalt coating is a wear resistant coating and is used in parts that are subject to abrasion and/or sliding action. Examples of parts that are coated with this type of coating are pump shafts, valve seats, conveyor screws etc. The coating thickness for this type of coating can vary from 100 microns to 400 microns depending on wear requirements.

Alumina for Electrical Insulation

Alumina, aluminium oxide, forms a hard and dense coating which is wear resistant and electrically non-conductive. In many cases a coating of this type is required for rollers, mandrels, textile machinery parts and the like, i.e. parts that need to be electrically insulating and wear resistant at the same time. Coating thicknesses for these applications are in the order of 150 to 300 µm.

Yttria-Stabilised Zirconia for Thermal Barriers

Yttria-stabilised zirconia (YSZ) is one of the most common Thermal Plasma Spray coating materials, because of its thermal properties. As a thermal barrier coating, it is used in gas turbines, aero-engine combustion chambers and industrial burner nozzles. It protects the metal beneath the surface by thermal insulation, and it retains its structural stability, even during rapid temperature changes.

MCrAlY Alloys for Oxidation Resistance

MCrAlY Alloys for Oxidation Resistance. MCrAlY alloys where M is nickel, cobalt or a combination of both are a tough oxidation-resistant bond coat. MCrAlY alloys are used extensively in aerospace and power generation and can be used as a bond coat with a ceramic top coat or as the top coat itself for parts exposed to hot gases.

Copper and Bronze Alloys for Bearing Surfaces

A worn bearing housing, worn bearing bushes or worn thrust faces can be restored with copper or bronze coatings. As these coatings can be machined after application, they are also suitable for parts that need to be dimensionally reworked.

By selecting the right coating material for your specific work requirement, you will avoid over designing a solution to a problem and provide cost effective solutions for your work.